Cold rolled channel without clip

Abstract

A stud bridge member used in the construction industry to span horizontally between studs is disclosed. The stud bridge member has at least one set of notches that engage with the stud and eliminate the use of a stud bridge clip and its associated costs and installation time for that stud.

Claims

1. An installation of a stud bridge member (100) and at least a first stud comprising: the stud bridge member, and the at least a first stud; the stud bridge member comprising: a web (200) having a web outer side (240), a web inner side (260), a web first edge (210) and a web second edge (220) defining a web plane (250) having a longitudinal axis (500); a first flange (300) and a second flange (400) extending into a space on the web inner side (260); and at least one notch set comprising a first notch (600) and a second notch (700), with the first flange comprising a first flange first edge (320) and a first flange second edge (340) defining a first flange plane (350) with the first flange first edge joined with the web first edge at a first juncture (510) having a first juncture outside angle (.sub.M1) from the web outer side to the first flange, with a corresponding explementary inner angle (.sub.M1), with the first juncture forming a first juncture line (520) which is substantially parallel to the longitudinal axis; the second flange (400) comprising a second flange first edge (420) and a second flange second edge (440) defining a second flange plane (450) with the second flange first edge joined with the web second edge at a second juncture (530) having a second juncture outside angle (.sub.M2) from the web outer side to the second flange, with a corresponding explementary inner angle (.sub.M2), with the second juncture forming a second juncture line (540) which is substantially parallel to the longitudinal axis, with either one of, or both, .sub.M1 and .sub.M2 having a value of greater than 270 and less than 360; the first juncture line, the first flange first edge, the first flange second edge, the second juncture line, the second flange first edge, and the second flange second edge being substantially parallel with the longitudinal axis; the first notch comprising a first notch length (620), a first notch width (640) measured perpendicular to the first notch length, and a first notch cut plane (630) wherein the first notch length begins in the first flange at a first flange notch point (680) and extends at least through the first juncture and to a web first notch point (660); the second notch comprising a second notch length (720), a second notch width (740) measured perpendicular to the second notch length, and a second notch cut plane (730), wherein the second notch length begins in the second flange (400) at a second flange notch point (780) and extends through at least the second juncture to a web second notch point (760), wherein either one of, or both, the first notch length and the second notch length do not extend completely across the respective first flange and second flange; and a line passing from the web first notch point to the web second notch point is perpendicular to the longitudinal axis; the first stud comprising a first stud web, a first stud hole passing through the first stud web with the first stud hole having a first stud hole depth and a first stud hole length; wherein the bridge member passes through the first stud hole with the first notch and the second notch engaged with the first stud at the first stud hole.

2. The stud bridge member of claim 1, wherein a notch plane defined by the line connecting the first flange notch point to the web first notch point to the web second notch point to the second flange notch point is substantially perpendicular to the longitudinal axis.

3. The stud bridge member of claim 1, wherein the first notch width is substantially perpendicular to and along the first notch length and increases beginning from the first flange notch point to a first notch inflection line (690), and the second notch width is substantially perpendicular to and along the second notch length and increases beginning from the second flange notch point to a second notch inflection line (790).

4. The stud bridge member of claim 3, wherein a notch plane defined by the line connecting the first flange notch point to the web first notch point to the web second notch point to the second flange notch point is substantially perpendicular to the longitudinal axis.

5. The stud bridge member of claim 3, wherein the first notch width decreases beginning from the first notch inflection line to the web first notch point, and the second notch width decreases beginning from the second notch inflection line to the web second notch point.

6. The stud bridge member of claim 5, wherein a notch plane defined by the line connecting the first flange notch point to the web first notch point to the web second notch point to the second flange notch point is substantially perpendicular to the longitudinal axis.

7. The stud bridge member of claim 3, wherein the first notch extends through about the first juncture and the second notch extends through about the second juncture.

8. The stud bridge member of claim 7, wherein a notch plane defined by the line connecting the first flange notch point to the web first notch point to the web second notch point to the second flange notch point is substantially perpendicular to the longitudinal axis.

Description

BRIEF DESCRIPTION OF FIGURES

(1) FIG. 1 depicts one embodiment of a stud bridge member as it is installed to bridge across two studs.

(2) FIG. 2A depicts a perspective inner view of a stud bridge member highlighting the notch set in the circle.

(3) FIG. 2B depicts a close-up perspective inner view of the notch set and the two notches noted in FIG. 2A.

(4) FIG. 3A depicts a perspective outer view of a stud bridge member.

(5) FIG. 3B depicts a close-up perspective outer view of one notch of the notch set noted in FIG. 3A.

(6) FIG. 3C depicts a close-up perspective inner view of the other notch of the notch set noted in FIG. 3A.

(7) FIG. 4 is a cut-a-way center view at the point noted in FIG. 3A.

(8) FIG. 5 is a cut-a-way center view at the point noted in FIG. 3A.

(9) FIG. 6A is an embodiment of the notches of a notch set.

(10) FIG. 6B is a separate embodiment of the notches of a notch set.

(11) FIG. 6C is a separate embodiment of the notches of a notch set.

(12) FIG. 6D is a separate embodiment of the notches of a notch set.

DETAILED DESCRIPTION

(13) This invention is to an improved stud bridge member. The specification is best understood referring to FIG. 1, which is a detailed drawing of the invented stud bridge member installed to bridge across two studs. Reference will now be made to the various Figures in which, unless otherwise noted, like numbers refer to like structures. As described herein and in the claims, the following numbers refer to the following structures as noted in the Figures. 100 refers to the stud bridge member. 200 refers to the web. 210 refers to the web first edge. 220 refers to the web second edge. 240 refers to the web outer side. 250 refers to the web plane on the outer side. 260 refers to the web inner side. 300 refers to the first flange. 320 refers to the first flange first edge. 340 refers to the first flange second edge. 350 refers to the first flange plane. 400 refers to the second flange. 420 refers to the second flange first edge. 440 refers to the second flange second edge. 450 refers to the second flange plane. 500 refers to the longitudinal axis. 510 refers to the first juncture. 520 refers to the first juncture line. 530 refers to the second juncture. 540 refers to the second juncture line. 600 refers to the first notch of a notch set. 620 refers to the first notch length. 630 refers to the first notch cut length and the first notch cut plane. 640 refers to the first notch width. 660 refers to the web first notch point. 680 refers to the first flange notch point. 690 refers to the first inflection line. 700 refers to the second notch of a notch set. 720 refers to the second notch length. 730 refers to the first notch cut length and the first notch cut plane. 740 refers to the second notch width. 760 refers to the web second notch point. 780 refers to the second flange notch point. 790 refers to the second inflection line. 800 refers to the stud. 810 refers to the hole passing through the web of the stud. 820 refers to the hole depth. 830 refers to the hole length. .sub.M1 refers to the first juncture outside angle. .sub.M1 refers to the first inner angle. .sub.M2 refers to the second juncture outside angle. .sub.M2 refers to the second inner angle.

(14) As described in the background section, the traditional method of installing stud bridge members is to lay the stud bridge member at a hole through the stud, and then use clips on either side to secure the stud bridge member to the stud.

(15) Advances were made to also provide stud bridge members with slots. As indicated in the background section these slots pass through the flanges of the stud bridge member. The stud bridge member is used with the channel, trough, or inner side facing down, making the stud bridge unsuitable for laying cable or wiring.

(16) The novel stud bridge member in this specification can be installed without using a clip at each stud, thus reducing the cost and time to install. As the clips are only used at the end of each stud bridge member, a stud bridge member spanning 3 studs and clipped to 2 other studs would eliminate the time and expense of using 3 clips.

(17) This novel stud bridge member is also installed so that the channel faces up, allowing the channel to be used for cabling or electrical lines.

(18) Additionally, as the stud bridge member places a single horizontal metal channel across the stud and in between the studs, the stud bridge is much stronger and not susceptible to bending as seen in the commonly used V-bridging member described in U.S. Pat. No. 6,708,460.

(19) As the novel stud bridge member uses notches, water gathered during construction is naturally drained out of the upward facing channel through the notches.

(20) This specification uses the term web to describe a middle planar component (200) and the term flange to describe the outer planar components (300 and 400). These terms are interchangeable.

(21) The invented stud bridge member is best described by starting with FIG. 1. As shown in FIG. 1, the stud bridge member (100) is used between two studs (800). The stud bridge member has a first flange (300), a web (200), and a second flange (400).

(22) In FIG. 1, the web is joined to the first and second flanges forming a juncture line for each juncture. The first juncture line (520) is formed by the juncture (510) of the web (200) and the first flange (300). The second juncture line (540) is formed by the juncture (530) of the web (200) and the second flange (400). Reference is made to FIG. 4 for the juncture annotations (510 and 530) with each juncture defined by the dashed lines, a web portion and a portion of the corresponding flange.

(23) Either or both of the first juncture (510) and the second juncture (530) could be a weld, a bend, glue, or any another means known where two components can be joined. The first juncture and the second juncture are not required to use the same means of joining two components together. For instance, the first juncture may be a weld while the second juncture is a bend. Preferably the stud bridge (100) is made of a unitary piece of construction and the junctures are bends of the same piece, preferably made of metal. Examples of such metals include steel, stainless steel, iron, aluminum, copper, brass, titanium, and the like. However, the stud bridge could alternatively be extruded through a die where it is formed into shape and could be made of a metal or plastic material.

(24) As shown in FIG. 1, stud bridge member (100) has a longitudinal axis (500). This longitudinal axis (500) is used to orient the location of other components of the stud bridge member. The longitudinal axis is at the middle of the web (200) and runs along the web length.

(25) The longitudinal axis (500), the first juncture line (520) and the second juncture line (540) are all preferably parallel with or substantially parallel with each other.

(26) The stud bridge member (100) will have at least one notch set, comprised of a first notch and a second notch. As noted in FIG. 1, the notch set comprises the first notch (600) and the second notch (700). As discussed later, the notches are preferably cut to create a pinch point in the flanges to frictionally engage with the stud (800).

(27) The detail of one notch embodiment is shown beginning with FIG. 2A. FIG. 2A depicts stud bridge member (100) without the stud. As seen, it has the web (200), and the second flange (400). The first flange is also shown, but it is not marked. Also shown are the first juncture line (520), the second juncture line (540) and the longitudinal axis (500). The notch set comprised of first notch (600) and second notch (700) is indicated by the circle referring the reader to FIG. 2B. As indicated, depending upon the length of the stud bridge member, there can be several notch sets. In fact, it may be that not all notch sets are engaged with a stud. For example, there may be notch sets cut every 6 inches, but only every third notch set is engaged if the studs are 18 inches apart.

(28) FIG. 2B depicts an inner view of the stud bridge member forming the trough or channel. The web (200), the first flange (300), and the second flange (400) are shown.

(29) In one embodiment, each notch is an opening passing through the outer side to the inner, or channel side, of one of the flanges, the corresponding juncture and the web. The invention is best understood using the preceding notch description.

(30) There are other embodiments. One alternative embodiment comprises a notch which is an opening passing through the outer side to the inner, or channel side, of one of the flanges, through the corresponding juncture and only slightly into the web. Another alternative embodiment is a notch passing through one of the flanges, and the corresponding juncture, but not into the web.

(31) Starting with the first notch (600), the first notch has a first notch length (620). The first notch length is the line running from a reference point called the first flange notch point (680) to the web first notch point (660). In this case, the first notch is an opening starting at the first flange notch point. The first notch runs from the first flange notch point to the web first notch point.

(32) Although not required to be symmetrical with the first notch (600), the second notch (700) can have the same analogous features. The second notch (700) has a second notch length (720). The second notch length is the line running from a reference point called the second flange notch point (780) to the web second notch point (760). In this case, the second notch is an opening starting at the second flange notch point. The second notch runs from the second flange notch point to the web second notch point.

(33) In the case where a notcheither the first notch of the second notchpasses through the juncture, but does not pass into the web, the web notch point is at the web edge where the juncture begins.

(34) Preferably, the notch does not extend across the entire flange. However, in some embodiments, it is possible for a notch to run across the entire flange. In some embodiments, one notch of the notch set may extend across the entire flange, while the other notch does not. In some embodiments, both notches extend across the entirety of their respective flanges. Preferably, both notches do not extend across the entirety of their respective flanges.

(35) FIG. 3A shows the stud bridge from the outer channel view, or outer side, where the channel is pointing away from the viewer. As shown in FIG. 3A the web (200) has a web first edge (210) and a web second edge (220) which define a web plane (250). While the term web plane refers to a plane, it does not mean that the web is flat. As an example, the web may contain reinforcing ridges running in any direction, such as perpendicular to the longitudinal axis, or parallel with the longitudinal axis.

(36) FIG. 3A also shows the first flange (300) having two first flange plane edges (320 and 340) defining a first flange plane (350). While the term first flange plane refers to a plane, it does not mean that the first flange is flat. As an example, the first flange may contain reinforcing ridges running in any direction, such as perpendicular to the longitudinal axis, or parallel with the longitudinal axis.

(37) FIG. 3A also shows the second flange (400) having two second flange plane edges (420 and 440) defining a second flange plane (450). While the term second flange plane refers to a plane, it does not mean that the second flange is flat. As an example, the second flange may contain reinforcing ridges running in any direction, such as perpendicular to the longitudinal axis, or parallel with the longitudinal axis.

(38) As can be seen, the first flange plane (350), the web plane (250), and the second flange plane (450) are substantially parallel with the longitudinal axis (500).

(39) FIG. 3A again highlights the notch set, pointing the viewer to FIG. 3B and FIG. 3C for an expanded view of the first notch (600) and the second notch (700), respectively.

(40) From the outer view, FIG. 3B shows that the first notch (600) has a first notch width (640) which is measured perpendicular to the first notch length (620). The first notch width can be constant along the distance of the notch length or it can have a variable width.

(41) A preferable embodiment is depicted in FIG. 3B, showing a variable notch width increasing as the notch progresses from the first flange notch point (680) across a portion of the first flange (300), across the first juncture line (520), and then decreasing as the notch approaches the web first notch point (660).

(42) The first notch cut plane (630) is defined by a cut made into the web and the first flange if the web and the first flange had been flat, or not bent, when the cut for the first notch was made. After bending, the cut in the web and the first flange form two legs of a triangle, which define the first notch cut plane.

(43) In the current embodiment, there is a first inflection line (690) which is the line perpendicular to the first notch length at which the first notch width (640) is at its greatest value. Because of the rectangular nature of this particular embodiment, the first inflection line coincides with, or is parallel with, the first juncture line (520).

(44) Analogously, FIG. 3C shows the second notch (700) having a second notch width (740) which is measured perpendicular to the second notch length (720). The notch width can be constant along the distance of the notch length or it can have variable widths. A preferable case is depicted in FIG. 3C, showing a variable notch width increasing as the notch progresses from the second flange notch point (780) across a portion of the second flange (400), across the second juncture line (540), and then decreasing as the notch approaches the web second notch point (760).

(45) The second notch cut plane (730) is defined by a cut made into the web and the second flange as if the web and the second flange had been flat, or not bent, when the cut for the second notch was made. After bending, the cut in the web member and the second flange form two legs of a triangle, which define the second notch cut plane.

(46) In the current embodiment, there is a second inflection line (790) which is the line perpendicular to the second notch length at which the second notch width (740) is at its maximum. Because of the rectangular nature of this embodiment, the second inflection line coincides with, or is parallel with, the second juncture line (540).

(47) To facilitate straight positioning of the stud bridge member between the studs, it is preferable that the first notch length (620) and the second notch length (720) not be parallel, but in the same plane.

(48) In a further embodiment the first notch length (620) and the second notch length (720) in a given notch set are perpendicular to the longitudinal axis.

(49) The notches may widen and then shrink to facilitate twisting the member into place and locking it onto the stud. This can be described as the first notch width (640) increasing along the first notch length (620) beginning from the first flange notch point (680) to the first notch inflection line (690) and then decreasing from the first notch inflection line (690) to the web first notch point (660). The notches widen to help account for build variation that occurs during stud to track to building assembly.

(50) Similarly, the second notch width (740) increases along the first notch length (720) beginning from the second flange notch point (780) to the second notch inflection line (690) and then decreases from the first notch inflection line (690) to the web second notch point (760).

(51) The first notch cut plane (630) and the second notch cut plane (730) form what is called the notch plane. The notch plane is also defined by the line connecting the first flange notch point (680) to the web first notch point (660) to the web second notch point (760) to the second flange notch point (780). It is preferable that the line passing from the web first notch point (660) to the web second notch point (760) be perpendicular to the longitudinal axis (500) in order to keep the notches properly aligned with the longitudinal axis.

(52) The notch plane may be perpendicular to, substantially perpendicular to, or not substantially perpendicular to, the longitudinal axis (500).

(53) The only force needed to engage the notches with a stud when the notch plane is substantially perpendicular to the longitudinal axis (500) is a force in the inner direction to engage the notches with a stud.

(54) In contrast, the installer slides the bridge in the longitudinal directional and pushes the bridge member in the inner channel direction to engage the notches with the stud when the notch plane is not substantially perpendicular to the longitudinal axis (500).

(55) The notch sets are parallel when a plurality of notch sets is present on the bridge member.

(56) It is also preferable that the notch points in the flange edges, i.e. the first flange notch point and the second flange notch point, are equidistant from the longitudinal axis.

(57) However, in an alternative embodiment, the notch points in the flange edges, i.e. the first flange notch point and the second flange notch point, may not be equidistant from the longitudinal axis.

(58) In one embodiment both notches in the notch set are symmetrical, i.e. the same geometric shape. In an alternative embodiment, the notches in the notch set are not symmetrical.

(59) FIG. 4 is a cutaway view as depicted in FIG. 3A. Shown in FIG. 4 are a web outer side (240), and a web inner or channel side (260) which is opposite of the web outer side. As further seen, one of the first flange edges (320) is joined with the web first edge (210). As shown, this joining is done at a first juncture (510) having a first juncture outside angle (.sub.M1) measured from the web outer side (240) to the outer side of the first flange (300).

(60) The value of .sub.M1 is preferably greater than 270 and less than 360. If .sub.M1 is less than 270 the stud bridge member is difficult to rotate onto the walls of the stud hole.

(61) As a corollary, there will be an explementary angle .sub.M1, which is the value of the angle opposing angle .sub.M1. .sub.M1 plus .sub.M1 will equal 360.

(62) The first juncture (510) of the stud bridge forms a first juncture line (520) which is substantially parallel to the longitudinal axis (500).

(63) The similar structure is true of the second flange. As with the first flange, one of the second flange edges (420) is joined with the web second edge (220) at a second juncture (530) having a second juncture outside angle (.sub.M2).

(64) Like .sub.M1, .sub.M2 is measured from the web outer side (240), i.e. the non-channel side, to the outer side of the second flange (400) as shown in FIG. 4. The value of .sub.M2 is preferably greater than 270 and less than 360. If .sub.M2 is less than 270 the stud bridge member will be difficult to rotate onto the walls of the stud hole.

(65) As a corollary there will be an explementary angle .sub.M2 which is the measurement of the angle opposing angle .sub.M2. .sub.M2 plus .sub.M2 will equal 360.

(66) It is preferred that .sub.M1=.sub.M2, although not required. Put another way, .sub.M1 and .sub.M2 have about the same value, or preferably are the same value.

(67) The second juncture forms a second juncture line (540) which is substantially parallel to the longitudinal axis (500).

(68) To define the C shape, or channel, as opposed to a Z, the first flange (300) and the second flange (400) must simultaneously be in a space on the web inner side (260).

(69) FIG. 5 is a cutaway view of the stud bridge member (100). It depicts the first flange (300), the second flange (400), the web (200) having a web outer side (240) and a web inner side (260). The web first notch point (660), the first flange notch point (680) and the first inflection point (690) are also shown. The web second notch point (760), the second flange notch point (780) and the second inflection point (790) are shown as well. One way to make the bridge member is to cut the notches into a flat piece of metal and then fold the flat piece of metal into the web with a flange on each side. This is depicted in FIG. 6A to FIG. 6D. When metal flat, the notch has a distinct shape.

(70) One preferred shape is an elongated rectangle, preferably an elongated square. This is depicted in FIG. 6B. The notch shape would appear flat as a diamond with elongated tips at the flange notch points. This elongated flaring from the flange notch point or necking down as the cut approaches the flange notch point, helps improve the engagement of the notch with the stud. This elongated flaring or necking down to a pinch point in the flange also creates a lead-in for the stud member to aid in the assembly process.

(71) FIG. 6A to FIG. 6D show alternative embodiments of the notches in the notch set. These embodiments demonstrate how the part of the notch in the flange has a pinch point, but that the part of the notch in the web should be minimized. To be minimized means that the maximum distance from the cut(s) in the web measured from any point along the cut in the web, perpendicular to the longitudinal axis to the juncture is less than about 10% of the width of the web, preferably less than 5% of the width of the web, with less than 1% of the width of web even more preferred. It is even possible that the notch is not cut into the web at all, but only through the juncture. The notch's radius into the web is preferably large while the notch width and length in the web should be smaller. The notch should be sharp in the flange, but well-rounded in the web

(72) In FIG. 6A, the unstretched square oriented as a diamond is shown.

(73) FIG. 6B, shows the stretched rectangle, or stretched diamond. This is a preferable embodiment so that the stud wall can be pinched by the part of the notch in the flange. The notch edge lines do not have to be straight but can be curved as indicated.

(74) In FIG. 6C, the embodiment of substantially forming a triangle is shown with the two sides of the notch tapering to a point in the flange side, and extending past the inflection point, through about the juncture and about, or optionally slightly into the web. While the drawing shows the part of the triangle in the web being a curve, that part of the notch line can be straight, zig-zagged, or two lines, provided that the maximum distance into the web is less than one of the preferred amounts noted above. The lines do not have to be straight but can be curved as indicated. In fact, the web first notch point (660) and web second notch point (760) can be immediately after the juncture at the respective web edge (210 and 220). Again, the notch's radius into the web is preferably large while the notch width and length in the web should be smaller. The notch should preferably be sharp in the flange, but well-rounded in the web.

(75) FIG. 6D shows the embodiment where the notch cuts through the juncture but does not enter the web. In fact, the web first notch point (660) and web second notch point (760) are in between the juncture and the respective web edge (210 and 220).