Steel Thermal Stud And Method Of Manufacture Thereof

Abstract

Disclosed herein is a steel thermal stud and method of manufacturing thereof. The steel thermal stud of the present invention can be used in load bearing and non-load bearing applications as a direct replacement for wood studs, however installed the same as traditional steel studs. The steel thermal stud is able to be insulated with a variety of insulation products depending on the application, and the stud discloses a superior thermal and acoustic properties while being much lighter than wood studs.

Claims

1. A steel thermal stud, said stud comprising: a pair of top and bottom flanges with webs AA, wherein each flange with respective webs includes a flange continuing to an inner web at a bend on both sides, said inner web continuing to a step on the both sides, an outer web continuing from said step terminates at a specified distance in an opposite direction of said step on the both sides, a plurality of slots located on said outer web on the both sides, and a plurality of aligned slots provided over said flange; multiple pairs of opposing formed plates AC, configured to be spaced along length of said pair of top and bottom flanges with webs AA, hence to hold together said top and bottom flanges with webs AA; and an insulation AB, adapted to be located inside of said stud, wherein said insulation AB is securely contained in place via said pair of top and bottom flanges with webs AA and said multiple pairs of opposing formed plates AC.

2. The stud of claim 1, wherein said plurality of aligned slots are configured to make said bend by merely rolling each of said top and bottom flanges with webs AA over.

3. The stud of claim 1, wherein said pair of top and bottom flanges with webs AA may allow a fastener to penetrate in order to prevent the movement of said fastener in any direction, to prevent deformation of the stud wall material, to prevent said fastener from backing out by having additional contact with less potential movement, to provide more pull-out strength and more strip resistance of said fastener during installation.

4. The stud of claim 1, wherein said each formed plate AC is comprised of a web and a pair of formed ends, and termination of said formed ends and an inner surface of said web tightly contact the inside and outside of said outer web of said top and bottom flanges with webs AA.

5. The stud of claim 1, wherein said plurality of slots are configured to stuck in each formed end of each of said formed plates AC.

6. The stud of claim 1, wherein said formed plates AC may help isolate and absorb vibration and thermal transfer, and assist with structural strengths.

7. The stud of claim 1, may further comprise a secondary flange AD which is configured to be located within said top, or said bottom, or said top and bottom flanges with webs AA, to provide additional penetration locations for mounting screws or fasteners, in order to allow multiple connection points on said screws or fasteners hence to make said screws or fasteners cantilevered to support loads.

8. The stud of claim 7, wherein said secondary flange AD is comprised of a pair of legs and a web.

9. The stud of claim 1, may further comprises additional holes, slots, ribs or other shapes for running conduits, pipes, tubes, insulation and other mechanisms through, and to assist with fastener drifting as well as allowing easier penetration for pointed or self-drilling fasteners.

10. A method of manufacturing a steel thermal stud, said method comprising steps of: decoding of strip slack sections to form a pair of top and bottom flanges with webs AA; forming of a step on each side of said strips of said top and bottom flanges via a roll-forming; forming of a bend on each side of said strips of said top and bottom flanges via a plurality of aligned slots; foaming an insulation AB and forming of a plurality of slots; installing multiple pairs of opposing formed plates AC through said plurality of slots to hold together said top and bottom flanges; and stacking and packaging of said steel thermal stud.

11. The method of claim 10, wherein said stud may be made by employing a forming process that includes a use of compression around the different stud components, and use of electro-magnetic to control the positioning of said top and bottom flanges with webs AA during a formed plate installation to ensure proper alignment with minimal tolerances to install said formed plates AC simultaneously at all locations on said stud, along with alignment electronic controls.

12. The method of claim 10, wherein said manufacturing process may allow the final bends at aligned perforations to be over-bent, pushing into said insulation AB, and recovering or springing-back to the correct angle, wherein said insulation AB may assist in maintaining the shape of said stud, both during the forming process and once said stud is ready for use.

13. The method of claim 10, wherein said steel stud may install a plastic spacer before forming of the final bend to prevent over-bending of the last-formed web when using light density insulation within said stud.

14. The method of claim 10, wherein said steel stud may be made using galvanized steel in coil form, and manufactured on roll forming machines with various in-line punches, dies, top and bottom rollers, wheels, shears, etc.

15. The method of claim 10, wherein said steel stud may also be made with multiple machines such as a turret press and brake press.

16. The method of claim 10, wherein said formed plates AC may be made up of a material such as stainless steel, snap-in fiber reinforced plastic pultrusions, injection molded and extruded plastics.

17. The method of claim 10, wherein said formed plates AC may have a plastic or other coating to help prevent vibration and acoustic transfer between said top and bottom flanges with webs AA and said formed plates AC.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0040] FIG. 1 is an isometric elevation view of a stud A including a pair of top and bottom flanges of metal, each with webs, and slots punched having a specific distance between them which will match the final formed stud width, according to an embodiment of the present invention.

[0041] FIG. 2 is an isometric elevation view of the pair of top and bottom flanges of FIG. 1 in the form of parallel strips with a space therebetween, according to an embodiment of the present invention.

[0042] FIG. 3 is an isometric elevation view of the strips of FIG. 2 with a step formed on each side of each strip along its length, according to an embodiment of the present invention.

[0043] FIG. 4 is an isometric elevation view of a semi formed stud A with a first bend in both flanges with webs, and an insulation piece installed in a gap therebetween the semi formed stud A, according to an embodiment of the present invention.

[0044] FIG. 5 is an isometric plan section view of a fully assembled stud A showing how the formed plates may connect the flanges with webs together, according to an embodiment of the present invention.

[0045] FIG. 6 shows an isometric elevation view of an alternate embodiment of the present invention which provides a secondary flange installed within either of the top or bottom flange with webs of the stud A for improved structural performance as well as improved fastener and external cantilevered load capabilities.

[0046] For a better understanding of the invention of this application, reference is made to the following detailed description of the preferred embodiments thereof which should be referenced to the prior described drawings.

DETAILED DESCRIPTION OF THE INVENTION

[0047] Various aspects of the present application will, evolve from the following detailed description of the preferred embodiments thereof which should be taken in conjunction with the prior described drawings.

[0048] Before explaining the present invention in detail, it is to be understood that the invention is not limited in its application to the details of the construction and arrangement of parts illustrated in the accompanying drawings. The invention is capable of other embodiments, as depicted in different figures as described above and of being practiced or conducted in a variety of ways. It is to be understood that the phraseology and terminology employed herein is for the purpose of description and not of limitation.

[0049] It should be understood that an embodiment is an example of a possible implementation of any features and/or elements presented in the attached claims. Some embodiments have been described for the purpose of illuminating one or more of the potential ways in which the specific features and/or elements of the attached claims fulfil the requirements of uniqueness, utility and non-obviousness.

[0050] Use of the phrases and/or terms such as but not limited to “exemplary embodiment,” “an embodiment,” “an alternate embodiment,” “one embodiment,” “another embodiment,” or variants thereof do not necessarily refer to the same embodiments. Unless otherwise specified, one or more particular features and/or elements described in connection with one or more embodiments may be found in one embodiment, or may be found in more than one embodiment, or may be found in all embodiments, or may be found in no embodiments. Although one or more features and/or elements may be described herein in the context of only a single embodiment, or alternatively in the context of more than one embodiment, or further alternatively in the context of all embodiments, the features and/or elements may instead be provided separately or in any appropriate combination or not at all. Conversely, any features and/or elements described in the context of separate embodiments may alternatively be realized as existing together in the context of a single embodiment.

[0051] For the purposes of the description, a phrase in the form “A/B” or in the form “A and/or B” or in the form “at least one of A and B” means (A), (B), or (A and B), where A and B are variables indicating a particular object or attribute. When used, this phrase is intended to and is hereby defined as a choice of A or B or both A and B, which is similar to the phrase “and/or”. Where more than two variables are present in such a phrase, this phrase is hereby defined as including only one of the variables, any one of the variables, any combination of any of the variables, and all of the variables, for example, a phrase in the form “at least one of A. B, and C” means (A), (B), (C), (A and B), (A and C), (B and C), or (A, B and C).

[0052] It is to be understood that the term “comprises” and grammatical equivalents thereof are used herein to mean that other components, ingredients, steps, etc. are optionally present. For example, an article “comprising” (or “which comprises”) components A, B, and C can consist of (i.e., contain only) components A, B, and C, or can contain not only components A, B, and C but also contain one or more other components.

[0053] It is to be understood that the terms “steel stud” and “stud” are interchangeable throughout the disclosure, unless otherwise specified.

[0054] Reference will now be made in detail to the preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawings.

[0055] According to a preferred embodiment of the present invention, an isometric elevation view of a stud A is shown in FIG. 1. With reference to FIG. 1, it is shown that the Stud A is comprising: a pair of top and bottom flanges with webs AA; multiple pairs of opposing formed plates AC, configured to be spaced along the length of the pair of top and bottom flanges with webs AA, hence to hold the top and bottom flanges together; and an insulation AB, adapted to be located full length inside of the Stud A, wherein the insulation AB is securely contained in place via the pair of top and bottom flanges with webs AA and the multiple pairs of opposing formed plates AC as shown in FIG. 1.

[0056] Further referring to FIG. 1, the pair of top and bottom flanges with webs AA, wherein each flange with respective web is comprised of: a flange 10, continuing to an inner web 14 at a bend 12 on both sides; the inner web 14 continuing to a step 16 on the both sides; an outer web 18 continuing from the step 16, terminates at a specified distance in an opposite direction of the step 16 on the both sides; a plurality of slots 26, located on the outer web 18 on the both sides, wherein the slots 26 are configured to stuck in both ends of each formed plate AC; and a plurality of aligned slots 28 provided over the flange 10, configured to make a bend by merely rolling the each of the flanges with webs over.

[0057] Continue referring to FIG. 1, the pairs of opposing formed plates AC, wherein each formed plate is comprised of a web 20 and a pair of formed ends 22, wherein the termination of the formed ends 22 and an inner surface of the web 20 tightly contact the inside and outside of the outer web 18 of the top and bottom flanges with webs AA as shown in FIG. 1.

[0058] In one embodiment, the pair of top and bottom flanges with webs AA is shown in the form of two strips parallel to each other with a space 24 therebetween as shown in FIG. 2. Further referring to FIG. 2, the slots 26 are shown extending along the length of each strip, at a specific distance apart from each other. Furthermore, the aligned slots 28 are shown extending the full length of each strip, and located adjacent to each other with a minimal distance, like a dashed line.

[0059] In one embodiment, each of the two strips of FIG. 2 is shown with the step 16 on each side as shown in FIG. 3. The step 16 may be roll-formed into the strips of the respective flanges with webs AA.

[0060] In one embodiment, a semi formed stud A is shown in FIG. 4. Now referring to FIG. 4, the strips of the respective flanges with webs AA of FIG. 3 are shown, each with the bend 12 made at one side, and the insulation AB is installed therebetween the flanges with webs AA. Further, the other side of the flanges with webs AA is shown open as the bend is not yet made at the aligned slots 28 on the other side.

[0061] In further embodiment, the strips of the respective flanges with webs AA of FIG. 4 are shown with the bends on the other side in FIG. 5 that make the stud A almost fully assembled. The bends are made at the aligned slots 28 of the respective flanges with webs AA. In addition, FIG. 5 depicts the slots 26 to show that how the formed plates AC may connect the flanges with webs AA together.

[0062] In one embodiment, the stud A may not apply the formed plates AC to hold the flanges with webs AA together, for applications such as, non-load bearing conditions, wherein the webs of the flanges with webs AA may have small interior facing barbs, formed with a punch press, that penetrate the insulation AB to prevent separation of the flanges with webs AA, and to keep the insulation AB positioned therebetween the flanges with webs AA.

[0063] According to an alternate embodiment of the present invention, an isometric elevation view of the stud A with an additional secondary flange AD is shown in FIG. 6. With reference to FIG. 6, the secondary flange AD is comprised of a pair of legs 40, 42, and a web 44. The secondary flange AD may be located within the top, or the bottom or the both flanges of the stud A, and the insulation AB can be sized consequently to match with the secondary flange AD, Moreover, the insulation AB may also be located between the pair of legs 40, 42 of the secondary flange AD.

[0064] According to abovementioned embodiment, the secondary flange AD is configured to provide additional and separated penetration locations for mounting screws or fasteners, in order to allow multiple connection points on the screws or fasteners so that they become cantilevered and able to support loads unlike a single walled stud.

[0065] The present invention further discloses a manufacturing process of making the stud A. The manufacturing process comprises a plurality of process steps, including, but not limited to, decoiling of strip slack sections to form the pair of top and bottom flanges with webs AA; forming of the step 16 on each side of the strips of the top and bottom flanges via a roll-forming; forming of the bend 12 on each side of the strips of the top and bottom flanges via the plurality of aligned slots 28; foaming the insulation AB and final forming of the plurality of slots 26; installing the formed plates AC through the plurality of slots 26 to hold together the top and bottom flanges; and stacking and packaging of the stud A.

[0066] In one embodiment, the stud A may be made by employing a forming process that includes a use of compression around the different stud components, and use of electro-magnetic to control the positioning of the flanges with webs AA during a formed plate installation to ensure proper alignment with minimal tolerances to install the formed plates AC simultaneously at all locations on the stud A, along with alignment electronic controls.

[0067] In one embodiment, the manufacturing process may allow the final bends 12 at aligned perforations to be over-bent, pushing into the insulation AB, and recovering or springing-back to the correct angle, wherein the insulation AB may assist in maintaining the shape of the stud A, both during the forming process and once the stud A is ready for use.

[0068] In one embodiment, the steel stud A of the present invention may be made using galvanized steel in coil form, and fabricated/manufactured on roll forming machines with various in-line punches, dies, top and bottom rollers, wheels, shears, etc. The stud A may also be made with multiple machines such as a turret press and brake press. Further, joining of the flange webs may be accomplished by using formed stainless-steel clips. The stud A may have additional holes, slots, ribs or other shapes traditionally used for “EQ” structural purposes, for reduction in thermal and acoustic transfer, for running conduits, pipes, tubes, insulation and other mechanisms through, and to assist with fastener drifting as well as allowing easier penetration for pointed or self-drilling fasteners.

[0069] In one embodiment, the formed plates AC may be made up of a material such as stainless steel which is formed by a process similar to a cardboard box staple gun, wherein the gun forms the stainless steel as the steel is entering matching slots in the webs of the top and bottom flanges AA. The formed plates AC may have a plastic or other coating to help prevent vibration and acoustic transfer between the flanges with webs AA and the formed plates AC. In alternate embodiment, snap-in fiber reinforced plastic pultrusions, injection molded and extruded plastics, and other materials may be used in place of the stainless-steel formed plates, wherein the entry points into the slots of the webs of the top and bottom flanges AA are pointed and unidirectional “fingers” so that they will insert, but not easily be removed from the webs of the top and bottom flanges AA.