METHOD OF MANUFACTURING A METAL FRAMING MEMBER

Abstract

A framing member incorporates a series of web slots along a portion of the member that are expanded through the process of manufacture. The expansion of the web slots creates voids and metal web elements in the webbed portion of the member, which can be a stud. The voids created during the expansion process can become the voids for running wiring, plumbing and heating ducts. The web elements can be designed to minimize thermal transmission from the exterior to the interior of a wall including the member, as well as provide adequate structure properties required from the structural member. The expanded slots allow the part to enlarge without increasing the amount of raw material and therefore substantially reducing the cost to manufacture.

Claims

1. A method of manufacturing a framing member comprising: providing a formed metal sheet having a length and a web region; placing a plurality of slots along a portion of the length in the web region; and expanding the slots of the web region to form expanded slots having a web element and a web void, the metal sheet being heat treated.

2. The method of claim 1, wherein providing the formed metal sheet includes roll forming a metal sheet.

3. The method of claim 1, wherein placing the plurality of slots includes piercing slots into the region.

4. The method of claim 1, wherein placing the plurality of slots includes stamping the slots into the region.

5. The method of claim 1, wherein expanding the slots includes passing the formed metal sheet over a tapered block.

6. The method of claim 1, wherein expanding the slots includes mechanically moving sides of the region apart.

7. The method of claim 1, further comprising reinforcing the expanded formed metal sheet.

8. The method of claim 7, wherein reinforcing includes placing a flange or dart in the web element.

9. The method of claim 1, wherein the formed metal sheet includes a first flange extending from the web region and a second flange extending from the web region in a direction substantially parallel to the first flange.

10. The method of claim 9, further comprising placing a plurality of slots along a portion of the length in each of the first flange and the second flange.

11. The method of claim 10, further comprising expanding the slots of the first flange and the second flange.

12. The method of claim 9, wherein the formed metal sheet further includes a closing region extending the first flange to the second flange to form a substantially tubular structure.

13. The method of claim 1, wherein placing the plurality of slots includes arranging the slots in offset columns substantially parallel to a length of the member.

14. The method of claim 1, further comprising heat treating the member after expanding the slots.

15. The method of claim 1, further comprising heat-treating the member prior to expanding the slots.

16. The method of claim 1, further comprising heat-treating the member while expanding the slots.

17. The method of claim 1, further comprising annealing the member.

Description

DESCRIPTION OF DRAWINGS

[0016] FIG. 1 is a perspective view of a portion of the member with forming complete and web created but prior to expansion into final configuration.

[0017] FIG. 1a is a perspective view of the member of FIG. 1 with forming complete, web slots created and expanded into its expanded configuration.

[0018] FIG. 2 is a perspective view of a portion of a member with insulation strips shown attached to the flanges.

[0019] FIG. 2a is a section view of the member of FIG. 2 with insulation strips shown attached to the flanges.

[0020] FIG. 3 is a perspective view of a portion of a member with darts and flanges shown in locations of the member. FIG. 3a is a section view of the member of FIG. 3 through a darted area showing a typical configuration.

[0021] FIG. 3b is a section view of the member of FIG. 3 through a flanged area showing a typical configuration.

[0022] FIG. 4a-4e are section views showing alternative flange configurations that could be used in conjunction with the expanded web.

[0023] FIG. 5 is a perspective of a portion of a member with expanded web in the flange area.

[0024] FIG. 6 is a perspective view of a portion of the member in a tubular configuration with forming complete, web slots created but prior to expansion.

[0025] FIG. 6a is a perspective of the member of FIG. 6 with forming complete, web slots created and expanded.

[0026] FIG. 7 is a perspective of a portion of a tubular section with expanded web design on both the web area and flange area.

[0027] FIG. 8 is a perspective of a portion of a member with an alternative web slot and web element configuration.

[0028] FIG. 9 is a perspective of a portion of a member with an alternative web slot and web element configuration.

DETAILED DESCRIPTION

[0029] A framing member can be manufactured by expanding metal in a web region, a flange region, or both, during the manufacturing process. Slots can be formed in a pattern such that the region can be expanded during the manufacturing process. The expansion creates the voids and web elements that extend at least one dimension of the framing member. The voids can create thermal resistance which reduces the thermal conductivity of the member and improves R-value of the ultimate structure. Because the metal is expanded, there is little or no scrap metal produced during manufacture.

[0030] FIG. 1 is an isometric view of a portion a framing member 100 prior to expansion into the final configuration but with the web slots 103 pierced into the web area. The placement, shape and length of the web slots 103 in a region having dimension a1 determine the width and length of the web elements 102 as well as the shape and size of the web voids. Flanges 101 extend away from the web region. The member can be manufactured in part or in whole through a roll forming process. Alternatively, a stamping process can be used to manufacture the member. The member can be manufactured from steel or aluminum, or any other suitable metal in sheet form. The sheet can have a thickness of, for example, 24 to 10 gauge.

[0031] Referring to FIG. 1a, which depicts an expanded framing member, the typical dimension c of flange 101 can be approximately 1.5 inches, although it can be adjusted for different applications. Web area dimension a1 in the region increases during the manufacturing process by expanding the slots to become significantly wider until the web area reaches the final dimension a2 is shown on FIG. 1a. The final quantity, shape and width and length of the web slots determine the size of web voids 104 and web elements 102 are selected to optimize all of the objectives and limitations of the material to be formed into the final shape. Optimization will depend upon specific customer needs. Dimension b can be 2.5 inches to 11.5 inches but can be higher if required. The final member length d can be 92 to 120 inches for wall studs and 2 feet to 20 feet for structural elements such as floor joists, although, generally, dimension d can be any length.

[0032] The framing member can be manufactured by a process, for example, that includes passing a sheet of metal from a coil through a series of form rolls that create the structural shape of the framing member. During the roll forming process, the web slots are pierced into the region to be expanded, such as center web area b. The piercing can be performed with a stamping die, a configured roll, laser or any other suitable method of creating the web slot. The web slot configuration can be adjusted to accommodate any desired shape or length in order to create a web void or web element that enhances the thermal performance, cost reduction, tradesperson access, structural enhancement or any other desired objective not currently realized.

[0033] After the web slots have been incorporated into the region of the member, the member can be expanded by moving the flanges perpendicularly opposed to one another until the desired width a2 is obtained. The expansion process can be performed in several ways including passing the member over a tapered forming block during the roll forming process. For example, the unexpanded member can be forced over a tapered forming block that fits between the two flanges. As the flanges move down forming line and over the tapered forming block, the flanges move progressively apart until reaching the desired width a2 shown in FIG. 1a. An alternative to a tapered forming block can be rolls or a block including rolls attached to the forming block. An alternative method of expansion by rolling can include expanding using a mechanical or hydraulic mechanism that locks onto the flanges on the member and move them apart to the desired width a2. The expansion can extend a dimension by a factor of 10% to 300%, 20% to 250%, or 50% to 100%.

[0034] The final width determines the overall width of the member as well as the final configuration and dimension of the of the web voids. After expanding, the member can be heat treated to strengthen a portion of the member, for example, by heating the portion of the member for a period of time, or the entire member, and quenching the member. The member can have a yield strength of between 10 and 100 ksi, or 30 to 60 ksi, for example, 33 ksi or 50 ksi.

[0035] An alternative method of manufacturing the expanded web is to apply heat to change the mechanical properties of the metal prior to or during expansion. The heat can be used in to anneal the material according to acceptable practices. This can be accomplished by heating and cooling to remove residual stress and work hardening that has taken place during the rolling process of steel manufacture. Annealing can maximize the ability to cold form and expand the web. In another example, the heat can be applied to heat the material to a temperature that can allow the web to be formed, or expanded, while in the elevated temperature state. After forming, the material can be cooled in whatever method or at whatever speed is desired to obtain the final desired mechanical properties. The second process allows the ability to create a higher strength steel product and significantly improve the mechanical properties of the stud if desired. In each method, the heat can be applied locally or globally to the material as desired.

[0036] Referring to FIGS. 2 and 2a an insulated strip 201 can be attached to the flange 203 by adhesive, staples, nails or other similar fasteners. The insulated strip can be made of wood, plastic, or other materials that can function as both a thermal insulated barrier fire resistant and exhibit characteristics that would allow conventional nailing. This can allow the use of nail guns and other automated tools normally used for attaching the structural members together and sheathing to flanges. This configuration can have insulated strips on either one or both flanges of the member.

[0037] FIG. 3 is perspective showing an expanded web framing member made with optional flanges 302 and darts or dimples 301 that can enhance the structural properties of the web elements, and the member. The expanded slots form regions of stress in the member, which can enhance or degrade the structural properties of the member. The darts or dimples, or flanges, can reduce stress in the member introduced during expanding, thereby strengthening the member. The flanges and darts can be incorporated, for example, during the roll forming operation of manufacture, or by stamping or rolling in to the sheet prior, to or after the shaping operation. The shape and configuration of the darts and flanges can be adjusted to any length, shape or depth in order to achieve the desired objectives. FIG. 3a shows a cross section of the member of FIG. 3 through the flanged area of the web element and depicts flanges 302. FIG. 3b shows a cross section of the members of FIG. 3 through the dimpled or darted area 301.

[0038] FIG. 4a-4e show a cross section of various members with alternative flange configurations 402 that can be applied to the expanded framing member. The effectiveness and benefits of the expanded web design can be enhanced by the different configurations of the flanges, however, any alternative flange configuration can generally be used.

[0039] FIG. 5 is a perspective of a framing member 500 that includes web slots 503 and web elements 502 within the flange 501 of the member.

[0040] FIG. 6 and FIG. 6a depict an alternative framing member 600 made of a tubular section 610 having web region 601, flanges 602, and closing region 608. FIG. 6 is the member 600 shown prior to expansion and FIG. 6a is the member 600 shown in the final expanded form. The tubular section can exhibit improved torsional rigidity as compared to an open C section (see, for example, the member of FIG. 1). The improved torsional rigidity can be desirable in some structural applications.

[0041] FIG. 7 is a perspective of another member 700 similar to the one shown in FIG. 6a, which includes web slots and web elements within the flange of the member.

[0042] FIGS. 8 and 9 depict perspective views of members 800 and 900, respectively, that include varied web element 802 and 902 and web void 902 and 903 configurations. It is important to state that the configuration of the web slots and web elements are determined on a case-by-case basis. These alternatives shown are only examples and are not meant to be limiting.

[0043] A number of embodiments have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the concepts described above. For example, the expanded framing member concept can apply to other structural members such as floor joists, in which the web slots can be designed to create web elements capable of withstanding a structural load. If required, the web slot and web elements can have darts and flanges added to create strength. Accordingly, other embodiments are within the scope of the following claims.