Stud with triangular longitudinal channel

Abstract

The integral stud has a central longitudinal side; a first longitudinal side joined at a 90° angle to the first end of the central longitudinal side; and a second longitudinal side joined at a 90° angle to the second end of the central longitudinal side. The central side has first and second planar faces joined by an intermediate acute-angled isosceles triangular channel. The first longitudinal side is formed from third and fourth planar faces joined by an intermediate acute-angled isosceles triangular channel. The second longitudinal side has fifth and sixth planar faces joined by an intermediate acute-angled isosceles triangular channel. At the ends opposite the 90° junction, the first and second longitudinal sides each have free ends forming a right-angled isosceles triangle with a gap. The longitudinal channels increase the axial and moment capacity of the stud.

Description

[Technical Field]

[0001] The present invention relates to building materials, and more particularly to studs having triangular longitudinal channels. [Background technology]

[0002] A typical problem with "CEE" studs currently on the market is that their height limit is often calculated from the building height, which requires the contractor to raise the gauge of the stud or size. Height limit is often overlooked by building services. Summary of the Invention [Problem to be solved by the invention]

[0003] As can be seen, there is a need for a stud that can support taller structures without increasing the gauge. [Means for solving the problem]

[0004] In one aspect of the invention, the integral stud includes: a central longitudinal side formed from a first planar surface having a first end and a second planar surface having a second end, the first and second planar surfaces being joined by a central acute isosceles triangular channel intermediate the first and second ends; a first longitudinal side joined at a 90° angle to the first end of the central longitudinal side and having a third end opposite the first end, the first longitudinal side being formed from a third planar surface and a fourth planar surface, the third planar surface and the fourth planar surface being joined by a central acute isosceles triangular channel intermediate the first end and the second end; a first side joined by an acute isosceles triangular channel intermediate the first end and a third end forming a right isosceles triangle with a first gap; and a second longitudinal side joined at a 90° angle to the second end of the central longitudinal side and having a fourth end opposite the second end, the first longitudinal side being formed from a fifth plane and a sixth plane, the fifth plane and the sixth plane being joined by the second side acute isosceles triangular channel intermediate the second end and the fourth end, the fourth end forming a right isosceles triangle with a second gap.

[0005] In another aspect of the invention, a method of manufacturing an integral stud includes the steps of: providing an elongated metal sheet having a first longitudinal end and a second longitudinal end; forming a first bend at a first length from the first longitudinal end; forming a second bend at the first length from the first bend; forming a third bend at a second length from the second bend; forming a fourth bend at a third length from the third bend; forming a fifth bend at a fourth length from the fourth bend; forming a sixth bend at a third length from the fifth bend; forming a seventh bend at a second length from the sixth bend; and forming an eighth bend at a fifth length from the seventh bend. forming a ninth bend at a second length from the eighth bend; forming a tenth bend at a sixth length from the ninth bend; forming an eleventh bend at a second length from the tenth bend; forming a twelfth bend at a fifth length from the eleventh bend; forming a thirteenth bend at a second length from the twelfth bend; forming a fourteenth bend at a third length from the thirteenth bend; forming a fifteenth bend at a fourth length from the fourteenth bend; forming a sixteenth bend at a third length from the fifteenth bend; forming a seventeenth bend at a second length from the sixteenth bend; and forming an eighteenth bend at a first length from the seventeenth bend.

[0006] The present invention provides studs that reduce the material required to construct a wall and therefore reduce the material required for construction. The studs of the present invention outperform commercially available studs, so significantly less material is required to construct a wall. The studs of the present invention increase the height of the wall that can be framed and strengthen the wall itself.

[0007] These and other features, aspects, and advantages of the present invention will become better understood with reference to the following drawings, description, and claims. [Brief explanation of the drawings]

[0008] [Figure 1]FIG. 1 is a perspective view of a convoluted profile stud in use according to one embodiment of the present invention; [Figure 2] A detailed perspective view [Figure 3] rear perspective view [Figure 4] Cross-sectional view taken along 4-4 ​​in Figure 1 DETAILED DESCRIPTION OF THE INVENTION

[0009] The following detailed description is of the best currently contemplated modes of carrying out exemplary embodiments of the invention. The description is not to be taken in a limiting sense, but is made merely for the purpose of illustrating the general principles of the invention, since the scope of the invention is best defined by the appended claims.

[0010] Generally, one embodiment of the present invention is a stud configured with bends that form triangular longitudinal channels that provide a 260% increase in axial capacity and a 45% increase in moment capacity compared to currently available 25, 20, 18, and 16 gauge "CEE" studs of otherwise similar dimensions.

[0011] The studs of the present invention may be used within and with surrounding materials to construct wall systems. This convoluted stud design may also be used as beams for ceiling and roof systems. However, the use of studs is not limited to construction. In the aviation field, they may be used as spars in aircraft wing designs. In the aerospace field, studs may be used as space shuttle tank "stringers" in shell wall designs. Studs may be used in the automotive industry for frame and chassis designs. Marine container walls may be supported with the studs of the present invention. The studs of the present invention may also be used as hull beams, deck beams, and longitudinal beams, and in submarine cross-stay frames. As is evident from the wide range of applications, studs may be structural or non-structural in nature.

[0012] The one-piece or integral stud of the present invention has two end longitudinal sides joined to a central longitudinal side. Each of the longitudinal sides and the central longitudinal side is formed by two parallel planes of equal dimensions, and between them, i.e., midway along each stud portion, is an acute-angled isosceles triangular groove with a gap. Each of the two longitudinal sides has a free end bent into a right-angled isosceles triangle with a gap. In other words, each isosceles triangle has a corner gap where the sides of the triangle do not meet. To form the various sides and triangles, the material has 18 bends.

[0013] The material of manufacture is not particularly limited and may be metal or injection molded plastic, but generally any suitable ductile and / or malleable metal. In embodiments utilizing metal, the metal may be, for example, steel, aluminum, and / or titanium. The studs may be reinforced with carbon fiber. Suitable types of steel may include, for example, ASTM A-36, 33 ksi for non-structural uses and 50 ksi for structural uses. In embodiments utilizing steel, the studs may have any suitable thickness, for example, from 10 gauge (0.1242 inches or 118 mils) to 25 gauge (0.0843 inches or 18 mils), depending in part on whether the function is structural or non-structural.

[0014] A method of making studs according to embodiments of the present invention includes, for example, cold forming, which involves applying bends to a flat, elongated metal sheet. Dimensions are not limited to those shown below. All bends in the exemplary stud are rounded, with a radius of 0.0849 inches. [Table 1]

[0015] 1The angles disclosed are incremental, with 0° indicating north or directly up and 90° indicating east or right. In other words, a first length of 0.50 inches extends from its starting point to a point southeast. The sheet is bent 45° (135 - 90 = 45), extending a length of 0.50 inches.

[0016] Referring to Figures 1-4, Figure 1 shows a wall 20 cut away to reveal a stud 10 according to one embodiment of the present invention. As can be seen more clearly in Figures 2 and 3, each stud has a central or intermediate bend 18 joining two parallel, planar central surfaces 24, each of which curves at opposing corners 32 to form a flange 12. Each flange 12 has a lateral bend 16 joining two parallel, planar flange surfaces 22. Distal to the corner 32 joining the first two planes, each flange curves along two angles 30, 32 to form a return lip 14. Each bend 16, 18 has four corners 34, 36, 38, 40 and 42, 44, 46, 48, forming a rounded triangular shape with a gap at one vertex. Each of the bends 16, 18 is equidistant between the 90° corners 32 at the ends of the planes. As shown in Figure 4, a wall or wall plate 20 can be secured to one of the flanges 12. The opposing flange 12 may be attached to another component of the structure.

[0017] Of course, the foregoing relates to exemplary embodiments of the present invention, and it will be understood that modifications may be made thereto without departing from the spirit and scope of the invention as set forth in the following claims.

Claims

1. An integral stud, a central longitudinal side formed from a first planar surface having a first end and a second planar surface having a second end; a first longitudinal side joined at a 90° angle to the first end of the central longitudinal side and having a third end opposite the first end; and a second longitudinal side joined at a 90° angle to the second end of the central longitudinal side and having a fourth end opposite the second end; Equipped with the first planar surface and the second planar surface are joined by a central acute isosceles triangular channel intermediate the first end and the second end; the first longitudinal side is formed from a third planar surface and a fourth planar surface, the third planar surface and the fourth planar surface being joined by a first side acute isosceles triangular channel intermediate the first end and the third end, the third end forming a right isosceles triangle having a first gap; The first longitudinal side is formed from a fifth planar surface and a sixth planar surface, the fifth planar surface and the sixth planar surface being joined by a second side acute isosceles triangular channel intermediate the second end and the fourth end, the fourth end forming a right isosceles triangle having a second gap. An integrated stud characterized by:

2. 2. The one-piece stud according to claim 1, characterized in that the corners are rounded.

3. 2. The integral stud of claim 1, wherein said first planar surface and said second planar surface have equal dimensions.

4. 2. The integral stud of claim 1, wherein said third planar surface and said fourth planar surface have equal dimensions.

5. 2. The integral stud of claim 1, wherein said fifth planar surface and said sixth planar surface have equal dimensions.

6. 2. The integral stud of claim 1, wherein the central acute isosceles triangular channel has a corner gap, a first side of the central acute isosceles triangular channel joins the first plane, and a second side of the central acute isosceles triangular channel joins the second plane.

7. 2. The integral stud of claim 1, wherein the first sided acute angled isosceles triangular channel has a corner gap, a first side of the first sided acute angled isosceles triangular channel joins the third planar surface, and a second side of the first sided acute angled isosceles triangular channel joins the fourth planar surface.

8. 2. The integral stud of claim 1, wherein the second sided acute angled isosceles triangular channel has a corner gap, a first side of the second sided acute angled isosceles triangular channel joins the fifth plane, and a second side of the second sided acute angled isosceles triangular channel joins the sixth plane.

9. An integral stud characterized in that it is made of metal.

10. 1. A method of manufacturing an integral stud, comprising: providing an elongated metal sheet having a first longitudinal end and a second longitudinal end; forming a first bend at a first length from the first longitudinal end; forming a second bent portion at a first length from the first bent portion; forming a third bend at a second length from the second bend; forming a fourth bend at a third length from the third bend; forming a fifth bent portion at a fourth length from the fourth bent portion; forming a sixth bent portion at a third length from the fifth bent portion; forming a seventh bend at a second length from the sixth bend; forming an eighth bent portion at a fifth length from the seventh bent portion; forming a ninth bend at a second length from the eighth bend; forming a tenth bend at a sixth length from the ninth bend; forming an eleventh bend at a second length from the tenth bend; forming a twelfth bent portion at a fifth length from the eleventh bent portion; forming a thirteenth bend at a second length from the twelfth bend; forming a fourteenth bend at a third length from the thirteenth bend; forming a fifteenth bend at a fourth length from the fourteenth bend; forming a sixteenth bend at a third length from the fifteenth bend; forming a seventeenth bend at a second length from the sixteenth bend; and forming an eighteenth bend at a first length from the seventeenth bend; A method comprising:

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