Note: Descriptions are shown in the official language in which they were submitted.
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The invention relates to a structural member formed
of sheet metal for use in construction of buildings, and
in particular to a metal stud member for use in building
of bearing and non-loadbearing walls and partitions.
Construction makes use of studs either of wood or
metal. Metal studs are greatly preferred in many forms
of construction, since they are resistant to termites,
rot and fire damage. Metal studs are lighter than wooden
studs, of equal strength, and are thus suitable for non-
loadbearing walls and partitions in commercial buildings.
In high rise buildings they are preferred, or even --
required by architects and engineers, in order to avoid
excessive weiqht in the building.
Metal studs support wall covering materials and are
frequently used in association with panels of drywall
material. Walls also carry services such as wiring, and
the like.
It is desirable that the walls shall readily pass
services to and fro without obstruction.
In any metal stud it is desirable to reduce the
effects inherent in the use of metal, such as transfer of
heat, and transfer of sound. Heat loss is a significant
problem in exterior walls. Various proposals have been
made to provide studs for exterior walls, in which the
path for heat transfer has been reduced by forming
openings in the stud.
In interior walls, the studs should be as free as
possible from sound transfer. It is also desirable that
they shall be as rigid as is required to maintain the
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panels in position, and also to be as light as possible.
In the past, typical metal drywall studs involved a
generally three sided channel section having a central
; web and two side walls, bent into a channel shaped cross-
section. This section was continuous along the length of
the studs.
These studs have been widely used in the past and
have proved satisfactory in many cases. There are
however various disadvantages which arise from this
particular design. In the first place the central web is
generally speaking a continuous barrier throughout the
height of the wall. Consequently, it is necessary to
leave openinqs in the web in order to pass wiring through
it. These tend to leave relatively sharp edges, which
may possibly lead to damage to services.
Also, these openings tended to weaken the stud and
make it less rigid, and such holes could only be opened
up in a very restricted manner.
Another disadvantage is the fact that unless such
studs were made of extremely thin gauge metal, they
tended to be unnecessarily heavy, and costly for the job
to be done.
In addition, it is desirable if possible to have a
stud which has the same overail dimensions as a regular 2
X 4 stud. However, for reasons of economy and the like,
it has been the practice to reduce the width of the web
of the metal stud, so that the end result was a wall
which was somewhat thinner than was the case using wooden
studs.
This tended to increase the sound transfer
through the walls. In addition, the existence of a
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- continuous metal web extending from one side of the wall
to the other tended to assist in transferring sound.
A further and more serious disadvantage arose
during installation of the drywall. When the drywall is
installed on such metal studs, the workman uses and
electrical screwdriver similar to a power drill, and a
self-tapping screw. The screw has a particular form of
self boring screw point which is intended to be applied
directly to the sheet metal of the stud, and to pierce
its own hole through the stud, after which it will
tighten up and secure the drywall panel to the stud.
These screws have proved most satisfactory. However,
where the thickness of the sheet metal in the metal stud
is reduced, for reasons of economy, the side walls of the
stud become relatively flexible. As a result, when the
~ drywall workmen are inserting the screws, as they press
i the screw point against the side wall of the stud the
side wall tends to flex. This then allows the screw to
slip to one side, consequently damaging the drywall, and
leading to a slow down in work. As a result, the thinner
gauge drywall studs of this type have caused various
problems.
~learly however, it is desirable as far as possible
to reduce the thickness of the gauge of sheet metal used
in such studs, providing the disadvantages listed above
can be avoided.
With a view to overcoming the foregoing
disadvantages, the invention comprises a light weight
structural metal stud member, formed of thin gauge sheet
metal, and having two parallel spaced apart generally L-
shaped angled members extending parallel to one another,
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a plurality of spaced apart strut members extending
integrally from one said angle member to the other, and
defining openings therebetween, edge flange formations
formed on the said strut members, enlarged root portions
on each end of said strut members where the same join
said L-shaped members, each of said L-shaped members
~` defining parallel spaced apart panel attaching facing
flanges, lying in generally parallel spaced apart planes,
to which wall covering materials may be attached, and, a
plurality of indented rib formations formed transversely
of said L-shaped angle portions, said ribs being formed
in said wall facing flanges, and in adjacent portions of
said L-shaped angle members, said ribs being formed at
spaced apart intervals along the length of said L-shaped
members, whereby to resist flexing of said facing flanges
during insertion of fastening members therethrough.
It is also an objective of the invention to provide
a wall construction comprising such structural members
and wall panelling attached thereto~
The various features of novelty which characterize
the invention are pointed out with particularity in the
claims annexed to and forming a part of this disclosure.
For a better understanding of the invention, its
operating advantages and specific objects attained by its
use, reference should be had to the accompanying drawings
and descriptive matter in which there are illustrated and
described preferred embodiments of the invention.
IN T~ DRAWINGS
Figure 1 is a perspective illustration of a
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portion of a typical wall, partially cut-away to reveal
: the structural members according to the invention;
Figure 2 is a greatly enlarged perspective
-~ illustration of the structural member of Figure 1;
Figure 3 is a section of an alternate form of stud;
- Figure 4 is a partial perspective of the stud of
Figure 3, and,
Figure 5 is an elevation of another embodiment.
DESCRIPTION 0~ A SPECIFIC ENBODIMENT
Referring first of all to Figure 1 it will be seen
that a typical wall comprises panels of walls covering
material, typically plasterboard or dry wall materials,
indicated as panels 10, supported on spaced-apart
vertical metal stud members indicated generally as 12.
The stud members 12 in this embodiment will typically be
! spaced apart at intervals of sixteen inches, assuming
that the panel 10 has a standard dimension of four feet
by eight feet. In some wall systems the studs may be
furt~er apart or closer together, and in any event this
i 20 is wQll known in the art and forms no part of the
invention.
In a typical wall system, there will be top and
bottom plate members (not shown) which will typically be
metal channel sections attached to the floor and to the
fabric of the ceiling, for securing the top and bottom of
each stud.
In some walls, there will also be intermediate cross
members tnot shown) extending between adjacent studs,
midway between the top and bottom plate members for
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bracing the studs.
- All of this is, in any event, well known in the art
" and forms no part of this invention.
While Fiqure 1 illustrates wall panelling materials
on both sides of the stud, and thus illustrates an
interior walll it will of course be appreciated that when
r used for exterior walls, wall panelling would be attached
usually to only one side, and some other material would
~ be attached to the other side, depending upon the type of
i lo construction.
It will be, of course, well understood that the
panels 10 are secured to the studs 12 by means of
fastening devices typically being so-called drywall
screws shown generally as 14. Such screws 14 while
forming no part of this invention, are of significance in
that they are generally formed with what is known as a
self-tapping point. In a typical drywall screw a portion
of such point is cut away so as to leave a sharp cutting
edge.
When such a point is driven into a metal stud 12,
and is rotated for example, by means of a power operated
screwdriver or the like, it will pierce its own hole in
the stud, and will bore its way into it, and then tighten
up thereby securing the wall panel to the stud.
Normally, there would be anywhere between thirty
and fifty screws per panel. It will thus be appreciated
that if there is any difficulty at all in inserting the
screws and causing them to pierce the stud and tighten
up, it will substantially slow down the installation of
the drywall and thereby increase the overall cost.
on the other hand, it is desirable to make the
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studs themselves of thin gauge material, so as to ~oth
save in weight, and also save in material cost.
As described above these two factors have tended to
conflict with one another in the construction of studs to
the point where any reduction in gauge was offset by an
increasing difficulty in inserting screws.
As better shown in Figures 2, 3 and 4, the drywall
stud according to the invention will be seen to comprise
inner and outer generally L-shaped angle portion 20 and
22.
For the purposes of this discussion, reference will
be made to inner and outer merely for the sake of
differentiating between one such angle member and the
other. It will, of course, be understood that in
interior walls there is no such thing as an inside or an
outside surface. In addition, the stud may be used
either way around, or either way up, so that either side
may be considered the inside or either side may be
considered the outside at any given moment.
Both angle portions 20 and 22 are of identical
construction. They comprise facing flanges 24, 26 and
side flanges 28, 30 normal thereto. The free edge of the
facing flanges 24 and 26 are turned in as at 32, 34. In
accordance with well known practice in the art, the
outwardly directed surface of the facing flanges 24, 26
may be provided with a surface formation defining a
plurality of small closely spaced indentations. These
indentations are not shown, but it is well understood
that they facilitate the insertion of the screwpoint into
the sheet metal, by their tendency to hold
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- the screw point and prevent it from slipping sideways on
~ the metal surface.
`~` Extending between the two angle portions 20 and 22,
~` are a plurality of generally diagonally arranged struts
36. Each of struts 36 comprises a web portion 38 and
sidewall portions 40-40.
The free inward edges of the side flanges 28 and 30
are turned inwardly as at 42, 44. The inturned portions
, 42-44 are continuous edge-wise extensions of the
o sidewalls 40-40 of the struts 36.
Because the struts 36, there are defined openings
~- 46 of generally trapezoidal shape.
The roots or ends of the struts 36 are flared
outwardly, as at 48,50, and thus provide a smooth
transfer of forces from the angle portion 20-22, through
the struts 36.
In order to increase the rigidity of the facing
flanges 24-26, and often enable the gauge of the metal to
be r~duced, a plurality of transverse indented rib
formation 52-54 are formed. The rib formations 52-54
extend in this preferred embodiment preferably in the
region of the flared portion 48-S0 at the end or roots of
the struts 36.
Additional such ribbed formations are formed at
periodic intervals along the length of the angle members
20-22.
Further ribs 56-58 are formed extending into the
roots of the struts and preferably merging with ribs 52-
54.
Ribs 56-58 will be formed at one stage of the
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manufacture. Ribs 52-54 will be formed later, after
formation of the longitudinal bends in an angle portions
20-22.
The operation of the invention is self-evident from
` Figure 1.
Once the studs have been erected side by side at
spaced intervals, the wall panel covering materials are
applied and fastened by means of screws.
As the screws are pressed through the wall
panelling material, against the facing flanges 24 or 26,
the point of the screw will pierce the facing flange, and
~- then pass through it, and the threads of the screw will
then form their own thread, thereby causing the screw to
beco~e fastened in the facing flange.
The tendency of the facing flange 24 or 26 to
become deflected under the pressure of the point of the
screw, is resisted by means of the indented ribs 52 or
54, which tend to hold the facing flange 24 normal to the
side flange 28 and 30. In this way, the tendency of the
screw point to skid off the surface of the flange 24 or
26 is reduced to mini~um.
It will, of course, be appreciated that if
possible, any services such as electrical wiring,
plumbing and the like will have been passed through the
openings 46 in the studs 12, prior to the application of
the wall panel.
The side flanges 28 and 30 provide a convenient
means for attaching electrical service boxes for example
again by means of sheet metal screws or drywall screws.
Once the wall has been covered in with wall
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panel, it will be appreciated that the tendency far the
wall to transmit vibrations or sound is substantially
reduced by the existence of the spaces 46, and the
relatively small portion of metal contained in the
diagonal struts 36. In this way sound transmission is
reduced to a minimum.
At the same time any tendency for the struts 12 to
flex is subst~ntially reduced by the angled formations 20
and 22, being connected by means of transverse struts 36,
which comprise channel sections along their length, and
having sidewalls 30 merging with inturned edge portions
42, 44 of the angled portions 20 and 22.
The improved rigidity inherent in a stud according
to the invention enables studs to be made of thinner
gauge sheet metal. This produces a saving in weight, and
also a saving in material cost, without an unacceptable
loss of rigidity.
A further embodiment of the invention is shown in
Figure 3 and 4. It will be seen that this embodiment
comprises inner and outer column portions 60 and 62, each
of which comprises a facing flange 64, adapted to lie in
the plane of the wall and adapted to support wall
covering materials. At right angles to the facing flange
64, is a side flange 66. At right angles to flange 66 is
a return flange 68. The free edge of facing flange 64 is
turned inwardly at right angles as at 70.
The free edge of return flange 68 is turned
inwardly at right angles, as at 72, and is located in a
plane spaced more or less between the plane of flange 66,
and
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edge 70.
` The two column portions 60 and 62 are
- interconnected in this embodiment by generally diagonal
struts 74. struts 74 are of generally channel shaped
cross section having an enlarged root portion 76, and
~i side walls 78 formed at right angles thereto.
Between the struts 74, openings are formed of
generally triangular shape.
Flanges or walls 78 continue completely around such
openings, and extend along side the free edges of flanges
72, thereby providing a continuous right angular
reinforcing rib or flange giving extra strength.
In order to resist flexing of the facing flanges 64
of tha members 60 and 62, right angular transverse
indentations for ribs 80 are formed at spaced intervals,
extending through the right angular cornQr between
flanges 64 and 66.
Additional strength can be provided by forming
similar further reinforcing ribs 82, across the right
t 20 angular ioint between flanges 66 and ~8.
If possible, the adjacent ends of the ribs 80 and
82 should overlap and register with one another so as to
form continuous ribs through flanges 66.
However, in many cases since these ribs 80 and 82
will have to be formed at different stages during
manufacture this will not always be practical. ~
In practice however it does not make too much -
difference to the overall strength whether such
overlapping is achieved or not.
Further reinforcing ribs 86 may also be provided
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at the roots of s,truts 76, extending through the flanges
72 and into the flanges 68.
~ A further embodiment of the invention is shown in
; Figure 5.
In this embodiment, right angular L-shaped portions
90 and 92 are formed, having panel supporting facing
flanges 94, and side flanges 96, formed at right angles
to one another.
Edge flanges 98 are turned in on the free edge of
flanges 94.
Members so and 92 are formed integrally of a sinqle
piece of sheet metal, and are connected integrally by
interconnecting struts 100.
Struts 100 are separated from one another by means
of openings 102 which in this case are formed as circular
openings. Rims or edge f langes 104 are turned inwardly
all around openings 102 for greater strength.
In order to give greater strength to the struts
100, transverse reinforcing ribs 106 are formed,
extending right through struts 100 and preferably into
s~de flanges 96.
In order to give greater strength to the L-shaped
angle portions 90 and 92, transverse indented rib
formations 108 are ~ormed in the same way as in the
embodiment of Figure 2, at spaced intervals there along,
whereby to resist flexing of the flanges 94.
The foregoing is a description of a preferred
embodiment of the invention which is given here by way of
example only. The invention is not to be taken as
limited to any of the specific features as described, but
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comprehends all s:uch variations thereof as come within
the scope of the appended claims.
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