Patent ID: 6401423
Filing Date: 2002-06-11
Classification: E04B,E04C

Abstract:
A method for forming a deflector track structure that includes a deflector track, comprising the steps of:predetermining a maximum allowed track deflection &dgr; under gravitational live load normal to a web of the deflector track; predetermining a length K, wherein K exceeds &dgr;, wherein K is a no-load distance that will separate the web and a stud after the stud is subsequently coupled to the track, and wherein the stud is adapted to be coupled to the track; providing a sheet of metal having a length along an x-direction, a width along a y-direction, and a thickness along a z-direction, wherein the x-direction, the y-direction, and the z-directions define an orthogonal coordinate system; forming at least one tongue within the sheet of metal, wherein an end of the tongue is integral with the sheet, and wherein the end of the tongue is oriented in the y-direction; forming at least one slat within the tongue, wherein the slat is oriented in the x-direction, and wherein a length of the slat in the z-direction exceeds 2&dgr;; bending the tongue rotationally about the end of the tongue, resulting in the tongue becoming a tab oriented in the z-direction such that the end of the tongue remains as an end of the tab; bending a first side of the sheet of metal rotationally about a first line in the sheet of metal to form a first flange of the deflector track, wherein the first line is oriented in the x-direction, wherein the first flange is oriented in the z-direction, wherein the web of the deflector track remains, wherein a length of the web is oriented in the x-direction, and wherein a height of the first flange in the z-direction exceeds K+&dgr;; and bending a second side of the sheet of metal rotationally about a second line in the sheet of metal to form a second flange of the deflector track, wherein the second line is oriented in the x-direction, wherein the second flange is oriented in the z-direction, and wherein a height of the second flange in the z-direction exceeds K+&dgr;.