Abstract:
Metallic track members having locking slots designed for receiving and retaining metallic stud members that contain construction aids enable the assembly of metallic frames used in the construction of buildings. A flat metallic strip is converted to a W-shaped metallic track member by a series of stamping, bending and severing steps. U-shaped stud members, manufactured in a similar manner are inserted into the track members and held relatively stable by upper and lower track members. An upper track member can be the same shaped design as the lower member or can be U-shaped with stud retaining means into which the stud members can slip-fit. The process for manufacturing is adaptable for computer aided manufacturing using data from the computer aid design of the building. Manufacturing equipment for the manufacture of the construction members is relatively light-weight and can be transported to the job site.

Description:
This is a continuation of Ser. No. 07/974,627, filed Nov. 12, 1992, now U.S. Pat. No. 5,720,138. 
    
    
     This invention relates to metallic wall framing for use in residential and commercial buildings. More particularly, it relates to metal framing that comprises upper and lower metallic track members and metallic vertical members connecting the upper and lower track members, the individual members, a method for producing the individual members from flat metallic stock and a portable apparatus for producing the members from flat metallic stock. 
     BACKGROUND OF THE INVENTION 
     Framing used in residential and commercial buildings generally have upper and lower horizontal members which are generally spaced apart vertically by a distance that corresponds to the vertical wall height. The upper and lower members which are referred to as “plates”, or “runners” or “tracks”, particularly when materials other than wood are used. In this application, the term “track member” is used and refers to the horizontal members. The vertical members of the framing that connect the upper and lower tracks are referred to as “studs” or “risers”. In the context of the present invention the vertical members for connecting the upper and lower tracks members are referred to as a “stud members”. 
     In commercial or residential buildings in which fire proofing or fire resistance is desired, conventional wood framing can not be used. As a result, there have been numerous metallic framing designs proposed, such as those disclosed in U.S. Pat. Nos. 2,173,721; 2,966,708; 3,001,615; 3,536,345; 3,680,271; 4,805,364; 4,854,096 and 4,918,899. However, there remains a need for a metallic track members which are capable of easily receiving and securely retaining studs and which track can be fabricated from flat metallic sheet at the job site and which can be assembled into construction framing with a minimum of labor and material costs. Prior metallic construction members such as those illustrated in the above patents lacked one or more of the above qualities. Certain members could not be readily manufactured at the job site. In certain types of members the stud member tended to move in one or more directions. Other designs of metallic construction members resulted in excessive field assembly time. Still other types of designs were cumbersome to transport from the production facility at which they were fabricated to the job site where they were to be used. 
     It is believed, therefore, that metallic members which obviates many of the disadvantages of prior metallic framing members would be an advancement in the art. 
     SUMMARY OF THE INVENTION 
     In accordance with one aspect of this invention there is provided a metallic longitudinal track that comprises first and second substantially identical and parallel vertical wall sections forming opposing vertical walls of the track, first and second substantially identical horizontal base sections of the track having a first width and projecting at about 90° from the corresponding adjacent wall sections at one extremity along the entire length thereof, first and second substantially identical vertical intermediate sections and projecting angularly from an extremity of adjacent base sections opposite to the respective wall sections and having transverse cross-sections in the shape of the sides and top of a truncated isosceles triangle; the intermediate sections have a plurality of transversely aligned locking slots for receiving and retaining portions of vertical transverse metallic stud members and a third horizontal base section having a second width between the vertical intermediate sections. 
     In accordance with another aspect of this invention there is provided a metallic stud member having a predetermined length comprising first and second spaced apart parallel wall sections extending the length of the stud member, a transition section perpendicular to and connecting the wall sections at one extremity of each wall section and flange sections projecting perpendicular from the opposing extremity of each corresponding wall section. The transition section has at least one construction aids at predetermined locations selected from the group consisting of: 
     i) a first receiving means capable of receiving and securing a metallic transverse member interconnecting an adjacent transition section of an adjacent stud member, 
     ii) a second receiving means capable of receiving and securing a mounting member for an electrical box, 
     iii) a passageway for enabling an electrical conduit to traverse said stud member, 
     iv) a pair of slots for receiving and securing end tabs of transverse framing for a door or a window and 
     v) an opening at the lower extremity of the transition section for passage of utility conduits. 
     In still other embodiments of this invention there are provided methods of producing the metallic track and stud members from a relatively flat metallic sheet. Additional embodiments provide portable mechanisms for producing the metallic track and stud members at the job site. Still other embodiments provide framing that comprises a pair of vertically spaced apart track members as set forth above and a plurality of U-shaped metallic stud members having the construction aids as described above and construction aids for mounting internal walls. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a fragmentary perspective view showing a lower track member interconnected with a vertical U-shaped stud member. 
     FIG. 2 is an end view of a track member. 
     FIG. 3 is a top view of the profile of a typical locking slot utilized in the practice of this invention. 
     FIG. 4 is a broken-away fragmentary perspective view showing an optional upper track member connected to the upper end of a slide member of this invention. 
     FIG. 5 is an end view optional upper track member. 
     FIG. 6 is a view of a segment of the optional upper track showing stud retainer of the optional upper track. 
     FIG. 7 is a perspective view illustration framing utilizing upper and lower track members of the present invention and stud members of the present invention. 
     FIG. 8 is fragmentary perspective view of the tabs of a head stock for door or window framing. 
     FIG. 9 is a detail view of a typical opening for receiving an angle member which will connect adjacent stud members in an interlocking relationship. 
     FIG. 10 is a fragmentary side view of a stud member of this invention is made and in which typical construction aids have been stamped. 
     FIG. 11 is a side view showing the initial insertion of retaining clips of an electrical conduit box into the receiving slot of the stud. 
     FIG. 12 is a side view showing an electrical conduit box mounted to a stud member. 
     FIG. 13 is a plan view showing a self locking furring channel mounting strip construction aid. 
     FIG. 14 is a side view showing the self locking furring channel mounting strip construction aid. 
     FIG. 15 is a fragmentary top view of a flat metallic plate from which a track member of this invention is made in which typical locking slots have been stamped. 
     FIG. 16 is a cross-sectional view of a stud member taken along line A—A in FIG.  10 . 
     FIG. 17 is a detail view of a typical access opening at the lower end of the stud through which various utility conduits can pass. 
     FIG. 18 is a detail view of showing typical openings for clips to retain an electrical outlet boxes. 
     FIG.  19 . is a detail view of a conduit passageway for electrical conduit. 
     FIG. 20 is a detail view of slots for receiving end tabs of header stock for window and door framing. 
     FIG. 21 is a flow diagram illustrating the method of producing the track members of this invention. 
     FIG. 22 is a flow diagram illustrating the computer aided manufacturing method and apparatus of this invention. 
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     For a better understanding of the present invention together with other and further objects, advantages and capabilities thereof, reference is made to the following detailed description and appended claims in connection with the above summary of the invention and the brief description of the drawings. 
     The track and stud members are preferably made from galvanized steel. However, any fire resistant metal sheet can be used which can be formed into the required shape without the creation of undue stress in the member. A typical preferred material is a sheet of 16 gage galvanized steel. In many instances the track members will be produced in a standard length, such as 12 feet, and transported to the job site, however, as hereafter described, portable on-site production equipment can be used to fabricate the track members from a roll of galvanized steel. The portable production facility is particularly useful when the amount of framing exceeds about 20,000 linear feet. 
     A typical roll of suitable metallic sheet from which the track members are fabricated will have a preferred a width of about 12 inches. In a similar fashion, the stud members can also be formed from a flat sheet having a typical width of about 7 inches. 
     With particular reference to FIGS. 1 and 2, a lower track member  10  has a first wall section  12 , and a second substantially identical and parallel vertical wall section  14  that form opposing vertical walls of the track. A first horizontal base section  16  and a second horizontal base section  18  receives flange sections  20 ,  21  of the stud member  22 . The first base section  16  and the second base section  18  are fabricated sufficiently narrow to prevent the stud member  22  from moving appreciably in the transverse direction. The base sections,  16 ,  18  project at about 90° from corresponding adjacent wall sections  12 ,  16  at the extremities A, J. A first vertical intermediate member  24  projects from extremity B of adjacent base section  16 . A second vertical intermediate member  26  which is substantially identical to first vertical intermediate member  24  projects from the corresponding extremity I of the second base section  18 . Both intermediate members have a transverse cross-sections in the shape of the sides  27   a ,  27   b ,  27   c ,  27   d  and tops  28   a ,  28   b  of truncated isosceles triangles. A third horizontal base section  29  extends between the vertical intermediate members  24  and  26 . Thus, as is portrayed in FIG. 2 the track member  10  is a W-shaped member. The first intermediate member has a locking slot  30  as shown in detail in FIG.  3 . The second intermediate member  26  has a similar locking slot  32 . The locking slots  30 ,  32  receive and retain portions  34 ,  36  of the transverse stud member  22 . A series of serrations extending from locking slot  30  form a series of locking teeth;  38   a-d ,  39   a-d ,  40   a-d  and  41   a-d , which enable a lower portion  34  of stud member  22  to be inserted and retained in locking slot  30 . In similar fashion another lower portion  36  of stud member  22  is retained in locking slot  32 . An upper track member  37 , FIG. 7 has a configuration similar to the lower track member  10  and receives and retains corresponding upper extremities of the stud member  22  similar to the lower track member  10 . The combination of the upper and lower track members having locking slots similar to those shown as  30 ,  32  in FIGS. 1 and 3 and the first and second base members similar to those shown as  16 ,  18  in FIG. 2 prevent the stud members from moving vertically, horizontally or longitudinally. Additionally, the upper and lower track members and the stud members can be assembled and moved into a desired position thereby reducing the time required for constructing wall framing of a building. 
     With particular reference to the fragmental views of FIG.  4  and top view FIG. 16, the U-shaped stud member has parallel wall sections  38 ,  40  with a transition section  42  connecting wall sections  38 ,  40 . As is shown in FIG. 4 the stud member is inserted into an alternate upper track  44 . With particular reference to FIGS. 5 and 6, the alternate upper track  44  has vertical walls  45 ,  46  and upper track transition section  47  between the walls  45 ,  46 . Stud retaining means  48   a ,  48   b  project from wall  45 . In a similar manner stud retaining means  49   a ,  49   b  project from wall  46  and are aligned with the stud retaining means  48   a ,  48   b  of wall  45  thereby enabling the wall sections  48 ,  40  of stud member  22  to be inserted between the stud retaining means  48   a ,  48   b ,  49   a  and  49   b.    
     With particular reference to FIG. 7 there is shown a wall framing segment  50  utilizing the concepts of this invention. Lower track member  10  receives and retains a plurality of stud members  22   a  through  22   e . An upper track member  37 , substantially identical to lower track member  10 , receives stud members  22   a  through  22   e . Angle reinforcing members  52   a  and  52   b  interlock stud members  22   a ,  22   b  and  22   c . Similarly, angle reinforcing members  52   c  and  52   d  interlock stud members  22   c  and  22   d , a door framing member  54  interconnects stud members  52   c  and  52   d.    
     FIG. 8 is an end segment of door framing member  54  in which tabs  56   a  and  56   b  are inserted into slots  58   a  and  58   b  of stud  22   c . The slots in the stud are described with reference to FIG. 20 herein. Similar tabs fit into slots in stud  22   d  and the opposing end of door framing member  54 . With particularly reference to FIG. 9 there is shown an opening  60  in stud member  22  which receives and retains angle reinforcing member  54 . 
     With particular reference to FIG. 10, there is shown a fragmentary side view of a stud member  22 . on access openings  62   a  and  62   b  which are described in detail in FIG. 17 are a substantially centered in the transition section  42 , conduit box receiving stations  64 ,  66 , which are described in detail with reference to FIG. 18 are vertically aligned and are at about 18 inches and 48 inches respectively from the lower end  68  of stud  22 . Conduit passageways  70 ,  72  are detailed with respect to FIG.  19 . Opening  60  which was described in detail with respect to FIG.  9  and framing slots  58   a ,  58   b.    
     With particular reference to FIG. 11 the upper conduit box tab  74   2 s inserted into upper slot  75  of the conduit box receiving station. After the initial insertion as shown in FIG. 11, the box is rotated so that lower conduit box tab  76  can be inserted in lower slot  77  as shown in FIG.  12 . After insertion of the lower conduit box tab  76 , the conduit box  78  is lowered and the box  78  is mounted on side of stud  22 . 
     With particular reference to FIGS. 13 and 14 there is shown a construction aid that can be used in conjunction with internal wall construction. While the construction aid is shown with respect to mounting upon a masonry or concrete wall which often are not true so that if an internal wall is mounted in a conventional manner the wall will not be true or level with respect to the other wall, the ceiling or the floor of the room. Construction aid comprises strip  80  having projections  82 ,  84  that provide for receiving and retaining transverse member  86  having a relatively flat surface. Strip  80  is anchored to the underlying wall by anchoring means  87 ,  88 . Shims, not shown, can be used at the anchoring means to provide a surface of member  86  that will enable the internal wall mounted thereupon to be true, thereby enabling the internal wall to be in the proper geometric relationship. With particular reference to FIG. 15, there is shown a fragmentary plan view of a metallic plate  88 , such as  16  gage galvanized steel, in which a series of locking slots  30   a-k  and  32   a-k  are cut. The slots are described in detail above with particular reference FIG. 3. A spacing “d 1 ” is shown. The spacings are chosen to enable the studs to have appropriate spacing to provide construction flexibility. A spacing of 2 inches is preferred. The plate  88 , after the locking slots have been cut, is heated to a metal deforming temperature and in a series of passes the plate is bent at dotted lines A—A through J—J to form a track having an end view as shown in FIG.  2 . The metal deformation produces a track having wall sections  12 ,  14 , first and second base sections  16 ,  18  and intermediate sections  24 ,  26 , and a third base section  29 . 
     With particular reference to FIG. 16, a cross section taken along line A—A of FIG. 10 the U-shaped metallic stud member  22  has first and second spaced apart parallel wall sections  38 ,  40  extending the length of the member, a transition section  42  is perpendicular to and connecting the wall sections  38 ,  40  at the extremities  43   a ,  43   b  of each wall section  38 ,  40 . Flange sections  20 ,  21  project perpendicular from corresponding wall sections  38 ,  40 . As shown in FIG. 10, the transition section  42  has various construction aids at predetermined locations along the length thereof. 
     With particular reference to FIG. 17, there is shown a detail view of typical access openings  62 . The openings are at the lower and upper ends respectively of the transition section  42  of stud member  22 . The openings as shown in FIG. 10 as  62   a ,  62   b  enable the various utility conduits such as water pipes and the like to pass through stud member  22 . 
     With particular reference to FIG. 18, conduit box receiver station  64 , comprises vertically aligned conduit box tab receiving means  88   a ,  89   a  which also contain upper and lower slots  75 ,  77  for receiving tabs from a conduit box  78  as shown in FIGS. 11 and 12. Another pair of identical means  88   b  and  89   b  are located at the opposite side of the transition section  64  of the stud member  22  so that electrical conduit boxes can be mounted for access to either side of the wall that is formed on either side of the framing. 
     With particular reference to FIG. 19 opening  72  in stud  72  is of a sufficient size to enable electrical conduit to be passed through the stud member  22 . 
     With particular reference to FIG. 20 slots  58   a  and  58   b  are sized to receive and retain tab  56   a  and  56   b  of the wall opening framing  54 , shown as a door  53  in FIG.  7 . If desired, however, similar framing can be used to provide opening for windows. 
     FIG. 21 illustrates the process of forming the metallic track members of this invention. A sheet of metallic material such as galvanized steel, cold rolled steel, aluminum, or other metals and metal alloys can be used. The flat metallic sheet material, typically 12 inches in width can be used from a spool or reel. The flat sheet, after being unwound from the spool or reel is stamped at step  92  to produce locking slots as shown in FIG. 3 thereby producing a strip of material as shown in FIG. 15. A first series of indicants are placed at intervals of 24 inches starting at one end of the stamped sheet. A second series of indicants are placed at intervals of 12 inches starting at 12 inches from the same end of the stamped sheet. A third set of indicates are placed at intervals of 16 inches starting at 16 inches from the same end of the stamped sheet. A simple method of providing indicants is to use paint wheels that mark a distinctive line or mark for each series of indicants. For example, a ¼″ black line can be used for the first series of indicants, {fraction (3/16)}″ red lines for the second series of indicants and ⅛″ yellow lines for the third series of indicants are suitable. 
     With particular reference to FIG. 22 the construction design input of the particular building to be built is programmed, either downloaded from the CAD system used to design the building or programmed manually and fed into the computer processing station  101  which yields a series of outputs. The data relating to the pressure required to stamp a particular metal sheet being processed, which will be dependent upon the thickness of the metal and the material of construction, can be processed and fed to the pressure controller  103 . The pressure controller  103  can regulate the stamping station  92  and as explained previously, indicants at preselected locations are useful to assist in the construction. The data for the linear repetitive location of the series of indicants can be processed and fed to location controller  104  which will operate the marking device  94  which will locate the first, second and third sets of indicants on the sheet. The configuration of the track, whether of the type shown in FIG. 2 or the type shown in FIG. 5 is programmed and inputted into the computer processing station  101 . The output from the computer processing station provided shape controller  105  which signals the bending wheel station, used to shape the flat sheet into the desired configuration. The input from the design of the building is used to program the length of each segment of track member that is required. The computer station  101  feeds the data to the locating control  106  which provides the desired signals to the severing station  98  that provides a shearing action to cut the processed track member to the lengths required in the building design. Additionally, the input from the building design can be used to provide outputs from the computer processing station to provide the locations of the locking slots. Thus, the location of the studs at the standard spacing can be designed as well as the location and width of wall openings such as doors, windows, floor to ceiling openings can also be fed into the manufacturing design of the track members. 
     A metallic sheet holding means such as a spool or reel holds the metallic strip prior to the sheet being fed to metal stamper  92  wherein a series of locking slots as shown in FIG. 15 as  30   a-k  and  32   a-k  are stamped at intervals d 1 , as shown on FIG.  15 . The distance d 1  is 2 inches as an example, however, d 1  can be varied as desired to give design flexibility. For example, in countries in which the metric system is used the distance d 1  can be varied from about 50 cm to about 100 cm to give a suitable design variability. The metal strip  108  is thereafter fed to a marking device  111  containing three retractable paint wheels  112 ,  113  and  114 . As described with reference to FIG. 21, the paint wheels are lowered at a prescribed location to provide three separate series of indicants. Each indicant is spaced equal distance from an adjacent indicant of the same type as was described with reference to FIG.  21 . After indicants have been marked on metal strip by paint wheels the strip is fed to a seaming press that provides seams prior to bending. The flat strip enters a series of bending wheels which in a series of 10 bends changes the profile to a track  10  as shown in profile in FIG.  2 . The track is sheared at a predetermined length. The shearing to produce the desired length can be after the bending thus enabling the metal strip to be in tension to convey the material through the various work stations. After the work is performed the formed track can be cut to the desired length 1 1 , such as 12 feet. If desired the flat strip can be cut to length 1 1  at any location prior to the last forming location. The metal forming production unit can be either self-propelled or can be transported to the job site by an external means such as a tractor. 
     While there have been shown what are considered to be the preferred embodiments of the invention, other and further modification may occur to those skilled in the art to which the invention pertains.