Abstract:
A multipurpose connector that minimally occludes the opening in a conventional steel wall stud when used to connect a conventional bridging member to the wall stud, conserving the opening&#39;s function as a pass-through for pipes, conduits and wiring. It has a tapering extension on one flange that maximizes its interface with a bridging member, and a matching central portion on the other flange that minimizes material waste when the connectors are cut from a roll of sheet metal on a progressive die machine. It has a pair of tapering tabs that maximize the functional interface with a wall stud and maximize the functional size of the opening in the wall stud. It has a plurality of fastener openings designed to permit a variety of secure connections to be made with the same fastener and a plurality of fasteners. It is one of a plurality of multipurpose connectors of different widths that can all be made on the same progressive die production line with minimal setup changes.

Description:
BACKGROUND OF THE INVENTION 
     The present invention relates to steel stud building wall systems and especially to apparatuses for stabilizing steed studs to prevent lateral movement and torsion in such systems. 
     Many industrial, and a growing number of residential, buildings are constructed with steel stud wall framing for a variety of reasons. Steel framing is fireproof, does not warp, cannot be infested, and does not rot. When a wall is built with any kind of stud, wood or steel, it is generally desirable to fix sequential studs relative to each other and each against lateral movement and torsion. In wood-stud walls, a short piece of wood blocking is typically nailed to adjacent stud pairs to stabilize them. In steel-stud walls, an elongated steel bridging member is typically inserted horizontally through pre-punched openings in a series of vertical studs to keep them aligned. Steel studs have excellent columnar strength when they are straight, but a significant portion of that strength is lost if the studs are twisted. Because steel studs are particularly vulnerable to torsion, the bridging member, which is typically channel-shaped, having a horizontal web and two vertical side flanges, is made to closely fit the openings in the vertical studs in order to maximize torque resistance. In additional to mechanical torque, metal studs can twist or bend in response to the heat of a fire when the drywall sheathing, which acts as a firebreak, is destroyed. When metal studs twist or bend, they lose their weight-bearing capacity, multiplying the damage caused directly by fire. 
     While channel-shaped bridging members closely received in the openings can help restrain the studs from twisting, some twisting can still occur and the studs can still shift or bend parallel to the wall. A variety of sheet metal brackets have been designed to prevent this shifting or bending. The prior art brackets are either simple L-brackets that are not specifically adapted for any particular connection or brackets that can only be used for a single type of connection, in this case the connection of bridging members to wall studs. The simple L-brackets form relatively weak connections and the others are limited in their utility. Neither is optimized for material saving and the ability to produce similar brackets of differing sizes on the same progressive die equipment with minimal changes. 
     It is an object of the present invention to provide a bracket that uses less material than prior art brackets, can be made in different widths on the same progressive die machinery with minimal equipment changes, and can be used to create a variety of connections in addition to one between wall studs and the bridging members that interconnect the wall studs for strength and stability. 
     SUMMARY OF THE INVENTION 
     The present invention provides a multipurpose connector that minimally occludes the opening in a conventional steel wall stud when used to connect a conventional bridging member to the wall stud, conserving the opening&#39;s function as a pass-through for pipes, conduits and wiring. 
     The present invention provides a multipurpose connector that has a tapering extension on one flange that maximizes its interface with a bridging member, and a matching central portion on the other flange that minimizes material waste when the connectors are cut from a roll of sheet metal on a progressive die machine. 
     The present invention provides a multipurpose connector that has a pair of tapering tabs that maximize the functional interface with a wall stud and maximize the functional size of the opening in the wall stud. 
     The present invention provides a multipurpose connector that has a plurality of fastener openings designed to permit a variety of secure connections to be made with the same fastener and a plurality of fasteners. 
     The present invention provides a plurality of multipurpose connectors of different widths that can all be made on the same progressive die production line with minimal setup changes. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is an upper front right perspective view of a connection made between a typical cold-formed steel wall stud, a typical cold-formed steel bridging member, and a bridging connector formed according to the present invention. 
         FIG. 2  is an upper front right perspective view of a bridging connector formed according to the present invention before the fasteners are used to attach the bridging connector to a typical cold-formed steel wall stud and a typical cold-formed steel bridging member. 
         FIG. 3  is a top plan view of a connection made between a typical cold-formed steel wall stud, a typical cold-formed steel bridging member, and a preferred form of the bridging connector of the present invention outside the steel wall stud channel. 
         FIG. 4  is a top plan view of a connection made between a typical cold-formed steel wall stud, a typical cold-formed steel bridging member, and a preferred form of the bridging connector of the present invention inside the steel wall stud channel. 
         FIG. 5  is a top plan view of a typical cold-formed steel wall stud, and a preferred form of the bridging connector of the present invention showing how the bridging connector fits within the steel wall stud. 
         FIG. 6  is an upper front right perspective view of an alternate preferred embodiment of the connector of the present invention. 
         FIG. 7  is a top plan view of the unbent blank of the alternate preferred embodiment of the connector of the present invention shown in  FIG. 6 . 
         FIG. 8  is a top plan view of the alternate preferred embodiment of the connector of the present invention shown in  FIG. 6 . 
         FIG. 9  is a front elevation view of the alternate preferred embodiment of the connector of the present invention shown in  FIG. 6 . 
         FIG. 10  is a rear elevation view of the alternate preferred embodiment of the connector of the present invention shown in  FIG. 6 . 
         FIG. 11  is a right side elevation view of the alternate preferred embodiment of the connector of the present invention shown in  FIG. 6 . 
         FIG. 12  is an upper front right perspective view of the preferred embodiment of the connector of the present invention shown in  FIGS. 1-5 . 
         FIG. 13  is a top plan view of the unbent blank of the preferred embodiment of the connector of the present invention shown in  FIG. 12 . 
         FIG. 14  is a top plan view of the preferred embodiment of the connector of the present invention shown in  FIG. 12 . 
         FIG. 15  is a front elevation view of the preferred embodiment of the connector of the present invention shown in  FIG. 12 . 
         FIG. 16  is a rear elevation view of the preferred embodiment of the connector of the present invention shown in  FIG. 12 . 
         FIG. 17  is a right side elevation view of the preferred embodiment of the connector of the present invention shown in  FIG. 12 . 
         FIG. 18  is an upper front right perspective view of an alternate preferred embodiment of the connector of the present invention. 
         FIG. 19  is a top plan view of the unbent blank of the alternate preferred embodiment of the connector of the present invention shown in  FIG. 6 . 
         FIG. 20  is a top plan view of the alternate preferred embodiment of the connector of the present invention shown in  FIG. 6 . 
         FIG. 21  is a front elevation view of the alternate preferred embodiment of the connector of the present invention shown in  FIG. 6 . 
         FIG. 22  is a rear elevation view of the alternate preferred embodiment of the connector of the present invention shown in  FIG. 6 . 
         FIG. 23  is a right side elevation view of the alternate preferred embodiment of the connector of the present invention shown in  FIG. 6 . 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     As seen in  FIGS. 1-4 , the present invention is a building connection  1  formed between a first elongated structural member  2  and a second elongated structural member  11  using a connector  19 . The connector preferably is fastened to the first elongated structural member  2  and to the second elongated structural member  11 . Preferably, the first elongated structural member  2  is a substantially vertical wall stud  2  in a building. The second elongated structural member  11  preferably is a substantially horizontal bridging member  11  used to stabilize adjacent wall studs  2 . 
     As seen in  FIGS. 1 and 2 , preferably the first elongated structural member  2  has a first opening  8  in a first elongated outer surface  7  between a first elongated side  4  and a second elongated side  5 . The second elongated structural member  11  preferably is substantially orthogonal to the first elongated structural member  2  and passes through the first opening  8  in the first elongated structural member  2 . Preferably, the second elongated structural member  11  has a first elongated external surface  16 . 
     The connector  19  preferably has a first flange  20  joined to a second flange  26  at a first angular juncture  73 . Preferably, a first side edge  33  and a second side edge  34  bridge the first angular juncture  73 . A first portion of the first side edge  33  and a first portion of the second side edge  34  preferably are on the first flange  20 , and a second portion of the first side edge  33  and a second portion of the second side edge  34  are on the second flange  26 . 
     Preferably, the first flange  20  has a first exterior surface  21  facing the first elongated outer surface  7  of the first elongated structural member  2 . The second flange  26  preferably has a second exterior surface  27  facing the first elongated external surface  16  of the second elongated structural member  11 . Preferably, the first flange  20  includes a central portion  75  with a first outer edge  76  that is disposed away from the first angular juncture  73 . The first flange preferably has a first projecting tab  77  along the portion of the first side edge  33  on the first flange  20  and a second projecting tab  78  along the portion of the second side edge  34  on the first flange  20 . Preferably, the first projecting tab  77  and the second projecting tab  78  project further away from the first angular juncture  73  than the first outer edge  76 . The second flange  26  preferably has a first extension  74  that projects further from the first angular juncture  73  than any portion of the first side edge  33  on the second flange  26  and any portion of the second side edge  34  on the second flange  26 . 
     As seen in  FIGS. 1-4 , preferably the first projecting tab  77  is fastened to the first elongated structural member  2  between the first elongated side  4  and the first opening  8 . The second projecting tab  78  preferably is fastened to the first elongated structural member  2  between the second elongated side  5  and the first opening  8 . Preferably, the central portion  75  at least partially overlaps the first opening  8  without projecting as far from the first angular juncture  73  as the first projecting tab  77  and the second projecting tab  78 . The first opening  8  preferably is less occluded than if the central portion  75  projected as far from the first angular juncture  73  as either the first projecting tab  77  or the second projecting tab  78 . Preferably, the second flange  26  is fastened to the second elongated structural member  11 . 
     Preferably, the first extension  74  has a second outer edge  79  disposed away from the first angular juncture  73 . 
     The first outer edge  76  of the central portion  75  of the first flange  20  and the second outer edge  79  of the first extension  74  of the second flange  26  preferably are parallel to the first angular juncture  73 . 
     Preferably, the first outer edge  76  is the same length as the second outer edge  79 . The first angular juncture  73  preferably is longer than the first outer edge  76  and the second outer edge  79 . 
     Preferably, the first side edge  33  has a first distal end  84  on the first flange  20  disposed away from the first angular juncture  73 . The second side edge  34  preferably has a second distal end  85  on the first flange  20  disposed away from the first angular juncture  73 . Preferably, the first outer edge  76  of the central portion  75  of the first flange  20  has a first end  80  and a second end  81 . The first end  80  and the second end  81  preferably are between the first side edge  33  and the second side edge  34 . Preferably, the first flange  20  narrows between the first end  80  of the first outer edge  76  and the first distal end  84  of the first side edge  33 . The first flange  20  preferably narrows between the second end  81  of the first outer edge  76  and the second distal end  85  of the second side edge  34 . In other words, the first flange  20  on either side of the first outer edge  76  beyond the central portion  75  as the first flange  20  projects away from the first angular juncture  73 . 
     Preferably, the second outer edge  79  of the first extension  74  of the second flange  26  has a first end  86  and a second end  87 . The first end  86  and the second end  87  preferably are not between the first side edge  33  and the second side edge  34 . Preferably, the second flange  26  widens between the first end  86  of the second outer edge  79  and the intersection of the first angular juncture  73  and the first side edge  33 . The second flange  26  preferably widens between the second end  87  of the second outer edge  79  and the intersection of the first angular juncture  73  and the second side edge  34 . In other words, the first extension  74  is narrowest at its second outer edge  79  and widens toward the first angular juncture  73 . In addition, the second flange  26  can flare or further widen between the first extension  74  and the first angular juncture  73 . 
     Preferably, the first outer edge  76  of the central portion  75  of the first flange  20  is joined to the first side edge  33  at least in part by a first angled side  88  that joins the first end  80  of the first outer edge  76  at a first reflex angle  90  less than 270 degrees as measured from within the first flange  20 . The first outer edge  76  preferably is joined to the second side edge  34  at least in part by a second angled side  89  that joins the second end  81  of the first outer edge  76  at a second reflex angle  91  less than 270 degrees as measured from within the first flange  20 . 
     Preferably, the second outer edge  79  of the first extension  74  of the second flange  26  is joined to the first side edge  33  at least in part by a third angled side  92  that joins the first end  86  of the second outer edge  79  at a first obtuse angle  94  as measured from within the second flange  26 . The second outer edge  79  preferably is joined to the second side edge  34  at least in part by a fourth angled side  93  that joins the second end  87  of the second outer edge  79  at a second obtuse angle  95  as measured from within the second flange  26 . 
     Preferably, the first reflex angle  90  and the first obtuse angle  94  are complementary, and the second reflex angle  91  and the second obtuse angle  95  are also complementary. 
     As seen in  FIGS. 1-4 , the first elongated structural member  2  preferably is a substantially vertical wall stud  2 , and the second elongated structural member  11  is a substantially horizontal bridging member  11 . The standard metal wall stud  2  is a C-channel made from sheet steel, with a first elongated web  3  with a first elongated side  4  and a second elongated side  5 , a pair of parallel elongated side members  6  orthogonally joined to the first and second elongated sides  4  and  5 , and a pair of smaller elongated reinforcing flanges  9  orthogonally joined to the first and second side members  6  so that the reinforcing flanges  9  are in the same plane and are parallel to the first elongated web  3 . The standard metal bridging member  11  is an inverted U-channel also made from sheet metal, with a second elongated web  12 , reinforced by a pair of bridging flanges  13  orthogonally joined to either side of the second elongated web  12 . 
     Preferably, the first angled side  88  is joined to the first side edge  33  by a first connecting side  96 , and the second angled side  89  is joined to the second side edge  34  by a second connecting side  97 . 
     The third angled side  92  preferably is joined to the first side edge  33  by a third connecting side  98 , and the fourth angled side  93  is joined to the second side edge  34  by a fourth connecting side  99   
     Preferably, the first angular juncture  73 , the first outer edge  76 , the second outer edge  79 , the first angled side  88 , the second angled side  89 , the third angled side  92 , the fourth angled side  93 , first connecting side  96 , the second connecting side  97 , the third connecting side  98  and the fourth connecting side  99  are all straight. 
     The substantially vertical wall stud  2  preferably is made of metal, and the substantially horizontal bridging member  11  is made of metal. The connector  19  is particularly adapted for use with standard cold-formed steel structural members. 
     Preferably, the first extension  74  of the second flange  26  is fastened to the second elongated structural member  11 . The added length of the first extension  74  allows the fasteners  83  to be placed as far away from the first angular juncture  73  as possible, which makes the resulting connection  1  stronger. 
     The first flange  20  and the second flange  26  each preferably have at least two fastener openings  82 . In particular, the preferred connection  1  between a substantially vertical wall stud  2  and a substantially horizontal bridging member  11  is best made with two fasteners  83  in each of the connected structural members  2  and  11 . 
     Preferably, the first connector  19  is fastened to the first elongated structural member  11  and the second elongated structural member  11  with separate fasteners  83 . Most preferably, the separate fasteners  83  are self-drilling sheet metal screws  81  that cut their own holes through the connected structural members  2  and  11 . 
     As seen in  FIGS. 1-4  the first flange  20  and the second flange  26  each preferably have at least one fastener opening  82  that is unused and specifically adapted for correctly positioning one or more fasteners  83  in an alternate building connection. Although the connectors  19  are particularly adapted for making a connection  1  between a C-channel metal wall  2  stud and a U-channel metal bridging member  11 , they gain added utility by being designed for other connections  1 , especially between cold-formed steel structural members. 
     As seen in  FIGS. 1-4 , preferably the first flange  20  has a first interior surface  22  facing away from the first elongated structural member  2 . The second flange  26  preferably has a second interior surface  28  facing away from the second elongated structural member  11 . Preferably, the first angular juncture  73  is ninety degrees between the first interior surface  22  and the second interior surface  28 . The connectors  19  as shown in all the drawing figures are adapted for making right-angled connections  1 , especially the connection  1  between a substantially vertical wall stud  2  and a substantially horizontal bridging member  11 . 
     As seen in  FIGS. 6-23 , in any given plurality of the connectors  19 , each preferably has a first flange  20  joined to a second flange  26  at a first angular juncture  73 , a first side edge  33  that bridges the first angular juncture  73  and a second side edge  34  that bridges the first angular juncture  73 , such that a first portion of the first side edge  33  and a first portion of the second side edge  34  are on the first flange  20 , and a second portion of the first side edge  33  and a second portion of the second side edge  34  are on the second flange  26 . Preferably, the first flange  20  of each has a first exterior surface  21 . The second flange  26  of each preferably has a second exterior surface  27 . Preferably, the first flange  20  of each includes a central portion  75  with a first outer edge  76  disposed away from the first angular juncture  73 , a first projecting tab  77  along the portion of the first side edge  33  on the first flange  20  and a second projecting tab  78  along the portion of the second side edge  34  on the first flange  20 , the first projecting tab  77  and the second projecting tab  78  projecting further away from the first angular juncture  73  than the first outer edge  76 . The second flange  26  of each preferably has a first extension  74  that projects further from the first angular juncture  73  than any portion of the first side edge  33  on the second flange  26  and any portion of the second side edge  34  on the second flange  26 . Preferably, the first side edge  33  and the second side edge  34  of at least one connector  19  of the plurality of connectors  19  are closer together than the first side edge  33  and the second side edge  34  of at least one other connector  19  of the plurality of connectors  19 . 
     The connectors  19  of the present invention are designed to make a variety of connections  1  with connectors  19  of differing widths that can all be made on the same progressive die machinery with a minimum of changes necessary to make the different sizes of connectors  19 . Changing the width of the sheet metal, which is centered on the die, changes the shape of the blank, shown in  FIGS. 7 ,  13  and  19 , by changing its width and the only modification necessary is changing the number and location of the fastener openings  82  that are punched in the sheet metal.