Abstract:
A metal framing member for use as a stud, joist, rafter, truss, etc. is disclosed. The framing member includes at least one knock out opening and a corresponding tab that is positioned onto the metal framing member during the manufacturing process via computer so that structures built using the studs such as window frames, door jams, etc. are accurately and quickly fabricated. The knock out opening can also be used as a chase to allow wiring or a stiffening rod to pass through the member. Each tab is also preferably provided with a pair of pre-punched holes so that the tab can be fastened to other building components using standard screws.

Description:
[0001]     This application is a continuation-in-part of U.S. patent application Ser. No. 10/459,868, filed Jun. 12, 2003, which was a continuation-in-part of 09/885,843, filed on Jun. 20, 2001, now abandoned. 
     
    
     FIELD OF THE INVENTION  
       [0002]     This invention relates to dwelling framing members, and in particular, to an attachment locking tab and opening which is used to attach one stud to another in such members by having the tab and its corresponding knock out positioned onto the metal stud via computer in accordance with the layout plans of the structure that is to be formed.  
       BACKGROUND OF THE INVENTION  
       [0003]     Structural members are frequently made of metal, as it has advantages over wooden structural members. Compared to wood, metal is insect proof, fire proof, and has high uniformity and strength. However, its use is limited due to high cost, erection problems, and handling difficulties. U.S. Pat. No. 5,315,804, issued to Attalla, addresses some of these concerns. The patent discloses an improved metal framing member (STRONG STUD) that utilizes stiffening sections to enable a lighter gauge of metal to be used. The framing member also features embossed surfaces that facilitate fastening using standard self-tapping fasteners. Safety edges are provided to eliminate the sharp edge problem of handling metal framing members.  
         [0004]     In addition to the above concerns, a framing member often must be provided with a chase to allow wiring or other objects to pass through the member. Introducing this chase after the framing member has been fabricated, as well as clipping or attaching the wiring to the member, can be tedious and time consuming. The patent mentioned above does not address this concern.  
         [0005]     U.S. Pat. No. 5,943,838, issued to Madsen et al. on Aug. 31, 1999, discloses the use of a bendable tab which must be bent on the job by the metal stud installer. The use of the STRONG STUD taught in the &#39;804 patent which utilizes heavy gauge, high strength material would make accurate and effective bending by the installer costly and difficult. Further, manual bending for even heavier gauge material that might be necessary in certain construction environments would be impossible.  
         [0006]     Further, Madsen et al. teaches the use of a tab that is substantially less than that of the opening or knock-out. However, the Madsen et al. knock-out opening is substantially greater than the size of the tab which weakens the stud and potentially can cause buckling or torsion problems. Nor does Madsen et al. disclose or suggest the use of pre-punched pilot holes but instead relies solely on the use of self-tapping screws to connect the tab to another structure.  
         [0007]     Therefore, what is needed is an improved metal framing member that includes a manufactured locating tab that is suitable for all metal studs, irrespective of the gauge of the metal, that can be placed at predetermined positions within the stud to serve to locate the attachment of other studs, has a knock-out opening that is substantially the same size as the size of the tab, that has pre-formed pilot holes for simplifying the installation of standard screw fasteners, and can serve as a preformed chase and a means of clipping objects passing through the chase to the member. Further, the use of a locking tab that enables one stud to be attached to a track member which can serve as a plate, header, footer, etc. without the need for additional fastening is also needed. A metal framing member including such a chase, locking tabs, that is low cost and can be handled safely is not found in the prior art.  
       SUMMARY OF THE INVENTION  
       [0008]     The present invention is a metal framing member including at least one manufactured locking tab. The framing member has a substantially rectangular cross-section. Preferentially, at least two stiffeners run longitudinally along the metal framing member. Two locking tabs are punched out of the bottom portion between the two stiffeners. The locking tabs resulting from the punched out section of the framing member have an angled locking guide which serves to assist the locking tabs to be mated to corresponding punched out tab openings in a slotted tab punched out of a track meant to be attached to said framing member. Once the framing member locking tab is slid over its mating slotted tab so that tab openings are aligned with the locking tabs, the framing member is locked into place along the track. Additional locking tabs are optionally provided on each leg of the framing member to enable the framing member to be more securely attached to the track member. The tab openings that engage by locking tabs on the framing member can be either round or rectangular. Also, rather than provide another tab arrangement on the legs of the framing member, an opening that matches a mating opening in the track member can be pinned together using press pins well known in the art. Each locking tab assembly on the framing member and its corresponding track member is made at the factory using computer software to accurately match each position in accordance with the building design. Thus, the two parts can be put together securely and quickly without the use of screws, bolts or other fasteners.  
         [0009]     Therefore, it is an aspect of this invention to provide an improved metal framing member.  
         [0010]     It is another aspect of the invention to provide a framing member with a locking tab assembly that will mate with a locking tab assembly on a track member.  
         [0011]     It is a further aspect of the invention to provide a metal framing member with a receiving opening for a locking tab that is preferably rectangular shaped.  
         [0012]     It is a further aspect of the invention to provide a metal track member with a receiving opening for a locking tab that is circular shaped.  
         [0013]     It is still another aspect of the invention to provide a metal framing member and corresponding track member that can be attached together without the use of screws, bolts or other fasteners well known in the art.  
         [0014]     Another aspect of the invention is to provide a metal framing member and track member that has computer generated tabs to enable the two parts to mate together accurately and easily.  
         [0015]     Another aspect of the invention is to provide a metal framing member and track member that can also be locked with a press pin through openings in the respective members.  
         [0016]     Still another aspect of the invention is to provide a metal framing and corresponding track member that has accurate and dependable fixed locations to eliminate installation errors and increase the productivity of the framing process.  
         [0017]     Still another aspect of the invention is to provide a metal framing member that has a punched locking tab having an angled material guide so that the metal framing member will easily snap over the mating locking tab openings on the track member.  
         [0018]     These aspects of the invention are not meant to be exclusive and other features, aspects, and advantages of the present invention will be readily apparent to those of ordinary skill in the art when read in conjunction with the appended claims and accompanying drawings. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0019]      FIG. 1  is an isometric view with a partial cut away view of the framing member showing one manufactured layout locating tab.  
         [0020]      FIG. 2  is a detail showing the knock out opening that can be used as a chase in the framing member.  
         [0021]      FIG. 3  is a top view of the tab.  
         [0022]      FIG. 4  is a cross sectional view of the framing member illustrating the stiffeners used in the preferred embodiment.  
         [0023]      FIG. 5  is a cross sectional view of another embodiment of the framing member without the stiffeners.  
         [0024]      FIG. 6  is still another alternative embodiment of the framing member showing a plurality of manufactured layout locating tabs.  
         [0025]      FIG. 7  is a detailed view of one tab positioned within the framing member shown in  FIG. 6 .  
         [0026]      FIG. 8  is cross sectional view of the tab within the framing member shown in  FIG. 6 .  
         [0027]      FIG. 9  is another embodiment of manufactured layout locating tab shown in the framing member depicted in  FIG. 6 .  
         [0028]      FIG. 10  is a detailed view of the tab embodiment shown in  FIG. 9 .  
         [0029]      FIG. 11  is a cross sectional view of the alternative embodiment of the tab.  
         [0030]      FIG. 12  is front view of a typical wall that is constructed with framing members in accordance with the invention.  
         [0031]      FIG. 13  illustrates a stiffening member that is inserted through the knock out opening of the framing member and attached to the tab provided via the knock out.  
         [0032]      FIG. 14  shows a typical stress that may be constructed using the framing members in accordance with the invention.  
         [0033]      FIG. 15  illustrates that the manufactured layout locating tab may be positioned anywhere on the framing member including the end.  
         [0034]      FIG. 16  is an isometric view of locking tabs being used to connect a stud with a track channel in accordance with the invention.  
         [0035]      FIG. 17  is a detailed isometric view of the preferred embodiment of the locking tab that is used on a stud.  
         [0036]      FIG. 18  is a front detailed view of the locking tab shown in  FIG. 17 .  
         [0037]      FIG. 19  is a detailed cross sectional view across section  4 - 4  shown in  FIG. 18 .  
         [0038]      FIG. 20  is a detailed cross sectional view of the stud locking tab and its corresponding mating track channel locking tab in position prior to having the stud inserted on the track channel.  
         [0039]      FIG. 21  is an isometric view of an alternative embodiment of the locking tabs.  
         [0040]      FIG. 22  is an isometric view of still another alternative embodiment of the locking tabs that use a press fit pin to improve the stability of the attachment.  
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0041]      FIG. 1  illustrates metal framing member  10  with knock out opening  12  and tab  14 . While tab  14  is usually made so that tab  14  is approximately 90 degrees with surface  16 , since tab  14  is made at the factory using computer assisted machinery, any precise angle may be selected. (See, e.g.  FIG. 13 ) Tab  14  and its corresponding knock out opening  12  are preferably located centrally in surface  16 , which runs the length of framing member  10 . However, since the stud is manufactured to the design specifications necessary to ensure precision and ease of fastening, other positions can be easily selected. In fact, different locations on surface  16  as well as different tab angles could be provided in each framing member if desired.  
         [0042]     Surface section  16  is generally 6″ to 8″ wide. In the preferred embodiment, surface section  16  includes stiffeners  18 , which run longitudinally along surface section  16 . Typically, as noted above, knock out opening  12  is centrally located between stiffeners  18 . Note that the geometry and size of knock out opening  12  and tab  14  are substantially the same, differing primarily due to the width of the cut. By having opening  12  and tab  14  substantially the same, less material is wasted and the framing member is stronger thus exhibiting a greater resistance to torsion forces and axis buckling.  
         [0043]     Knock out opening  12  is shown in detail in  FIG. 2 . Opening  12  is cut out of surface portion  16  in an area preferably no greater than two inches by two inches. Because this opening and tab  14  are made during the time of manufacturing the framing member  10 , the gauge of framing member  10  can be far thicker than would be otherwise possible if the installer had to bend tab  14  at the construction site.  
         [0044]     In the preferred embodiment, opening  12  is 1 11/16″ by 1 11/16″, with upper end  20  of the chase having a radius of ⅞″ instead of being cut square. Tab  14  is not completely severed from opening  12 , but is connected along lower edge  22 . Preferably, tab  14  is folded up at lower edge  22  so that tab  14  is substantially perpendicular to raised surface section  16 . However, as noted above, other angles are easily selectable depending on the needs of the construction project.  
         [0045]      FIG. 3  details tab  14 . In addition to the primary purpose of tab  14  to provide an accurate positioning and fastening location for adjacent framing members, tab  14  can serve as a point of attachment for any objects passing through opening  12  such as wiring. Wiring or other objects may be passed from one side of the framing member to the other through opening  12  thus serving as a chase. These objects may then be fastened to tab  14  without adding additional clips.  
         [0046]     In the preferred embodiment, two holes  24  are provided in tab  14  to serve as fastener holes. One hole  24  is positioned ½″ from lower edge  22 , while the other is positioned ½″ from rounded edge  26 . Holes  24  are otherwise centered on tab  14 . Holes  24  preferably have a radius of 3/32″ and are capable of receiving standard screw fasteners (not shown) to attach wiring, stiffening rods, or other framing members to tab  14 .  
         [0047]     Returning to  FIG. 1 , metal framing member  10  includes left and right rectangular sections  28 . Rectangular side sections  28  are preferably at least 1⅝″ in length, but may vary depending on the particular need for the framing member. Rectangular side sections  28  share an edge with surface section  16  and are substantially perpendicular to surface section  16  while being parallel to each other. At the distal ends of rectangular side sections  28  are left and right rectangular returns  30 . Left and right rectangular returns  30  are preferably perpendicular to rectangular side sections  28  and parallel to bottom section  16 .  
         [0048]      FIG. 4  is a cross section of metal framing member  10 , including stiffeners  18  that run the length of the member. Stiffeners  18  are ideally located on surface section  16  about 1½″ to 2″ from rectangular side sections  28 , depending on the width of bottom section  16 . As can be seen from  FIG. 4 , rectangular returns  30  do not generally extend out over stiffeners  18 . It can also be seen that corners  32 , formed where rectangular side sections  28  meet bottom section  16 , and corners  34 , formed where rectangular returns  30  meet rectangular side sections  28 , may be radiused edges rather than sharp corners.  
         [0049]      FIG. 5  is a cross section of an alternate embodiment of framing member  10 . In this embodiment, bottom section  16  does not include stiffeners  18 . Rather, surface section  16  is flat across its entire width other than opening  12  and tab  14 .  
         [0050]     As shown in  FIG. 6-8 , there is another alternative embodiment of the framing member  15  showing a plurality of manufactured layout locating tabs  14 . Note that the position of tabs  14  and the corresponding knock out openings  12  can be located anywhere along the framing member. That is, it is unnecessary to use only 16 inches on center as would be required if tabs  14  and openings  12  were not made specifically to meet the requirements of each and every construction project.  
         [0051]      FIG. 9  is another embodiment of manufactured layout locating tabs  14 ′ shown in the framing member depicted in  FIG. 6 . In this embodiment, tabs  14 ′ and their corresponding knock out openings  12 ′ are rectangular in shape. Clearly, other shapes are likewise possible such as triangular, octagonal, hexagonal, etc. depending on the job requirements. Since the tabs and openings are made during the construction process of the framing member, with the tab aligned at the predetermined angle relative to the web surface of framing member, a virtual infinite number of tab permutations and combinations are possible.  
         [0052]      FIG. 12  shows a typical framed wall that uses the tabs  14  to attach one framing member to the next in precise alignment. Note that the distance between the respective framing members is not always a standard (16 inches O.C.) so that the tabs (not shown) on header framing member  42  are adjusted accordingly. Also, openings and tabs can be provided so that cross bracing members  44  and  46  are accurately position therethrough thus providing a tab for attachment as well as making certain the framed wall is square. This can be seen more clearly in  FIG. 13  which shows that tab  14  is positioned at an angle other than 90 degrees with respect to surface portion  16 .  
         [0053]     As shown in  FIG. 14 , the framing member invention can even be used to construct trusses which require joining one framing member to another at varying angles and positions. The flexibility of this system is clearly illustrated in  FIG. 15  which illustrates that tab  14  can be positioned at the top of framing member  10  such that one framing member  10  can be attached to another at substantially right angles.  
         [0054]      FIG. 16  is an isometric view of locking tabs being used to connect a stud member  50  with a track channel member  58  in accordance with the invention. While the stud member  50  is shown as the applicant&#39;s patented STRONG STUD described above, a track channel, other metal structural members can also be used with the invention.  
         [0055]     A tab attachment assembly having at least two raised portions  52  is provided in the web of stud member  50 . A punched locking tab  54  is provided in each of raised portion  52 . An angled material guide  56  is also provided in each of raised portion  52 . At least two punched knock-out tabs openings  62  are provided in the upper portion of slotted tab  60  in track channel member  58 . Track channel member locking assembly is aligned so that tab opening  62  is aligned with the tab attachment assembly of stud member  50 . Once stud member  50  is inserted over upper portion of slotted tab  60 , the two parts are attached together. The stability of the attachment is augmented by the use of knock-out locking surface  64  of stud member  50  which engages locking surface of locking tab  66  of track channel member  58 . This is shown only on one leg of the respective parts but could also be used as a match set on both legs.  
         [0056]     Referring now to  FIGS. 17-19 , detailed views of the preferred embodiment of the locking tab assembly that is provided on stud member  50  are shown. Note that guide member  56  is angled slightly to enable the locking tab assembly to be slid over the upper portion of slotted tab  60  of the track channel member  58 . Punched locking tab  54  engages punched knock-out tab opening  62  of tab  60  so that the two parts are held firmly together as shown in  FIG. 20 .  
         [0057]      FIG. 20  is a detailed cross sectional view of the stud locking tab and its corresponding mating track channel locking tab in position prior to having the stud member  50  attached to track channel member  58 . Note that once fully engaged, locking tab  66  is inserted into punched knock-out tab opening  62  thus holding the two parts firmly together.  
         [0058]      FIG. 21  is an isometric view of an alternative embodiment of the locking tabs. In this embodiment, the knock-outs are a radius locking tab  74  and a corresponding circular opening  76 . As can be seen, the tab and its receiving knock-out opening can be any mating shaped pair such as a rectangle, square, circular, oval, etc. as long as the opening and its tab are dimensioned so that the tab fully engages the opening once one member engages the other.  
         [0059]      FIG. 22  is an isometric view of still another alternative embodiment of the locking tabs that use a press fit pin  72  to improve the stability of the attachment. Matched openings  68  and  70  are provided wherein pin  72  is pressed through the two fully engaged parts to more firmly hold the two together. Pin  72  may be plastic or metal or another material that has sufficient structural strength to withstand the forces expected when the two parts are attached. Press pin  72  is preferably shaped so that once pin  72  is inserted, removal is extremely difficult thus ensuring that the two parts are locked together as is accomplished with locking tab assembly.  
         [0060]     Although the present invention has been described with reference to certain preferred embodiments thereof, other versions are readily apparent to those of ordinary skill in the art. Therefore, the spirit and scope of the appended claims should not be limited to the description of the preferred embodiments contained herein.