Patent Publication Number: US-7594331-B2

Title: Method of production of joining profiles for structural members

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     The present application claims priority under 35 USC §119 to Australian Provisional Patent Application No. 2005907348, filed Dec. 30, 2005, and to Australian Provisional Patent Application No. 2005906274, filed Nov. 5, 2005, both of which are entitled METHOD OF PRODUCTION OF JOINING PROFILE FOR STRUCTURAL MEMBER, and is also related to U.S. patent application Ser. No. 09/979,214, filed May 14, 2002, entitled “STRUCTURAL MEMBERS AND JOINING ARRANGEMENTS THEREFOR”, U.S. patent application Ser. No. 11/146,534, filed Jun. 7, 2005, entitled “STRUCTURAL MEMBERS WITH GRIPPING FEATURES AND JOINING ARRANGEMENTS THEREFOR”, and U.S. Provisional Patent Application No. 60/780,099, filed Mar. 8, 2006, entitled “FIRE RATED WALL STRUCTURE”, the entire contents of each application being expressly incorporated by reference herein. 
    
    
     STATEMENT RE: FEDERALLY SPONSORED RESEARCH/DEVELOPMENT 
     (Not Applicable) 
     BACKGROUND 
     The present invention relates generally to joining systems and, more particularly, to a method of forming joining profiles in structural frames such as metallic frames having a channel shaped cross section. Such structural frames may be used in the construction of wall assemblies such as partitioning walls and curtain walls. 
     In building construction, conventional wall fabrication techniques employ the use of upper and lower headers that are disposed in spaced relationship to one another. The upper and lower headers may be attached to the ceiling and floor portions of a building structure and are interconnected with a plurality of stud members disposed in spaced, parallel relationship to one another. The stud members are typically connected to the top and bottom headers with mechanical fasteners such as nails, screws and the like. 
     The framing, which is comprised of the upper and lower headers and the stud members, may be of wooden or metallic construction. Panels such as drywall, gypsum board, sheetrock, and the like are then installed on opposing sides of the framing in order to complete the basic wall structure. Unfortunately, traditional wall construction suffers from several drawbacks include the time consuming nature of such traditional wall construction methods and resultant high costs. 
     Metallic framing systems typically employ the use of lightweight steel stud members which are generally channel shaped or U-shaped. The stud members are attachable at opposing ends to horizontally oriented top and bottom members. The top and bottom members are, in turn, secured to the building structure adjacent the ceiling and floor. In this regard, a metallic framing system comprises a series of spaced apart steel stud members engaged to the top and bottom plate members and which includes wall board which is attached to opposing sides of the metallic faming system. 
     In conventional construction methodology, the frames may be assembled on the ground with the top and bottom members being disposed in spaced apart relationship. The stud members are then connected to the top and bottom members by engaging the ends of the stud with screws or other suitable fasteners. Because the metallic framing system is dependent upon fasteners for interconnecting the stud members to the top and bottom members, the framing system is generally structurally weak when the stud members are initially engaged to the top and bottom members prior to fastener installation. The framing system does not achieve full strength until wall board is affixed to the frame and therefore provides insufficient rigidity until fasteners are inserted. 
     Another method of securing the stud members to the top and bottom members involve the use of a tab and slot arrangement wherein tabs disposed on extreme ends of the top and bottom members engage corresponding slots in the stud members. Such engagement is facilitated by manually urging (i.e., with a hammer) the tabs so that they are reoriented at an angular orientation relative to the stud members which thereby locks the stud members against the top and bottom members. 
     Unfortunately, such method of interconnecting the stud members to the top and bottom members requires additional material to form the top and bottom members. Furthermore, the reorienting or bending of the tabs into the locking position requires additional labor and is therefore relatively time consuming. Although the tab and slot method of connecting the stud members to the top and bottom members is generally effective in securing such members, the amount of time required to bend the tab a total of four times for each stud member represents a significant drawback which detracts from the overall utility of this type of metallic framing system. 
     Another method of constructing a metallic framing system from stud members and top and bottom members involves the use of cooperating formations in each of the components. The formations consist of a securing notch formed in the walls of the mating stud member and top and bottom members. In order to facilitate the positioning of the stud member, the walls of the top and bottom members include an upturned lip formed at a location where the stud member mates with the top and bottom members. 
     Unfortunately, the additional materials required to form such lip increases overall material costs and necessitates the use of a securing clip which further adds to labor and assembly costs. Another drawback associated with such methodology of connection is the low strength of the framing system due to the minimal amount of engagement between the mating components. More specifically, the limited engagement between the mating components minimizes the overall resistance of the framing system to rotation, twisting and separation of the stud member and top and bottom plate members. 
     Another problem associated with prior art metallic framing systems is a result of irregularities in floor to ceiling heights. More particularly, in building construction, poor concrete finishing and/or irregularities in the height of the ceiling structure necessitates the time-consuming task of cutting and fitting individual stud members to fit between the top and bottom members mounted to the ceiling and floor. Ideally, the spacing between the floor and the ceiling structure is preferably constant such that the stud members may generally be of the same length. 
     However, irregularities in spacing often occur such that each of the stud members must be custom fit. Furthermore, windows and/or doors installed in many wall structures require that the stud members must be cut and fit on a trial-and-error basis to accommodate the specific window or door size. In other words, a plurality of custom-fit stud members must be first cut to an approximate length and test-fit and then often trimmed in order to form the framing above and below the windows and/or doors. As may be appreciated, such individual cutting, fitting and trimming of the stud members is time consuming and adds additional labor costs to the overall wall installation. 
     A further deficiency associated with conventional wall structures is the rigid or non-adaptive nature of the wall structure to changes in ceiling height as a result of settling of the building foundation and/or building movement such as may be caused by seismic activity or creeping of load-carrying beams in the building structure over time. The same drawbacks described above associated with relative movement between the framing system and the wall board is present in ceiling movement or building settling. 
     As can be seen, there exists a need in the art for a method of producing joining profiles in metallic framing for a wall structure such that structural members which make up the metallic framing may be securely fastened in a convenient and time efficient manner. It should be pointed out that it is well known in the art that relatively thin or light gauge steel is particularly prone to tearing and unwanted deformation during manipulation or forming thereof. In the case of producing joining profiles in light gauge steel, simultaneous stretching and compression operations are performed on different planes of a structural member. 
     The combined effects of the conflicting stretching and compression forces during forming of a joining profile greatly increases the propensity of the steel material to tear and produce unwanted deformations. Therefore, there exists a need in the art for a method of introducing such joining profiles in structural members fabricated of light gauge steel which overcomes propensities for unwanted tearing and deformation during simultaneous stretching and compression of the structural members. Furthermore, there exists a need in the art for introducing joining profiles via a method that provides for the manipulation of light gauge structural steel members at very high speeds such that such structural members may be mass-produced quickly, economically, and efficiently. 
     BRIEF SUMMARY 
     The above-mentioned deficiencies and drawbacks associated with prior art wall framing methods are specifically addressed and alleviated by the method disclosed herein. More specifically, provided herein is a method for introducing a joining profile into a structural member such (e.g., stud) that the structural member may detachably engage another member (e.g., horizontal member, header or footer)having a corresponding mating profile. The structural member may be configured as a channel shaped cross-section having a web with a pair of flanges extending outwardly therefrom. 
     The method comprises an ordered sequence of steps that includes the use of a forming assembly and which entails mounting the structural member on the forming assembly, advancing a mid anvil toward the structural member until the structural member is clamped to a base member, urging a pair of side anvils toward a respective one of the flanges of the structural member, and forming the joining profile in the flanges while engaging protrusions underneath the web of the structural member in order to force the web upwardly to accommodate formation of the joining profile. 
     The forming assembly preferably comprises the base member and includes a forming body and/or mid anvil and which has at least one, and preferably, a pair of the side anvils each having an anvil profile formed therein. The side anvil includes a vertically oriented protrusion disposed adjacent to the anvil profile. Likewise, the mid anvil has opposing faces each including anvil profiles formed thereon. Preferably, the anvil profiles of the mid anvil are formed complementary to the anvil profiles of the side anvils. 
     The structural member is mounted on the base member or base plate of the forming assembly by placing the web thereon. A hydraulic cylinder or hydraulic actuator may be used to actuate the forming body in alternating retraction and advancement of the mid anvil toward the structural member until the web is clamped between the forming body (i.e., mid anvil) and the base of the forming body member. Hydraulic cylinders may also be utilized to actuate the side anvils toward a corresponding one of the flanges until the anvil profiles engage the flanges. In this manner, at least one and, more preferably, a pair of parallel, spaced joining profiles are formed in each of the flanges of the structural member. 
     Such joining profiles are introduced by clamping the flanges between the mid anvil and the side anvils. As was earlier mentioned, the joining profiles are preferably formed with a gender opposite that of the gender of the anvil profiles. The protrusions simultaneously engage an underside of the web adjacent the anvil profiles while the side anvils are advanced into the flanges. In this manner, the protrusions force localized portions of the web upwardly (when under compression) into areas adjacent to each one of the joining profiles and thereby direct excess compressed material into a receptacle area that, in turn, provides stress relief to the web which minimizes distortions that may otherwise occur into the structural member. 
     The method may further include the step of cutting the structural member along a direction transverse to a longitudinal axis of the structural member. Such cutting may be facilitated by advancing a vertically reciprocative cutting assembly or cutting blade (e.g., knife) downwardly into the structural member while the web is clamped between the forming body (i.e., mid anvil) and the base member. Ideally, the pair of joining profiles are formed in each of the flanges in spaced relation to one another such that each of the joining profiles is located proximate ends of the newly formed pair of structural members. 
     The anvil profiles may be V-shaped such that the joining profile is also V-shaped. However, it is contemplated that the anvil profiles may be provided in any size, shape and configuration. In addition, the joining profiles may be formed in either parallel or normal orientations relative to the longitudinal axis of the structural member. The joining profile thereby results in a recess formed in an external face of the flange and a projective formed in an opposing internal face of the flange opposite the recess. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       These and other features and advantages of the various embodiments disclosed herein will be better understood with respect to the following description and drawings in which like numbers refer to like parts throughout and in which: 
         FIG. 1  is an exploded perspective view of a forming assembly adapted for introducing a joining profile into a structural member wherein the forming assembly is shown without a cutting assembly for cutting or shearing the structural member. 
         FIG. 2  is an end view of the forming assembly shown in  FIG. 1  and illustrating a forming body in a retracted position relative to a structural member prior to forming of the joining profile therein; 
         FIG. 3  is an end view of the forming assembly shown in  FIG. 2  illustrating a mid anvil advanced toward the structural member wherein the mid anvil clamps the structural member to a base member of the assembly prior to forming the joining profile; 
         FIG. 4  is an end view of the forming assembly of  FIG. 2  and illustrating the mid anvil directly engaged to the structural member and further illustrating a pair of side anvils advanced toward and engaging flanges of the structural member during formation of the joining profile therewithin; 
         FIG. 5  is a perspective view of one of the side anvils directly engaged to one of the flanges of the structural member during formation of the joining profile; 
         FIG. 6  is a perspective view of the forming assembly mounted in a mounting frame as may be used in a method for forming joining profiles in the structural member; 
         FIG. 7  is a perspective view of the various forming components in their respective retracted positions; 
         FIG. 8  is a perspective view of the forming station showing the engagement of the mid anvil to the structural member and indicating directions along which the mid anvil and the side anvils advance during forming of the joining profiles; 
         FIG. 9  is a perspective view of the forming station illustrating the mid anvil and side anvils directly engaged to the structural member and illustrating a cutting blade in a retracted position; 
         FIG. 10  is a perspective view of the forming station illustrating the mid anvil and both side anvils and the cutting blade advanced into the structural member; 
         FIG. 11  is an enlarged perspective view of the pair of side anvils and a mid anvil for forming the joining profiles; 
         FIG. 12  is an enlarged perspective view of a pair of profiles and a groove as may be formed in each of the side anvils; 
         FIG. 13  is an exploded end view of the forming assembly shown in  FIG. 9  wherein the side anvils and cutting assembly are disengaged from the structural member; 
         FIG. 14  is an end view of the side anvils and mid anvil prior to direct engagement thereof with the structural member and illustrating the cutting blade in a retracted position; 
         FIG. 15  is an enlarged end view of the side anvils prior to direct engagement with the structural member; 
         FIG. 16  is an end view of the side anvils and mid anvil directly engaged to the structural member to form the joining profile thereinto while the cutting blade is retracted; 
         FIG. 17  is an exploded view of a wall structure employing structural members having the joining profiles formed therewithin such that the structural members may detachably engage another member having a corresponding mating profile; and 
         FIG. 18  is an end elevation view of the wall structure of  FIG. 17  and illustrating the detachable engagement of a vertically oriented structural member with a horizontally oriented structural member via engagement of the joining profiles formed in the respective structural members. 
     
    
    
     DETAILED DESCRIPTION 
     Referring now to the drawings wherein the showings are for purposes of illustrating the present invention and not for purposes of limiting the same, shown in the figures is a forming assembly  10  as may be used for introducing joining profiles  84  in structural members  70  such that the structural members  70  may detachably engage another member having a corresponding mating profile. Advantageously, the present invention provides a method by which the forming assembly  10  may be utilized to provide an improved, efficient and economic method for introducing such joining profiles  84  into structural members  70  in mass production. 
     The method may be performed in a two-step or three-step process wherein certain steps may be sequentially and/or simultaneously performed. In this regard, the method of formation of the joining profiles  84  provides a clamping step wherein the structural member  70  is clamped to the forming assembly  10  followed by, or coincident with, a forming step wherein the joining profiles  84  are formed in the structural member  70 . Importantly, the method of formation provides a depression  92  in the structural member  70  adjacent each of the joining profiles  84  in order to lead and direct excess material into a receptacle relief  54  area to provide a natural response for compression and stretching of the structural member  70  which thereby avoids distortion of the structural member  70 . 
     Furthermore, the method of the present invention may optionally include a cutting step wherein the structural member  70  may be cut into at least two pieces following introduction of joining profiles  84  in the structural member  70 . Ideally, the joining profiles  84  are formed within opposing pairs of flanges  76  of the structural member  70 . A pair of the joining profiles  84  is preferably formed in each of the flanges such that the joining profiles  84  are preferably spaced apart. In this manner, the structural member  70  may be split between the pairs during the cutting step. The method disclosed herein provides for mass production of structural members  70  while minimizing manufacturing steps such as additional forming steps with a resultant decrease in production time and cost. 
     Referring now to  FIGS. 17 and 18 , shown is a wall assembly  98  which may utilize structural members  70  of the type that are formed with joining profiles  84  using the methods disclosed herein. As can be seen, the wall assembly  98  includes a plurality of the structural members  70  and may have a panel member  100  secured thereto. At extreme ends  90  of the vertically oriented structural members  70  can be seen the joining profiles  84 . The joining profiles  84  are specifically configured to detachably engage corresponding mating profiles  96  formed lengthwise along upper and lower horizontal members  102  to which the vertically oriented structural members  70  may be engaged. 
     As can be seen, the upper and lower horizontal members  102  are preferably disposed in spaced, parallel relation to one another and may be mounted to a floor and a ceiling of a building. The vertically oriented structural members  70  are interconnected to the upper and lower horizontal members  102 . As is well known in the building construction arts, vertically oriented structural members  70  are generally provided in predefined spaced intervals and are connected to the upper and lower horizontal members  102  in order to provide a means for attaching panel members  100  such as drywall or wall board to form the wall assembly  98 . 
     As can be seen in  FIG. 18 , each one of the upper and lower horizontal members  102  generally may have a channel shaped cross-section. The channel shaped cross-section is formed by a web  72  having flanges  76  extending outwardly therefrom. A pair of opposing and inwardly directed male features extend continuously along longitudinal edges  36  of the upper and lower horizontal members  102 . The male features may be provided in a V-shaped cross-section which is configured to engage with the joining profiles  84  formed in ends  90  of the vertically oriented structural members  70 . 
     The structural members  70  may also have a channel shaped cross-section with opposing terminus ends  90 . As best seen in  FIG. 17 , a telescopic mechanism may optionally be incorporated into each of the vertically oriented structural members  70  in order to adapt for changes in spacing between the upper and lower horizontal members  102  such as may occur during differential heating and/or cooling of the metallic structure relative to the non-metallic panel member  100 . An upper portion of the panel member  100  may be slideably engaged to the structural members  70  while a lower portion may be fixedly secured thereto via mechanical fasteners such as sheet metal screws or drywall screws. In this manner, the length of the metallic structural members  70  may expand and retract relative to the panel members  100 . Such relative movement between the structural members  70  and the panel member  100  may be the result of a fire generating excessive heat in a room contained by the wall assembly, or may result from building movement such as may occur during seismic activity. Additionally, the relative expansion or contraction of the structural member  70  may result from settling of the building over time. 
     Referring back to  FIG. 1 , shown is the forming assembly  10  which may be used in introducing joining profiles  84  into structural members  70 . The forming assembly  10  may include a forming body  26  which is reciprocativelyZz moveable via an activation system such as a hydraulic actuator or hydraulic cylinder  16 . The forming body  26  may be advanced and retracted in the directions shown in  FIGS. 8-10  in order to effectuate formation of the joining profile  84  as shown in  FIGS. 2-4 . The forming body  26  may include a bush  28  which engages a spigot  30  which, in turn, engages a control plate  32  for mounting a mid anvil  34 . The mid anvil  34  is specifically provided with formations  48  for introducing joining profiles  84  in the structural member  70 . 
     The forming assembly  10  further includes at least one and, more preferably, a pair of side anvils  38  which cooperate with the mid anvil  34  to introduce the joining profiles  84  into the structural member  70 . The forming assembly  10  may further comprise a base member  20  to which may be mounted a pair of mid plates  22  and a base plate  24  interposed between the mid plates  22 . In such an arrangement, the base member  20  may receive and supports the mid plates  22  and the base plate  24 . Each of the side anvils  38  may be engaged to or mounted upon a seat  42 . 
     Importantly, the seat  42  may include at least one and, more preferably, a pair of protrusions  44  which assist in the formation  48  of the joining profiles  84  in a manner to be described in more detail below. Each of the side anvils  38  may be reciprocatively moved into and out of engagement with the structural member  70  via the hydraulic cylinder  16  similar to that which is used to move the forming body  26 . In this regard, the side anvils  38  are specifically configured to move in a direction perpendicular to the direction of movement of the forming body  26 .  FIGS. 7-9  illustrate each of the side anvils  38  mounted to a rod  18  which may be interconnected to a hydraulic actuator.  FIGS. 2-5  illustrate the movement of the side anvils  38  toward the structural member  70 . The forming body  26  may be mounted to one and, more preferably, a pair of rods  18  which may be interconnected to a hydraulic cylinder  16 . 
     As can be seen in  FIG. 2 , each of the side anvils  38  are initially retracted away from the structural member  70  while the mid anvil  34  is advanced downwardly toward the structural member  70 . The side anvils  38  are positioned laterally outwardly relative to a pair of flanges  76  of the structural member  70 . As shown, each of the side anvils  38  may include the seat  42  and at least one of the protrusions  44  extending upwardly therefrom. The protrusion  44  may preferably be a dome shaped protrusion  44  although other configurations of the protrusion  44  are contemplated in order to effectuate production of localized depressions  92  in the structural member  70  adjacent the joining profiles  84 . Preferably, each of the protrusions  44  of the respective side anvils  38  are in alignment with one another in a direction normal or perpendicular to the flanges  76  of the structural member  70 . 
     Shown in  FIG. 3  is an additional end view of the forming assembly  10  wherein the forming body  26  and/or mid anvil  34  is shown advanced toward the structural member  70 . The structural member  70  is preferably a generally channel shaped cross-section comprised of a horizontally oriented web  72  having the flanges  76  extending laterally outwardly (i.e., upwardly) therefrom. Each of the flanges  76  may further include a flange return  78  extending laterally inwardly from respective ones of the flanges  76 . As can be seen in  FIG. 3 , the mid anvil  34  may be advanced toward the structural member  70  until the web  72  is clamped between the mid anvil  34  and the base member  20 . In this regard, the web  72  and flanges  76  of the structural member  70  define an open channel space  74  to which the mid anvil  34  is specifically sized and configured to occupy. 
     As can be seen in  FIGS. 2 and 3 , the mid anvil  34  may optionally include a pair of notches  52  disposed on opposite sides of the mid anvil  34  at upper ends thereof. Such notches  52  are specifically sized and configured to bend or fold the flange returns  78  downwardly into overlapping engagement with respective ones of the flanges  76  when the side anvils  38  are directly engaged to the flanges  76 . As shown in  FIG. 3 , the protrusions  44  engage respective ones of the flanges  76  of the structural member  70 . The protrusions  44  are initially brought into touching engagement with the flanges  76  prior to the next stage of the forming process. 
     In  FIG. 4 , shown is an end view of the forming assembly  10  wherein the forming body  26  is completely advanced toward the structural member  70  such that the mid anvil  34  clamps the web  72  to the base member  20 . The side anvils  38  are also shown completely advanced toward the flanges  76  of the structural member  70  in order to introduce the joining profiles  84  thereinto. Likewise, the flange returns  78  may be bent into overlapping relationship with the flanges  76  in order to provide a reinforced edge of the structural member  70  at locations adjacent to the joining profiles  84 . Likewise, the protrusions  44  are engaged with the web  72  on opposing sides of the structural member  70  while the side anvils  38  are urged toward the flanges  76  such that a portion of the web  72  is forced upwardly by the protrusion  44  in order to accommodate (i.e., allow stretching of) the structural member  70  during formation of the joining profiles  84 . 
     In summary, the sequence of steps comprises initially mounting the member on the base member  20 , advancing the forming body  26  or mid anvil  34  toward the member until the web  72  is clamped to the base member  20 , urging the side anvil(s)  38  toward an external face(s)  80  of the flange(s)  76  along a direction perpendicular to a plane of the flange(s)  76  such that the side anvil(s)  38  engage the flange(s)  76  thus forming the joining profile(s)  84  in the flange  76 . As is illustrated in the figures, the joining profiles  84  formed in the structural member  70  have a gender or shape which is opposite to that of the gender formed in the side anvils  38 . 
     More specifically, each of the side anvils  38  has at least one anvil profile  46  formed therein. Hence, the joining profile  84  will have a configuration which mirrors the anvil profile  46  of the side anvil  38 . During formation  48  of the joining profile  84 , the protrusions  44  are engaged with the web  72  in an area adjacent to the joining profile  84 . Movement of the forming body  26  or mid anvil  34  as well as movement of the side anvils  38  is effectuated by action of the hydraulic cylinders  16 . The side anvils  38  may preferably advance concurrently toward the flanges  76  in order to prevent lateral movement of the structural member  70  relative to the base member  20 . 
     As shown in  FIGS. 2-4 , the mid anvil  34  may include longitudinal edges  36  at a lower end  90  thereof. Such edges  36  are specifically configured to engage the flange returns  78  of the structural member  70  as the mid anvil  34  initially contacts the flanges  76 . Simultaneously, the protrusions  44  of the side anvils  38  initially engage the flanges  76  adjacent to the web  72 . As the mid anvil  34  continues downwardly, the edges  36  thereof contact the flange returns  78  causing the flanges  76  to partially spread apart or deflect laterally outwardly in order to clear a path for the mid anvil  34  as it travels downwardly toward the web  72 . Simultaneously, the edges  36  cause the flange returns  78  to deform downwardly in order to initiate overlapping engagement of the flange returns  78  with the flanges  76 . 
     Each of the side anvils  38  cooperates with the mid anvil  34  to form opposing joining profiles  84  in the structural member  70 . As can be seen in  FIG. 5 , a pair of joining profiles  84  may be formed in each flange  76  of the structural member  70 . However, it is contemplated that any number of joining profiles  84  may be formed in the structural member  70 . For example, a single joining profile  84  may be in one of the flanges  76  of the structural member  70 . However, formation  48  of the pair of joining profiles  84  in each of the opposing flanges  76  facilitates efficient mass production of structural members  70  as the structural member  70  may be split between the joining profiles  84  after forming in order to produce a pair of structural members  70  each having a joining profile  84  formed adjacent at least one of the respective ends  90  thereof. 
     Referring more particularly now to  FIG. 4 , shown is the forming assembly  10  in an end view wherein the side anvils  38  are directly engaged to the flanges  76 . As can be seen in  FIG. 4 , a relief  54  may optionally be provided in a bottom portion of the mid anvil  34  at opposing sides thereof. Such reliefs  54  are preferably aligned with each of the anvil profiles  46  of the mid anvil  34  and side anvils  38 . Additionally, the reliefs  54  in the mid anvils  34  are preferably aligned with the protrusions  44  such that the web  72  may be forced upwardly by the protrusions  44  during formation  48  of the joining profiles  84 . In this regard, the protrusions  44  advance and retract in concert with the side anvils  38  in a direction perpendicular to a longitudinal axis  94  of the structural member  70 . As was earlier mentioned, each of the protrusions  44  provides a response to compression and stretching of the metallic structural member  70  during forming of the joining profiles  84  by providing a path of resistance to thereby avoid distortion of the completed structural member  70 . 
     Referring now to  FIG. 5 , shown in perspective is a partial view of the forming assembly  10  wherein the mid anvil  34  and one of the side anvils  38  has one of the flanges  76  clamped therebetween. The mid anvil  34  clamps the web  72  against the base member  20  while the side anvil  38  is shown laterally advanced to its maximum extent to complete one of the joining profiles  84  in the structural member  70 .  FIG. 5  further illustrates the joining profile  84  which comprises a recess  86  formed on an external face  80  of the flange  76  and a projection  88  formed on an internal face  82  of the flange  76  opposite the recess  86 . Also shown in  FIG. 5  is the flange return  78  which is folded downwardly against the flange  76  in order to provide reinforcement along the edges  36  of the structural member  70 . 
     At an intersection of the flange  76  with the web  72 , a depression  92  is provided in the web  72  in order to accommodate formation  48  of the joining profiles  84  without undue distortion of the structural member  70 . The side anvil  38  can be seen mounted on or integrally formed with the seat  42  and which has one and, more preferably, a pair of protrusions  44  formed on the seat  42  in order to facilitate formation  48  of the reliefs  54 . At an upper portion of the mid anvil  34  can be seen a notch  52  extending along a lateral side thereof. The notch  52  may be provided to facilitate overlapping of the flange return  78  with the flange  76 . 
     As can be seen in the figures, each of the mid anvil  34  and side anvils  38  includes anvil profiles  46  formed therein. The anvil profiles  46  may be V-shaped although various other shapes of the anvil profiles  46  are contemplated. The anvil profiles  46  of the mid anvil  34  are preferably formed complementary to (i.e., opposite to) the corresponding anvil profiles  46  formed in the side anvils  38 . In this regard, the anvil profile  46  of the mid anvil  34  opposes the anvil profiles  46  of the side anvils  38 . Although the configuration of the anvil profiles  46  illustrates inwardly directed joining profiles  84  as shown in  FIG. 5 , it is contemplated that the anvil profiles  46  in the mid anvil  34  and side anvils  38  may be configured to introduce outwardly directed joining profiles  84  in the structural member  70 . 
     Furthermore, although the anvil profiles  46  are shown as being generally V-shaped, it is contemplated that the anvil profiles  46  may be generally rounded or have various alternative shapes that are specifically configured to mate with corresponding mating profiles formed in another member in the manner shown in  FIG. 17 . However, regardless of the configuration of the joining profiles  84 , the gender or direction of protrusion of each of the anvil profiles  46  is preferably such that a joining profile  84  of opposite gender is formed in the structural member  70 . 
     Referring briefly still to  FIG. 5 , although the joining profile  84  is shown as being oriented perpendicularly relative to the longitudinal axis  94  of the structural member  70 , it is contemplated that the forming assembly  10  comprising the mid anvil  34  and side anvils  38  may be configured such that the joining profiles  84  are formed in either parallel and/or normal orientations relative to the longitudinal axis  94  of the structural member  70 . Further in this regard,  FIG. 5  illustrates the joining profile  84  formed along a substantial portion of the flange  76 . More specifically, the structural member  70  flange  76  defines a height extending from the web  72 . 
     The joining profile  84  is preferably formed to extend along a substantial portion of the flange  76  height in order to facilitate detachable engagement of the structural member  70  to a corresponding mating profile  96  in another member. For example, as shown in  FIGS. 17 and 18 , each of the forming profiles is preferably located proximate the web  72  and extends along a substantial portion of the flange  76  height. In addition, each of the joining profiles  84  as shown in  FIGS. 17 and 18  is preferably formed at a location adjacent an end  90  of the structural member  70  in order to enhance the structural integrity of the engagement between the structural member  70  and another member such as the horizontally oriented member. 
     By locating the joining profile  84  adjacent at least one end  90  of each of the structural members  70 , the corresponding mating profile  96  which extends substantially continuously along a length of the upper and lower horizontal members  102  resists excessive outward deflection of the flanges  76  of the such horizontal members  102  which reduces the risk of inadvertent disengagement or disconnection between the vertically oriented structural member  70  and the upper and lower horizontal members  102  of a wall assembly  98  such as that which is shown in  FIGS. 17 and 18 . Furthermore, it is contemplated that each of the joining profiles  84  formed in opposing flanges  76  of the structural member  70  are formed at equal distances from the web  72  such that the joining profiles  84  are substantially aligned with one another. Such alignment of the joining profiles  84  facilitates engagement with a corresponding mating profile  96  in a another member. 
     Referring to  FIG. 6 , shown is the forming assembly  10  retained in a mounting frame  12  wherein the mounting frame  12  includes at least one and, more preferably, a plurality of hydraulic and/or electrical actuators which are interconnected to the side anvils  38  and which assist in advancement and retraction thereof for forming the joining profiles  84 . The structural member  70  may be placed on the base member  20  in preparation for the formation  48  steps. The forming station  14  comprises the side anvils  38  which advance and retract along the rods  18 . The side anvils  38  selectively engage opposing flanges  76  of the structural member  70  following clamping of the member between the mid anvil  34  and the base member  20 . 
     Optionally, the forming assembly  10  includes a cutting assembly  56  that is separately reciprocative in relation to movement of the mid anvil  34  and/or forming body  26 . The cutting assembly  56  may be moveable along an axis that is parallel to the movement of the mid anvil  34  and may be separably activated by a hydraulic cylinder  16 . The cutting assembly  56  may include a cutting blade  58  or similar cutting element which is advanceable through grooves  60  formed in the control plate  32  and in the mid anvil  34 . Likewise, grooves  60  may also be formed in each of the side anvils  38  in order to accommodate the cutting blade  58  therein. 
       FIGS. 7-10  illustrate a sequence whereby the joining profiles  84  may be formed and the structural member  70  is thereafter cut into two pieces.  FIG. 7  is an exploded perspective view of the forming assembly  10  isolated from the forming station  14  and showing the side anvils  38  and the mid anvil  34  retracted away from the structural member  70 . Furthermore, the cutting assembly  56  is shown in a retracted state. In  FIG. 8 , the mid anvil  34  is shown advanced toward the structural member  70 . As the mid anvil  34  advances past the flange returns  78 , the flanges  76  are thereby bent slightly outwardly while the flange returns  78  are deformed slightly downwardly as shown in  FIG. 3 . More specifically, the flanges  76  bend outwardly away from the mid anvil  34  as it travels past the flange returns  78  and into direct engagement with the web  72  whereby the mid anvil  34  clamps the web  72  to the base member  20 . The side anvils  38  are shown retracted away from the structural member  70  during clamping of the mid anvil  34  to the web  72 . 
       FIG. 9  is an exploded perspective view of the forming assembly  10  wherein the mid anvil  34  is advanced into contact with the web  72  and the side anvils  38  are both advanced into contact with the flanges  76 . In this step, the joining profiles  84  are formed by clamping the flanges  76  between the side anvils  38  and the mid anvil  34 . Likewise, the flange returns  78  may be completely bent over into direct overlapping engagement with respective ones of the flanges  76 . Furthermore, the protrusions  44  of each of the side anvils  38  are urged underneath the web  72  such that the web  72  is forced upwardly into the reliefs  54  formed in the mid anvil  34  in order to accommodate stretching of excess compressed material in the structural member  70 . 
       FIG. 10  illustrates the cutting assembly  56  advanced downwardly in order to effectuate splitting or cutting of the structural member  70  into two pieces. As best seen in  FIG. 8 , the cutting assembly  56  may include the cutting blade  58  which may have a generally non-linear cutting edge  36 . More specifically, the cutting edge  36  may define a generally inverted W-shape that is complementary to the channel shape of the structural member  70 . In this manner, the cutting edge  36  accommodates substantially simultaneous cutting of the flanges  76  and web  72 . Following cutting of the structural member  70 , the cutting assembly  56  may be retracted away from the structural members  70  as are the side anvils  38  and mid anvil  34  thereby freeing the structural member  70  from the forming assembly  10 . The method may be repeated by mounting a new unformed structural member  70  onto the forming assembly  10  to form joining profiles  84  thereinto optionally followed by a cutting step. 
       FIG. 12  is an enlarged perspective view of the mid anvil  34  and side anvils  38  illustrating a groove  60  formed therein which is preferably sized to facilitate the cutting blade  58 . Shown in  FIG. 11  is a profile plate  40  which may be mounted to opposing sides of the mid anvil  34  and which are preferably formed complementary to the anvil profiles  46  formed in the side anvils  38 . More specifically, each one of anvil profiles  46  comprises at least one and, more preferably, a pair of parallel, aligned formation  48  extending vertically along a length thereof. 
     In the enlarged perspective view of  FIG. 12 , formations  48  can be seen formed in the side anvils  38 . The formations  48  may include V-shaped features extending along a substantial vertical length thereof down to the seat  42  of the side anvil  38 . The groove  60  can be seen extending through and bisecting the side anvil  38  in order to accommodate the cutting assembly  56 . The groove  60  divides the side anvils  38  into separate bifurcated forming profiles. 
     In addition, shown in  FIG. 12  are the anvil profiles  46  which include ramped surfaces  50  that may be formed at an acute angle. Corresponding ramped surfaces  50  of opposite gender are preferably formed in the mid anvil  34 . The series of ramped surfaces  50  provide a smooth transition of the joining profiles  84  from the flange  76  to the web  72  of the structural member  70 . In this regard, the ramped surfaces  50  leads material in a similar way toward protrusions  44  shown in  FIG. 5  and causes excess material to fold and accommodate the compression process. Furthermore, this action prevents formation  48  of sharp corners which may act as stress risers that can result in cracking of the structural members  70  over time due to induced stresses. 
       FIGS. 13-16  illustrate progressive movements of the forming assembly  10  as was described above with reference to  FIGS. 8-10 . As can be seen in the  FIGS. 13-16 , the side anvils  38  include the anvil profiles  46  which advance toward and retract away from the opposing flanges  76  of the structural member  70  along opposing directions indicated by the laterally-oriented arrows. Likewise, the mid anvil  34  is configured to advance toward and retract away from the structural member  70  along a direction indicated by the vertically oriented arrow. As the mid anvil  34  advances toward the structural member  70 , edges  36  thereof respectively engage flange returns  78  which causes the flange returns  78  to bend in the region of contact with the edges  36  clearing a path for the mid anvil  34  downwardly toward the web  72  of the structural member  70 . 
       FIG. 14  illustrates the side anvils  38  initially engaged to the flanges  76  while the cutting assembly  56  is shown retracted away therefrom.  FIG. 15  illustrates a close-up of the relative positioning of the side anvils  38  with the flanges  76 .  FIG. 16  illustrates the direct engagement of the side anvils  38  and mid anvil  34  with the structural member  70  in order to effectuate introduction of the joining profiles  84  in the structural member  70 . The cutting assembly  56  may be advanced toward the structural member  70  whereby the cutting blade  58  may descend in order to subdivide the structural member  70  into separate pieces. The resulting cutting operation results in ends of each of the separate pieces including separate joining profiles  84 . It should be noted that although the step of cutting is illustrated as being performed after introduction of the joining profiles  84 , cutting of the structural member  70  may be performed prior to or after introduction of the joining profiles  84 . 
     It should be noted that the cutting assembly  56  is preferably configured to be moveable in an orientation transverse to the longitudinal axis  94  of the structural member  70  whereby the cutting blade  58  may be advanced toward the structural member  70  while the web  72  is clamped between the forming body  26  (i.e., mid anvil  34 ) and the base member  20 . Furthermore, the forming assembly  10  is preferably configured such that the structural member  70  is cut such that the joining profiles  84  are located proximate an end  90  of the members. 
     Advantageously, the anvil profiles  46  preferably include ramped surfaces  50  as was earlier described in order to facilitate introduction of the joining profiles  84  into the structural member(s)  70 . The ramped surfaces  50  cause excess material to fold and deform in localized areas of the structural members  70  as the side anvils  38  advance toward the flanges  76 . The unique geometry of the formations  48  (i.e., the ramped surfaces  50 ) alone of in combination with the protrusions  44  provides a means to enable compression of material which allows for appropriate metal stretching and enables introduction of the joining profiles  84  without over-stressing and/or inducing cracking or unwanted deformations of the material. More specifically, such ramped surfaces  50  and protrusions  44  relieve undue material stresses during formation of the joining profiles  84 . In this manner, the ramp surfaces, the protrusions  44  as well as the flange returns  78  enhances the structural integrity of the finished product. 
     The above description is given by way of example, and not limitation. Given the above disclosure, one skilled in the art could devise variations that are within the scope and spirit of the invention disclosed herein including various ways of forming the joining profile  84 . Furthermore, the various features of the embodiments disclosed herein can be used alone or in varying combinations with each other and are not intended to be limited to the specific combination described herein. Thus, the scope of the claims is not to be limited by the illustrated embodiments.