Patent Publication Number: US-2005115192-A1

Title: Curved structural member

Description:
TECHNICAL FIELD  
      The present invention relates to a structural member for use in construction, and more specifically to a curved metal structural member which is useful in making various architectural features.  
     BACKGROUND OF THE INVENTION  
      In the construction of various styles of buildings such as light commercial, and other types of construction, architects, as well as municipal building codes sometime require the use of metal framing studs for portions of the construction. These metal framing studs are well known, and are formed into a generally channel-shaped member which may have, at various locations, apertures formed therethrough which allows for the passage of pipes, or other electrical conduits therethrough. These metal framing studs are typically formed into predetermined lengths, and are thereafter cut to length and fastened one, to the other, by means of various fasteners such as screws, rivets or the like.  
      While these prior art metal structural members or studs have been utilized with a great deal of success, they have limited utilization in a number of different environments. For example, in view of the fact that the strength of such members is a result of the channel like structure, the use of such metal studs is often limited when it is employed in some angulated orientations, or when a portion of one or both the sidewalls of the metal stud are removed.  
      In addition to the foregoing limitations, prior art metal studs have not been useful, as a general matter, in forming curved surfaces which might find usefulness in forming arched doorways, curved walls, domed ceilings or the like.  
      A curved structural member which addresses the shortcomings attendant with the prior art is the subject matter of the present application.  
     SUMMARY OF THE INVENTION  
      One aspect of the present invention relates to a structural member which includes a first portion which is defined by a first peripheral edge; and a plurality of tabs are made integral with the first portion, and which are disposed in spaced relation along the first peripheral edge, and wherein the respective tabs are oriented in angulated relation relative to the first portion.  
      Another aspect of the present invention relates to a structural member and which includes a first portion and which is defined by a first curved peripheral edge; and a second portion having a peripheral edge, and wherein a plurality of tabs are disposed in angularly spaced relation along the peripheral edge of the second portion, and wherein at least one of the tabs is fastened to the first portion, and wherein the plurality of tabs permit the second portion to be positioned, at least in part, along the first curved peripheral edge and deformed into a shape having a curvature which is substantially similar to the curved first peripheral edge of the first portion.  
      Yet a further aspect of the present invention relates to a structural member which includes first, second and third portions which are joined together, and which define a channel, and wherein at least one of the first, second or third portions have a peripheral edge, and wherein a plurality of tabs are made integral with the peripheral edge, and are disposed in spaced relation along the peripheral edge, and wherein at least one of the plurality of tabs is affixed to an adjacent portion.  
      Still another aspect of the present invention relates to a structural member having a curved shape and which includes a first, centrally disposed web portion, and which has opposite, first and second peripheral edges, and wherein the first centrally disposed web portion has a longitudinal axis, and is deformable substantially along the longitudinal axis into a curved shape; a plurality of tabs made integral with the each of the first and second peripheral edges of the first web portion, and wherein the plurality of tabs are disposed in spaced relation along each of the first and second peripheral edges and extend angularly outwardly relative to the first, centrally disposed web portion, and wherein the respective tabs permit the first, centrally disposed web portion to be deformed substantially along the longitudinal axis into the curved shape; a second portion having a curved shape which is substantially similar to the curved shape of the first, centrally disposed web, and wherein at least some of tabs disposed along the first peripheral edge are affixed to the second portion, and wherein the plurality of tabs positions the second portion in angulated spaced relation relative to the first centrally disposed web; and a third portion having a curved shape which is substantially similar to the curved shape of the first, centrally disposed web portion, and wherein at least some of tabs disposed along the second peripheral edge are affixed to the third portion, and wherein the plurality of tabs positions the third portion in angulated spaced relation relative to the first centrally disposed web portion.  
      Moreover, another aspect of the present invention relates to a structural member having a curved shape and which includes a first, centrally disposed web portion, and which has opposite first and second peripheral edges and which has a curved shape; a second and a third portion each having opposite first and second peripheral edges, and a longitudinal axis, and wherein each of the second and third portions are deformable substantially along their respective longitudinal axes into a curved shape which is substantially similar to the curved shape of the first centrally disposed web portion; and a plurality of tabs made integral with each of the first peripheral edges of the respective second and third portions, and wherein the respective tabs are disposed in spaced relation along each of the first peripheral edges of the second and third portions and extend angularly outwardly relative thereto, and wherein at least some of the tabs disposed along the first peripheral edge of the second portion are affixed to the first centrally disposed web, and which positions the second portion in angulated juxtaposed relation relative to the first peripheral edge of the first, centrally disposed web portion, and wherein at least some of the tabs disposed along the first peripheral edge of the third portion are affixed to the first centrally disposed web, and which positions the second portion in angulated juxtaposed relation relative to the second peripheral edge of the first, centrally disposed web portion.  
      These and other aspects of the present invention will be discussed in further detail hereinafter. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       FIG. 1  is a perspective, side elevation view of a first form of the structural member of the present invention.  
       FIG. 2  is a bottom plan view of the first form of the structural member shown in  FIG. 1  with some underlying surfaces shown in phantom lines.  
       FIG. 3  is a top plan view of the first form of the structural member shown in  FIG. 1  with some underlying surfaces shown in phantom lines.  
       FIG. 4  is a transverse, vertical sectional view of one possible cross sectional profile of the first form of the present invention and which is taken along line  4 - 4  of  FIG. 3 .  
       FIG. 5  is a second, possible, transverse, vertical sectional view of the first form of the present invention.  
       FIG. 6  is a third, possible, transverse, vertical sectional view of the first form of the present invention.  
       FIG. 7  is a fourth, possible, transverse, vertical sectional view of the first form of the present invention.  
       FIG. 8  is a perspective, side elevation view of a second form of the structural member of the present invention. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
      This disclosure of the invention is submitted in furtherance of the constitutional purposes of the U.S. Patent Laws “to promote the progress of science and useful arts” (Article 1, Section 8).  
      A first form of a structural member  10  of the present invention is shown in  FIGS. 1-7 . The first form of the structural member  10  includes a first centrally disposed web portion  11 , having a main body  12 , and which has opposite first and second peripheral edges  13  and  14 , respectively. Still further, the main body  12  has an inside facing surface  15 , and an outside facing surface  16 . The inside and outside facing surfaces are substantially planar and the main body  12  is formed into a curved shape having a predetermined curvature.  
      The first form of the present invention  10  further includes a second portion which is generally indicated by the numeral 20, and which includes opposite first and second peripheral edges  21  and  22 , respectively. The second portion further has an outside facing surface  23  and an inside facing surface  24 . The second portion  20  is defined by a longitudinal axis which is generally indicated by the line labeled  25 . The second portion  20  is deformable substantially along the longitudinal axis  25  into a curved shape which is substantially similar to the curved shape of the first peripheral edge  13  of the first, centrally disposed web portion  11 . As seen in  FIG. 1 , and following, a third portion  30  is provided, and it similarly has first and second peripheral edges  31  and  32 , an outside facing surface  33  and an inside facing surface  24 . The third portion  30 , like the second portion  20 , has a longitudinal axis which is generally indicated by the line labeled  35 . The third portion  30  is similarly deformable substantially along the longitudinal axis  35  into a curved shape which is substantially similar to the curved shape of the second peripheral edge  14  of the first, centrally disposed web portion  11 .  
      As seen in  FIG. 1  and following, a plurality of tabs, which are generally indicated by the numeral 40, are made integral with each of the first peripheral edges  21  and  31  of the respective second and third portions  20  and  30 , respectively. The respective tabs as seen in  FIG. 1 , and following, are disposed in spaced relation along each of the first peripheral edges  21  and  31  and extend angularly outwardly relative thereto. As seen in  FIG. 4  for example, the tabs may extend in a substantially perpendicular orientation relative to the respective portions, or further may extend in various angular orientations relative thereto as seen in  FIGS. 5, 6  and  7 , respectively. Still further, it will be seen that the tabs may be substantially equally spaced along the first and second peripheral edges  21  and  31 , or further may be spaced at irregular intervals based upon the curvature of the first form of the invention  10 . As will be seen in the drawings, a space  41  defined between the plurality of tabs  40  and which permits the second and third portions  20  and  30  to be deformed substantially along their respective longitudinal axis  25  and  35  in order to conform the curvature of the respective second and third portions to the curvature of the first and second peripheral edges  13  and  14  of the first centrally disposed web portion  11 . As seen in  FIG. 1  and following, at least one of the tabs  40  is fastened or otherwise affixed by a rivet screw of the like  42  to the first centrally disposed web  11 , such that the second and third portions are disposed in juxtaposed angulated and spaced relation relative to the first and second peripheral edges  13  and  14  of the centrally disposed web portion  11 , to form the first form of the invention  10 .  
      Referring now to  FIG. 8 , the second form of the present invention is generally indicated by the numeral 50. The second form of the invention  50  includes a first, centrally disposed web portion which is generally indicated by the numeral 51. The web portion further has a main body  52 , and which is defined by a longitudinal axis which is generally indicated by the numeral 53. The first centrally disposed web portion  51  is formed from a deformable substrate which permits the centrally disposed web portion  51  to be deformed substantially along the longitudinal axis  53  into a curved shape having a desired curvature as seen in  FIG. 8 . The first centrally disposed web portion  51  further includes a first peripheral edge  54 , and an opposite, second peripheral edge  55 . Still further, the first centrally disposed web portion  51  has an inside facing surface  56 , and an opposite outside facing surface  57 . As seen in  FIG. 8 , the second form of the structural member  50  further has a second and third portion  60  and  70 , respectively. Each of these portions have opposite first and second peripheral edges  61 , and  62 , and  71  and  72 , respectively. Still further, the respective second and third portions  60  and  70  each have an outside facing surface  63  and  73 ; and inside facing surfaces  64  and  74 , respectively. As illustrated in  FIG. 8 , each of the second and third portions  60  and  70  have a curved shape which is substantially similar to the curved shape of the first centrally disposed web portion  51 .  
      A plurality of tabs  80  are made integral with each of the first and second peripheral edges  54  and  55  of the first centrally disposed web portion  51 . The plurality of tabs  80  are disposed in spaced relation along each of the first an second peripheral edges, and extend angularly outwardly relative to the first centrally disposed web portion  51 . The respective tabs  80  allow the second and third portions  60  and  70  to be disposed in angulated, spaced relation relative to the first centrally disposed web portion  51 . At least one of the tabs  80  is fastened to the respective second and third portions by means of a screw, rivet or the like  81 , thereby orienting the second and third portions in juxtaposed angulated relation relative to the first centrally disposed web portion  51 . A plurality of spaces  82  are defined between the respective tabs, and which permits the first web portion  51  to be formed into the curved shape.  
      With respect to the first and second forms of the invention  10  and  50  respectively, it should be understood that while the peripheral edges of the respective portions  11 ,  20 ,  30 ,  51 ,  60  and  70  are illustrated herein as having peripheral edges which are substantially parallel, it is not necessary that these edges be in this relationship in order for the invention to function in an appropriate manner. Still further, and as earlier discussed, while the respective plurality of tabs  40  and  80  as discussed with respect to the first and second forms of the invention  10  and  50  are shown as being of substantially equal dimensions and are disposed in equally spaced relation one relative to the other, other sizes and spacings for the respective tabs may be selected based upon the desired curvature (including complex curves) for the first and second forms of the invention  10  and  50 , respectively. As seen in the drawings, each form of the invention defines a curved channel  90 . For purposes of the present application and the appended claims, a substantially similar curvature will be defined as one wherein the curvature as measured in feet/radii is within less that about 30%.  
     OPERATION  
      The operation of the described embodiment of the present invention is believed to be readily apparent and is briefly summarized at this point.  
      In its broadest aspect the present invention relates to a structural member  50  which is defined by a first peripheral edge  54 , and wherein a plurality of tabs  80  are disposed in spaced relation along the first peripheral edge. The respective tabs  80  are oriented in angulated relation relative to the first portion.  
      More specifically, the present invention includes a structural member  10  which includes a first portion  11  which is defined by a first curved peripheral edge  13 . The structural member  10  further includes a second portion  20  having a peripheral edge  21 , and wherein a plurality of tabs  40  are disposed in angularly spaced relation along the peripheral edge  21  of the second portion  20 . At least one of the tabs  40  is fastened to the first portion  11 , and wherein the plurality of tabs  40  permit the second portion  20  to be positioned, at least in part, along the first curved peripheral edge  13  and deformed into a shape having a curvature which is substantially similar to the curved first peripheral edge  13  of the first portion  11 .  
      In addition to the foregoing, the present invention relates to structural members having a first form  10  and a second form  50 . In the first form of the invention as seen in  FIG. 1 , the structural member  10  includes a first, centrally disposed web portion  11 , and which has opposite, first and second peripheral edges  13  and  14 , and which further has a curved shape. A second and third portion  20  and  30  are provided, each having opposite first and second peripheral edges  21 ,  22 ,  31  and  32 , respectively and respective longitudinal axes  25  and  35 . Each of the second and third portions  20  and  30  are deformable substantially along their respective longitudinal axes  25  and  35  into a curved shape which is substantially similar to the curved shape of the first centrally disposed web portion  11 . A plurality of tabs  40  are made integral with the each of the first peripheral edges  21  and  31 . The respective tabs  40  are disposed in spaced relation along each of the first peripheral edges and extend angularly outwardly relative thereto. Some of the respective tabs of the individual portions are affixed to the first, centrally disposed web portion. These tabs  40  facilitate the positioning of the second and third portions  20  and  30 , in angulated juxtaposed relation relative to the respective peripheral edges  13  and  14  to form the structural member  10 .  
      In the second form of the invention which is generally indicated by the numeral 50, and which is seen in  FIG. 8 , a first, centrally disposed web portion  51  is provided, and which has opposite, first and second peripheral edges  54  and  55 . Still further, the first centrally disposed web portion has a longitudinal axis that is indicated by the numeral 53. The first centrally disposed web portion is deformed substantially along the longitudinal axis into a curved shape. A plurality of tabs  80  are made integral with each of the first and second peripheral edges of the first web portion. The plurality of tabs  80  are disposed in spaced relation along each of the first and second peripheral edges  54  and  55 , and extend angularly outwardly relative to the first, centrally disposed web portion. The respective tabs permit the first, centrally disposed web portion to be deformed substantially along the longitudinal axis into the curved shape. Second and third portions  60  and  70  are provided. Each of the second and third portions have a curved shape which is substantially similar to the curved shape of the first, centrally disposed web portion. At least some of tabs  80  positioned along the first and second peripheral edges  54  and  55  are affixed to the second and third portion, thereby positioning the second and third portions in angulated spaced relation relative to the first centrally disposed web portion.  
      Therefore it will be seen that the present structural member  10  and  50  provides many advantages over the prior art metal studs utilized heretofore and permits a builder to fabricate various curved surfaces in a fashion not possible heretofore. Still further, in view of the nature of the invention, a wide variety of curvatures (including complex curves) can be readily fabricated thereby allowing structural members of various shapes to be formed for a wide variety of novel structures.  
      In compliance with the statute, the invention has been described in language more or less specific as to structural and methodical features. It is to be understood, however, that the invention is not limited to the specific features shown and described, since the means herein disclosed comprise preferred forms of putting the invention into effect. The invention is, therefore, claimed in any of its forms or modifications within the proper scope of the appended claims appropriately interpreted in accordance with the doctrine of equivalents.