Patent Publication Number: US-2015059275-A1

Title: Construction System Using Metal Stud Frame Element

Description:
BACKGROUND OF THE INVENTION 
     The present invention relates to metallic stud frames of a type used in the formation of a frame of a residential, commercial or industrial structure, and is an improvement of the invention of my U.S. Pat. No. 6,988,347, entitled Metal Stud Frame Element. 
     Historically, frames of such structures were formed of either wood, steel or concrete. In the case of load bearing structures, it is common to use a steel bar, know as rebars within a poured concrete structure. The use of vertical light gauge steel studs, in lieu of wooden studs to accomplish internal framing within a wood frame structure, is also well known in the art. It is, however, not known to employ thin gauge vertical studs in combination with exterior wall concrete framing in which the vertical stud operates to define an offset the distance between an exterior poured concrete wall and an interior plasterboard wall which is secured to one surface of such a vertical steel stud. 
     A need for such a vertical steel stud frame element has arisen as a consequence of rapid on-site assembly high techniques employing thin external concrete walls which have developed in the construction arts. The present invention therefore relates to such vertical metallic stud in which one rectilinear surface thereof may be poured as a part of a process of casting of an exterior concrete wall, its base and/or load bearing resultant structure. 
     SUMMARY OF THE INVENTION 
     1. The inventive construction system comprises a metallic stud definable in terms of an x, y, z coordinate system, the system itself comprising: (i) a z-axis elongate substantially rectangular integral web within a yz plane thereof; (ii) two xz plane surfaces, each projecting within a substantially x-axis direction, in which xz-axis lines of dependence exists between a common web and in said xz surfaces of said web of said stud; and (iii) a plurality of tabs integral with and elevated from at least one said xz plane surfaces. Included is a concrete slab into which at least one set of substantially all of said elevated tabs of said plurality thereof are wholly embedded therein prior to the hardening of said slab. 
     It is an object of the invention to provide an improved element particular adapted for use with a concrete framing structure. 
     It is another object to provide a metallic stud of the above type which can function as an interior to exterior wall defining offset. 
     It is a further object of the invention to provide a vertical metallic stud capable of defining the shape and extent of vertical load bearing concrete columns within a poured concrete structure. 
     The above and yet other objects and advantages of the present invention will become apparent from the hereinafter set forth Brief Description of the Drawings, Detailed Description of the Invention and Claims appended herewith 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of an inventive metallic stud in accordance with my invention and the X, Y, Z coordinate system associated therewith. 
         FIG. 2  is a transverse cross-sectional view taken through Line  2 - 2  of  FIG. 1 . 
         FIG. 2A  is a transverse cross-sectional view taken through Line  2 A- 2 A of  FIG. 1 . 
       FIG.  2 AA shows a variation of the embodiment of  FIG. 2A . 
         FIG. 2B  is a transverse cross sectional view, similar to the view of  FIG. 2A , however, showing a second embodiment of the inventive metallic stud. 
         FIG. 2C  is a transverse cross-sectional view, similar to the view of  FIG. 2A , however, showing a third embodiment of the metallic stud. 
         FIG. 2D  a transverse cross-sectional view, similar to the view of  FIG. 2A , however, showing a fourth embodiment of the invention. 
         FIG. 2E  is an enlarged view of the tab of  FIG. 2A . 
         FIG. 3  is an exploded view showing the stud frame of  FIGS. 1 and 2A  in combination with upper and lower system framing elements. 
         FIG. 4  is an assembly view of the exploded view of  FIG. 3 . 
         FIG. 5  is a view, further to the view of  FIG. 4 , in which a concrete base of a resultant structure has been formed. 
         FIG. 6  is a fragmentary bottom vertical sectional view of a resultant structure showing a yz plane tab of the inventive stud wall. 
         FIG. 7  is a xy sectional view of  FIG. 6  showing the yz plane tab wholly embedded within a poured exterior wall. 
         FIG. 8  is a horizontal (yz) cross-sectional view of  FIGS. 6 and 7 . 
         FIG. 9  is an enlarged view of a tab of  FIG. 2A  embedded within the an exterior wall of  FIG. 8 . 
         FIG. 10  is a vertical view of a stud, similar to that of  FIG. 1 , but showing a different spacing between the tabs thereof. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     With reference to the perspective view of  FIG. 1 , the present inventive metallic stud for use in the framing of construction systems may be defined by an x, y, z coordinate system which is also shown in  FIG. 1 . More particularly, an inventive stud  10  may be seen to include an integral web  12  having a z-axis elongate structure, which is substantially rectangular in cross-section from a first major base  18  and an opposing second major base  24 , which bases are substantially parallel with each other, both of which depend from web  12  along z lines  14  and  16 , in an xz plane. See  FIG. 2 . Further shown are tabs  19  which depend from first base  18  of stud  10 , and which typically are punched therefrom with plane face or cross-section to produce a corrugated section. 
     Stud  10  is preferably formed of a light gauge steel in a range of 24 to 8 gauge. Certain surfaces of which may be corrugated. 
     The view of  FIG. 2A  is a cross-section taken along Line  2 A- 2 A of  FIG. 1 . 
     More particularly, in  FIG. 2A  are shown said bases  18  and  14  from which sub-elements  26  and  26 A respectively depend, and which are substantially parallel with web  12 . A trapezoidal tab  19  depends from said stud base  18 . 
     In the embodiment of FIG.  2 AA of the sub-element  26 A of  FIG. 2A  is eliminated from base of stud  110 .  FIG. 2A  represents a preferred embodiment, as between the two, in which an x-axis dimension thereof increases as a function of y-axis directionality of the tab  19 . 
     In  FIG. 2B  is shown a further embodiment of the invention which generally resembles that of the embodiment of  FIG. 2A  but in which an elevated tab  219  exhibits a generally polygonal shape. As such, in the embodiment of  FIG. 2B , it is to be understood that an outermost end of tab  219  may define a square, hexogen, or any other polygon. 
     In  FIG. 2C  is shown a third embodiment of the invention in which tab  319  depending from base  318  defines a T-shape in the xy plane. 
     In  FIG. 2D  is shown a further embodiment in which tab  419 , depending from base  418  of stud  410 , defines a circular shape in the xy plane. 
     In all embodiments of  FIGS. 2A to 2D , it is to be noted that the tabs need not be at right angles to the base  18  of the stud. Further, in one embodiment, the y-axis dimension of each of said tabs exhibits a ratio of about 1:1 to and axis, or width, dimension thereof. Further, an acceptable ratio of y to x axis dimension is in the range of 0.5 to 2.5. 
     Also, it is noted that any of said tabs may be corrugated, as indicated by the phantom lines of  FIGS. 2A-2D . 
     The fashion of integration of frame stud  10  into a larger structure may be seen with reference to the exploded view of  FIG. 3  in which three of the inventive metallic studs  10  are shown in vertical position relative to horizontal framing members  28  and  30 . In  FIG. 4 , the elements of  FIG. 3  are shown in assembly view. 
     In  FIG. 5  the structure of  FIG. 4  is shown, however, with the addition of a horizontal concrete footing  32 . 
     The view of  FIG. 7  is further to that of  FIG. 5  in which a resultant structure, including a capstan  33 , is shown which is cast over horizontal framing members  28  and  30 . Further shown in  FIG. 7  are rebars  35  within said capstan, and rebar  37  within footing  32 .  FIG. 9  is also a yz end plan view of  FIG. 6 , showing the vertical relationship between stud  10  and inner and outer walls of  34  and  36  respectively of a resultant framed structure. Shown within outer wall  34  is wire mesh  41 . 
     In  FIG. 8  is shown the manner in which tabs  19  of the metallic stud  10  are embedded within a thin concrete wall  34 , which forms an exterior of a structure to be framed and as may be further seen in  FIG. 9 . Attachment of plaster boards  36  or the like to sub-elements  24  of the metallic stud  10  is also shown. Such attachment is typically effected through screw attachment, although other means of securement, i.e., glue or adhesion may be employed. As may be further noted in  FIG. 8 , studs  10  may be used to form vertical molds into which columns  38  and  40  may be poured to provide load bearing capability to the resultant structure. 
     The above described metal stud  10  constitutes a cost-effective means for rapid assembly of a large variety of structures which obviates entirely the need for wood, steel I-beams, or heavy steel rebars within concrete. Further, structures resultant from the use of stud  12  do not require large or massive quantities of concrete to produce a structure of suitable resistance to loads and stresses, both horizontally and vertically. In addition, because vertical concrete columns, such as columns  38  and  40 , may be formed through the use of the inventive metallic stud, traditional truss structures may be placed thereupon where special purpose roofing designs are required. 
     While there has been shown and described the preferred embodiment of the instant invention it is to be appreciated that the invention may be embodied otherwise than is herein specifically shown and described and that, within said embodiment, certain changes may be made in the form and arrangement of the parts without departing from the underlying ideas or principles of this invention as set forth in the Claims appended herewith.