Lumber-compatible lightweight metal construction system

• US 5,842,318 A
• Filed: 11/19/1997
• Issued: 12/01/1998
• Est. Priority Date: 03/31/1993
• Status: Expired due to Fees

• Current Assignee: Deceased, Kenneth R. Bass, Donna Bass
• Original Assignee: Pacific STUD Company LLC
• Inventors: Bass, executor, by Donna, Bass, deceased, Kenneth R.
• Primary Examiner(s): KENT, CHRISTOPHER T
• Application Number:
  US08/974,571
• Time in Patent Office: 377 Days
• Field of Search: 52/653.1, 52/262, 52/271, 52/283, 52/655.1, 52/656.9, 52/731.9, 403/201, 403/280, 403/363
• US Class Current: 52/653.1
• CPC Class Codes: E04C 2003/0413 being built up from several parts
• CPC Class Codes: E04C 2003/0417 demountable
• CPC Class Codes: E04C 2003/0421 comprising one single unitary part
• CPC Class Codes: E04C 2003/043 the hollow cross-section comprising at least one enclosed cavity
• CPC Class Codes: E04C 2003/0439 the cross-section comprising open parts and hollow parts
• CPC Class Codes: E04C 2003/0456 hollow flanged, i.e. "dogbone" metal beams
• CPC Class Codes: E04C 2003/0469 triangular-shaped
• CPC Class Codes: E04C 2003/0486 Truss like structures composed of separate truss elements
• CPC Class Codes: E04C 2003/0491 the truss elements being located in one single surface or in several parallel surfaces
• CPC Class Codes: E04C 3/065 with special adaptations for the passage of cables or conduits through the web
• CPC Class Codes: E04C 3/07 at least partly of bent or otherwise deformed strip- or sheet-like material
• CPC Class Codes: E04C 3/09 at least partly of bent or otherwise deformed strip- or sheet-like material
• CPC Class Codes: E04C 3/11 with non-parallel upper and lower edges, e.g. roof trusses arched girders, portal frames E04C3/38
• CPC Class Codes: E04C 3/292 the materials being wood and metal
• CPC Class Codes: E04C 3/32 of metal E04C3/36 takes precedence
• CPC Class Codes: E04G 23/0218 Increasing or restoring the load-bearing capacity of building construction elements E04G23/0203 and E04G23/0266 take precedence
• CPC Class Codes: F16B 7/00 Connections of rods or tubes, e.g. of non-circular section, mutually, including resilient connections F16B11/008, F16B17/00 take precedence; umbrella frames A45B25/02; welding or soldering of connections B23K; vehicle connections in general B60D; railway couplings B61G; bicycle frames B62K; couplings for transmitting rotation F16D; couplings for tubes conveying fluids F16L
• CPC Class Codes: Y10T 403/4949 Deforming component is inserted section

Abstract

The lightweight metal construction system begins with a beam formed from a single piece of cold formed sheet steel or other sheet metal which is bent lengthwise along four lines to form a triangular cross-section with two wings, side-by-side, extending from its apex. Various connectors which have lengths much shorter than the lengths of the beams are provided for attaching one beam to another. Connectors include gussets made of sheet metal or wood stud sections. The ends of the beams may be modified to form joints which are used to connect two beams together or to connect the beam to another construction material. Brackets formed from strips of sheet steel or other metal are bent to conform to outer surfaces of the beams or other construction materials are used to attach the beams to other beams or other construction materials. Fasteners or adhesive may be used to firmly attach the joints, connectors and/or brackets to the beams and construction materials.

Claims

1. A lightweight metal construction system comprising:

a plurality of beams, each beam formed from sheet metal as a triangular tube having a base, two sides and two wings corresponding to each side of said two sides extending from an apex of said triangular tube, each said beam having a beam length, an inner beam surface and an outer beam surface and being openable between said two wings;

a plurality of connectors for connecting two beams of said plurality of beams to a construction material having an upper surface, a lower surface, and at least one side surface, wherein said two beams are spaced apart at a spacing with their respective apexes facing each other, each connector of said plurality of connectors having at least one tab portion extending from said base of each said two beams so that when an end of each said two beams is abutted against said lower surface of said construction material, said at least one tab portion extends beyond said upper surface of said construction material so that said at least one tab portion may be bent flush with said upper surface; and

a plurality of fastening means for fastening said plurality of connectors to said construction material.

2. A lightweight metal construction system as in claim 1, wherein each said connector further comprises a base portion connected to said at least one tab portion, said base portion extending to abut said outer beam surface of at least one of said two wings of each said two beams, at least one of said two sides of each said two beams, and said base of each said two beams.

3. A lightweight metal construction system as in claim 2, wherein said at least one tab portion is bendable so that at least a portion of said at least one tab portion is flush with both said at least one side surface and said upper surface of said construction material.

4. A lightweight metal construction system as in claim 1, wherein said at least one tab portion has a hole therethrough for facilitating placement of a fastening means of said plurality of fastening means.

5. A lightweight construction system as in claim 1, wherein said two beams are formed from a single piece of sheet metal so that they are pre-joined in a parallel relationship to each other.

6. A lightweight construction system as in claim 5, wherein said base of each said two beams extends beyond said beam length forming a base tab.

7. A lightweight metal construction system as in claim 6, wherein said base tab of each said two beams is bendable so that at least a portion of said base tab of each said two beams is flush with said upper surface of said construction material.

8. A lightweight, lumber-compatible metal construction system comprising:

a plurality of sheet-metal beams, each beam of said plurality of sheet-metal beams formed as a triangular-shaped tube openable at an apex and having a base, two sides adjacent said base and angled inward towards said apex, and two wings corresponding to said two sides and extending from said apex in a plane perpendicular to said base, each said beam having a beam length, an inner beam surface, and an outer beam surface;

a plurality of connectors for connecting a first beam and a second beam of said plurality of sheet-metal beams to a construction material, said first beam and said second beam having respective apexes facing each other, wherein said first beam and said second beam are abutable against a first side of said construction material, each connector of said plurality of connectors comprising at least one tab extending beyond said base of each said first beam and said second beam so that said at least one tab is bent flush with a second side of said construction material, wherein said at least one tab is parallel to said base; and

a plurality of fastening means for fastening said at least one tab to said construction material.

9. A lightweight, lumber-compatible metal construction system as in claim 8, wherein each said connector further comprises a base portion which extends to abut at least one of said two wings of each said first beam and said second beam, at least one of said two sides of each said first beam and said second beam, and said base of each said first beam and said second beam.

10. A lightweight, lumber-compatible metal construction system as in claim 8, wherein said at least one tab has a hole therethrough for facilitating placement of a fastening means of said plurality of fastening means.

11. A lightweight, lumber-compatible construction system as in claim 8, wherein said first beam and said second beam are formed from a single piece of sheet metal so that they are pre-joined in a parallel relationship to each other.

12. A lightweight, lumber-compatible construction system as in claim 11, wherein said base of each said first beam and said second beam extends beyond said beam length forming a base tab.

13. A lightweight, lumber-compatible metal construction system as in claim 12, wherein said base tab of each said two beams is bendable so that at least a portion of said base tab is flush with said second side of said construction material.