STRUCTUAL STUD

• US 20070245657A1
• Filed: 02/09/2007
• Published: 10/25/2007
• Est. Priority Date: 02/10/2006
• Status: Active Grant

• Current Assignee: Hi-Tech Tilt Intellectual Property Management, Inc.
• Original Assignee: Hi-Tech Tilt Intellectual Property Management, Inc.
• Inventors: Valle, John, Medina, Jose, Guajardo, Abdiel, Valls, Kenneth
• Granted Patent: US 7,823,350 B2
• Time in Patent Office: Days
• US Class Current: 52/356
• CPC Class Codes: E04B 2/58 with elongated members of metal
• CPC Class Codes: E04B 2/60 characterised by special cross-section of the elongated members
• CPC Class Codes: E04B 2/845 the form leaf comprising a wire netting, lattice or the like
• CPC Class Codes: E04B 2103/02 of ceramics, concrete or other stone-like material
• CPC Class Codes: E04B 2103/06 of metal
• CPC Class Codes: E04C 2/044 of concrete E04C2/049 takes precedence
• CPC Class Codes: E04C 2/06 reinforced
• CPC Class Codes: E04C 2/08 of metal, e.g. sheet metal E04C2/26 takes precedence
• CPC Class Codes: E04C 2/28 combinations of materials fully covered by groups E04C2/04 and E04C2/08
• CPC Class Codes: E04C 2/30 characterised by the shape or structure translucent E04C2/54
• CPC Class Codes: E04C 2/46 specially adapted for making walls E04C2/52, E04C2/54 take precedence; structure of slab-shaped elements E04B1/02; walls of elements of relatively thin form E04B2/72
• CPC Class Codes: E04C 2003/0473 U- or C-shaped
• CPC Class Codes: E04C 3/07 at least partly of bent or otherwise deformed strip- or sheet-like material
• CPC Class Codes: E04C 3/32 of metal E04C3/36 takes precedence
• CPC Class Codes: E04C 5/04 Mats combined with reinforcing elements protruding out of the plane of the mat E04C5/0627; three-dimensional mats E04C5/0636; bases for plaster E04F13/04
• CPC Class Codes: Y10T 29/49632 Metal reinforcement member for nonmetallic, e.g., concrete, structural element

Abstract

Embodiments of a structural stud and panel for use in building a tilt-wall building are disclosed. Devices and methods for forming structural studs and panels are also disclosed.

Claims

1. A structural stud comprising:

a stud having a sidewall and

a tab punched out of the sidewall, the tab comprising;

a tab leg that is substantially planar and is connected to the sidewall at one end of the tab leg, and that projects outwardly from the sidewall at an angle of less than ninety degrees to the sidewall; and

a tab foot extending from the tab leg and curving either away from or toward a hole in the sidewall created by the tab punched out of the sidewall.

24. The structural stud of claim 1, wherein the stud comprises at least two tabs, one of the tabs being a vertical tab and the other tab being a horizontal tab;

the vertical tab comprising;

a tab leg that is substantially planar and is connected to the sidewall at one end of the tab leg, and that projects outwardly from the sidewall at an angle of less than ninety degrees to the sidewall; and

a tab foot extending from the tab leg of the vertical tab and curving either away from or toward a vertical hole in the sidewall resulting from the vertical tab punched out of the sidewall; and

the horizontal tab comprising;

a tab leg that is substantially planar and is connected to the sidewall at one end of the tab leg, and that projects outwardly from the sidewall at an angle of less than ninety degrees to the sidewall; and

a tab foot extending from the tab leg of the horizontal tab and curving either away from or toward a horizontal hole in the sidewall resulting from the horizontal tab punched out of the sidewall;

where the end of the vertical tab leg that is connected to the sidewall is substantially perpendicular to the end of the horizontal tab leg that is connected to the sidewall.

25. The structural stud of claim 24, where:

the vertical hole is defined by a base side and a top side, the base side has a greater length than the top side, and the vertical tab leg the extends from the base side; and

the horizontal hole is defined by a base side and a top side, the base side has a greater length than the top side, and the horizontal tab leg the extends from the base side.

26. The structural stud of claim 24, where the structural stud comprises a plurality of vertical tabs and resulting vertical holes and horizontal tabs and resulting horizontal holes.

27. The structural stud of claim 26, where the vertical tabs and vertical holes and the horizontal tabs and horizontal holes are positioned in an alternating arrangement on the sidewall such that there is a horizontal tab and horizontal hole between each vertical tab and vertical hole.

28. The structural stud of claim 27, where the horizontal holes and the vertical holes are spaced such that the distance between the centers of successive vertical and horizontal holes is less than about 6 inches.

29. The structural stud of claim 28, where the horizontal holes and the vertical holes are spaced such that the distance between the centers of successive vertical and horizontal holes is about 4 inches.

2-23. -23. (canceled)

30-31. -31. (canceled)

32. A method of forming a structural stud comprising:

obtaining a stud having a sidewall;

striking the sidewall of the stud with a punch; and

forcing the punch into a die, creating a tab punched out of the sidewall, the tab comprising;

a tab leg that is substantially planar and is connected to the sidewall at one end of the tab leg, and that projects outwardly from the sidewall at an angle of less than ninety degrees to the sidewall; and

a tab foot extending from the tab leg and curving either away from or toward a hole in the sidewall created by the tab punched out of the sidewall.

33. The method of claim 32, where at least two tabs are created in the sidewall, one of the tabs being a vertical tab and the other tab being a horizontal tab;

the vertical tab comprising;

a tab leg that is substantially planar and is connected to the sidewall at one end of the tab leg, and that projects outwardly from the sidewall at an angle of less than ninety degrees to the sidewall; and

a tab foot extending from the tab leg of the vertical tab and curving either away from or toward a vertical hole in the sidewall resulting from the vertical tab punched out of the sidewall; and

the horizontal tab comprising;

a tab leg that is substantially planar and is connected to the sidewall at one end of the tab leg, and that projects outwardly from the sidewall at an angle of less than ninety degrees to the sidewall; and

a tab foot extending from the tab leg of the horizontal tab and curving either away from or toward a horizontal hole in the sidewall resulting from the horizontal tab punched out of the sidewall;

where the end of the vertical tab leg that is connected to the sidewall is substantially perpendicular to the end of the horizontal tab leg that is connected to the sidewall.

34. The method of claim 33, where:

the vertical hole is defined by a base side and a top side, the base side has a greater length than the top side, and the vertical tab leg the extends from the base side; and

the horizontal hole is defined by a base side and a top side, the base side has a greater length than the top side, and the horizontal tab leg the extends from the base side.

35. The method of claim 33, where a plurality of vertical tabs and resulting vertical holes and horizontal tabs and resulting horizontal holes are created in the sidewall.

36. The method of claim 35, where the vertical tabs and vertical holes and the horizontal tabs and horizontal holes are positioned in an alternating arrangement on the sidewall such that there is a horizontal tab and horizontal hole between each vertical tab and vertical hole.

37. The method of claim 36, where the horizontal holes and the vertical holes are spaced such that the distance between the centers of successive vertical and horizontal holes is less than about 6 inches.

38. The method of claim 37, where the horizontal holes and the vertical holes are spaced such that the distance between the centers of successive vertical and horizontal holes is about 4 inches.

39. The method of claim 33, where each tab is created in one strike of the sidewall with the punch.

40. A method of building a tilt-wall building comprising:

obtaining a plurality of structural studs, each stud comprising;

a stud having a sidewall;

a vertical tab punched out of the sidewall and a vertical hole resulting from the vertical tab, the vertical tab comprising;

a tab leg that is substantially planar and is connected to the sidewall at one end of the tab leg, and that projects outwardly from the sidewall at an angle of less than ninety degrees to the sidewall; and

a tab foot extending from the tab leg of the vertical tab and curving either away from or toward the vertical hole; and

a horizontal tab punched out of the sidewall and a horizontal hole resulting from the horizontal tab, the tab comprising;

a tab leg that is substantially planar and is connected to the sidewall at one end of the tab leg, and that projects outwardly from the sidewall at an angle of less than ninety degrees to the sidewall; and

a tab foot extending from the tab leg of the horizontal tab and curving either away from or toward the horizontal hole;

where the end of the vertical tab that is connected to the sidewall is substantially perpendicular to the end of the horizontal tab that is connected to the sidewall;

combining the plurality of structural studs with a structural mesh on a substantially horizontal surface such that the studs and mesh are substantially parallel to each other and to the substantially horizontal surface and there are voids formed between the structural studs;

embedding the structural studs and structural mesh in concrete to form a panel; and

raising the panel such that it is substantially perpendicular to the ground.

41. The method of claim 40, further comprising:

laying lifting anchors in the voids formed between the structural studs prior to embedding the structural studs and structural mesh in concrete;

embedding the structural studs, structural mesh, and lifting anchors in concrete to form a panel, such that a portion of each lifting anchor is exposed; and

using the lifting anchors to raise the panel.

42. The method of claim 40, further comprising:

laying support anchors in the voids formed between the structural studs prior to embedding the structural studs and structural mesh in concrete;

embedding the structural studs, structural mesh, and support anchors in concrete to form a panel, such that a portion of each support anchor is exposed; and

attaching supports to the support anchors.