Sheet metal stud and composite construction panel and method

Abstract

A composite construction panel having a thin panel of concrete material and a reinforcing grid of sheet metal studs with embedment portions which are actually embedded into the concrete panel, each of the studs having a web, right angular flange formed on a free edge of the web, an angled edge strip formed along the free edge of the right angular flange, an embedment angled flange portion formed along the opposite edge of the web, an edge strip formed on the angled flange at an angle thereto; and, spaced apart angled flange openings formed in the angled flange for flow of concrete therethrough. An alternate form of stud has a triangular tube structure along one edge of the web. Another form of stud has a discontinuous webs defining spaces between them. In one embodiment two concrete panels may be secured to the studs in spaced relation to create a hollow structure.

What is claimed is  
     
         1 . A composite construction panel and having a thin panel of cast material, and a reinforcing grid of sheet metal studs comprising parallel studs and top and bottom studs, wherein said reinforcing studs have embedment portions which are embedded into the cast panel, and wherein each of said reinforcing studs comprises; 
 a web defining a free edge, which is not embedded in the panel;    right angular flange formed on said free edge;    an angular edge strip formed along the free edge of said right angular flange an embedment flange portion formed along the opposite edge of said web, opposite to said free edge;    an edge strip formed on said embedment flange portion; and,    a plurality of spaced apart embedment flange openings formed in said embedment flange portion:    
     
     
         2 . A composite construction panel as claimed in  claim 1  wherein said embedment flange openings are formed by a series of semi-arcuate openings located spaced apart lengthwise along said embedment flange portion.  
     
     
         3 . A composite construction panel as claimed in  claim 2  and including web openings of generally circular shape formed through said web between said embedment flange portions and said free edge right angular flanges, and edges of said circular openings being formed out of the plane of said web, to define an annular continuous ring.  
     
     
         4 . A composite construction panel as claimed in  claim 3  and including generally circular depressions formed in said web between said web openings and said right angular flanges, and between said web openings and said embedment flange portions, and semi-circular openings formed within said depressions.  
     
     
         5 . A composite construction panel as claimed in  claim 4  wherein said web between said web openings defines generally hour-glass shaped web portions, which are narrower at about the mid point of said web, and wherein said semicircular openings are directed towards said narrower portions of said hour-glass shaped web portions.  
     
     
         6 . A composite construction panel having a thin panel of cast material, a reinforcing grid of sheet metal studs formed by parallel reinforcing studs and top and bottom studs, wherein said reinforcing studs have embedment portions which are embedded in the cast panel, and wherein each of said reinforcing studs comprises; 
 a web defining a free edge which is not embedded in said panel;    a triangular tube formation formed on said free edge, having a first angled tube wall, a second transverse tube wall, and a return tube wall;    a free edge of said return tube wall being fastened to said web;    an embedment flange portion formed along the opposite edge of said web;    an embedment edge strip formed on said embedment flange portion; and,    a plurality of spaced apart flange openings formed in said embedment flange portion.    
     
     
         7 . A composite construction panel as claimed in  claim 6  wherein said embedment flange openings are formed by a series of semi-arcuate openings located spaced apart lengthwise along said embedment flange portion.  
     
     
         8 . A composite construction panel as claimed in  claim 7  and including web openings of generally circular shape formed through said web between said embedment flange portions and said free edge tubular formations, and edges of said circular openings being formed out of the plane of said web, into a continuous annular ring.  
     
     
         9 . A composite construction panel as claimed in  claim 8  and including generally circular depressions formed in said web between said web openings and said triangular formation, and between said web openings and said embedment flange portions, and semi-circular openings formed within said depressions.  
     
     
         10 . A composite construction panel as claimed in  claim 9  wherein said web between said web openings defines generally hour-glass shaped web portions, which are narrower at about the mid point of said web, and wherein said semi-circular openings are directed towards said narrower portions of said hourglass shaped web portions.  
     
     
         11 . A reinforcement stud for use in forming a composite construction panel wherein the panel is formed with a thin panel of cast material, and a reinforcing grid of sheet metal studs wherein said reinforcement studs have embedment portions which are embedded in the cast panel, and wherein each of said reinforcement studs comprises; 
 a web defining a free edge, which is not embedded in the panel; right angular flange formed on said free edge;    an angular edge strip formed along the free edge of said right angular flange an embedment flange portion formed along the opposite edge of said web, opposite to said free edge;    a retention edge strip on said embedment flange portion formed out of the plane of said embedment flange portion; and,    a plurality of spaced apart embedment flange openings formed in said embedment flange portion.    
     
     
         12 . A reinforcing stud for use in forming a composite construction panel as claimed in  claim 11  and wherein said embedment flange portion is formed at an angle to said web and wherein said embedment flange openings are formed by a series of semi-arcuate openings located spaced apart lengthwise along said embedment flange portion.  
     
     
         13 . A reinforcing stud for use in forming a composite construction panel as claimed in  claim 12  and including web openings of generally circular shape formed through said web between said embedment flange portions and said free edge right angular flanges, and edges of said circular openings being formed out of the plane of said web into a continuous annular ring.  
     
     
         14 . A reinforcing stud for use in forming a composite construction panel as claimed in as claimed in  claim 13  and including generally circular depressions formed in said web between said web openings and said right angular flanges, and between said web openings and said embedment flange portions, and semicircular openings formed within said depressions.  
     
     
         15 . A reinforcing stud for use in forming a composite construction panel as claimed in as claimed in  claim 14  wherein said web between said web openings defines generally hour-glass shaped web portions, which are narrower at about the mid point of said web, and wherein said semi-circular openings are directed towards said narrower portions of said hour-glass shaped web portions.  
     
     
         16 . A reinforcing stud for use in forming a composite construction panel wherein the panel is formed with a thin panel of cast material, and a reinforcing grid of sheet metal studs wherein said reinforcing studs have embedment portions which are embedded in the cast panel, and wherein each of said reinforcement studs comprises; 
 a web defining a free edge which is not embedded in said panel;    a triangular tube formation formed on said free edge, having a first angled tube wall, a second transverse tube wall, and a return tube wall;    a free edge of said return tube wall being fastened to said web;    an embedment flange portion formed along the opposite edge of said web;    a retention edge strip formed on said embedment flange portion and formed out of the plane of said embedment flange portions; and,    a plurality of spaced apart flange openings formed in said embedment flange portion.    
     
     
         17 . A reinforcing stud for use in forming a composite construction panel as claimed in  claim 16  wherein said embedment flange portion is formed at an angle to said web and wherein said embedment flange openings are formed by a series of semi-arcuate openings located spaced apart lengthwise along said embedment flange portion.  
     
     
         18 . A reinforcing stud for use in forming a composite construction panel as claimed in  claim 17  and including web openings of generally circular shape formed through said web between said embedment flange portions and said free edge tubular formations, and edges of said circular openings being formed out of the plane of said web, into a continuous annular ring.  
     
     
         19 . A reinforcing stud for use in forming a composite construction panel as claimed in  claim 18  and including generally circular depressions formed in said web between said web openings and said triangular formation, and between said web openings and said embedment flange portions, and semi-circular openings formed within said depressions.  
     
     
         20 . A reinforcing stud for use in forming a composite construction panel as claimed in  claim 19  wherein said web between said web openings defines generally hour-glass shaped web portions, which are narrower at about the mid point of said web, and wherein said semi-circular openings are directed towards said narrower portions of said hour-glass shaped web portions.  
     
     
         21 . A reinforcing stud for use in forming a composite construction panel wherein the panel is formed with a thin panel of cast material, and a reinforcing grid of sheet metal studs wherein said reinforcing studs have embedment portions which are embedded in the cast panel, and wherein each of said reinforcing studs comprises; 
 a web defining a free edge which is not embedded in said panel;    a triangular tube formation formed on said free edge, having a first angled tube wall, a second transverse tube wall, and a return tube wall;    a free edge of said return tube wall being fastened to said web;    a series of generally V-shaped web portions extending from said free edge; an apex on each of said V-shaped web portions;    an embedment portion formed on each said apex; and,    each said apex having an embedment opening formed therein.    
     
     
         22 . A reinforcing stud for use in forming a composite construction panel as claimed in  claim 21  wherein said embedment openings are formed by a series of semi-arcuate openings.  
     
     
         23 . A reinforcing stud for use in forming a composite construction panel as claimed in  claim 22  and including web openings of generally circular shape formed through said web in said V-shaped web portions and edges of said circular openings being formed out of the plane of said web, into a continuous annular ring.  
     
     
         24 . A reinforcing stud for use in forming a composite construction panel as claimed in  claim 23  and including generally circular depressions formed in said V-shaped web portions between said web openings and said triangular formation. and semi-circular openings formed within said depressions.  
     
     
         25 . A reinforcing stud for use in forming a composite construction panel as claimed in  claim 24  wherein said web between said web openings defines generally web portions, which are narrower at about the mid point of said web, and wherein said semi-circular openings are directed towards said narrower portions.  
     
     
         26 . The method or making a composite construction panel comprising the steps of; 
 assembling a plurality of reinforcing studs, each having webs with circular openings therethrough, in parallel spaced apart relation with said circular openings aligned with one another, and with cross members arranged transversely at the ends of said parallel reinforcing studs thereby forming a grid of studs, said parallel reinforcing studs having embedment flange portions thereon;    pouring panel material into a form shaped to provide a planar cast panel;    placing reinforcing mesh in said panel material;    placing said grid of studs over said panel material in said form and lowering the same until said embedment flange portions of said reinforcing studs are at least partially immersed in said panel material;    allowing said panel material to cure, and removing said formed composite panel consisting of cured material with said grid of studs secured in and extending from said panel.    
     
     
         27 . The method or making a composite construction panel as claimed in  claim 26  and wherein said reinforcing studs have web openings of generally circular shape formed through said web and edges of said circular openings being formed out of the plane of said web into a continuous annular ring.  
     
     
         28 . The method or making a composite construction panel as claimed in  claim 27  and wherein said reinforcing studs are formed with generally circular depressions formed alongside said web openings and semi-circular openings formed within said depressions.  
     
     
         29 . A steel stud suitable for use in construction of thermally efficient buildings and comprising; 
 a web defining two edges;    a first right angular flange formed on one said edge;    a first angular edge strip formed along the free edge of said first right angular flange;    a second right angular flange formed on the other said edge;    a second angular edge strip formed along the free edge of said second right angular flange;    web openings of generally circular shape formed through said web between said first and second right angular flanges;    edges of said circular openings being formed out of the plane of said web into generally annular rings;    generally circular depressions formed in said web between said web openings and said right angular flanges; and,    semi-circular openings formed within said depressions.    
     
     
         30 . A steel stud as claimed in  claim 29  and wherein said web between said web openings defines generally hour-glass shaped web portions, which are narrower at about the mid point of said web, and wherein said semi-circular openings are directed towards said narrower portions of said hour-glass shaped web portions.  
     
     
         31 . A steel stud suitable for use in construction of thermally efficient buildings and comprising; 
 a web defining two edges;    a first triangular tube formation formed on one said edge;    a second triangular tube formation formed on the other said edge;    web openings of generally circular shape formed through said web between said first and second triangular tube formations;    edges of said circular openings being formed out of the plane of said web into generally annular ring;    generally circular depressions formed in said web between said web openings and said triangular tube formations; and,    semi-circular openings formed within said depressions.    
     
     
         32 . A steel stud as claimed in  claim 31  and wherein said web between said web openings defines generally hour-glass shaped web portions, which are narrower at about the mid point of said web, and wherein said semi-circular openings are directed towards said narrower portions of said hour-glass shaped web portions.  
     
     
         33 . A composite construction member having a first thin panel of cast material, and a second thin panel of cast material spaced from said first panel, and a reinforcing grid of sheet metal studs comprising parallel studs wherein said reinforcing studs have embedment portions which are embedded into one said cast panel, and said reinforcing studs are secured to the other said panel and wherein each of said reinforcing studs comprises; 
 a web defining a free edge, which is not embedded in the panel;    right angular flange formed on said free edge;    an angular edge strip formed along the free edge of said right angular flange an embedment flange portion formed along the opposite edge of said web, opposite to said free edge;    a retention edge strip formed on said embedment flange portion; and,    a plurality of spaced apart embedment flange openings formed in said embedment flange portion.    
     
     
         34 . A composite construction member as claimed in  claim 33  and including 
 generally circular depressions formed in said web between said web openings and said right angular flanges; and,  
 semi-circular openings formed within said depressions.  
 
     
     
         35 . A composite construction member having a first thin panel of cast material, and a second thin panel of cast material spaced from said first panel, and a reinforcing grid of sheet metal studs comprising parallel studs wherein said reinforcing studs have embedment portions which are embedded into one said cast panel, and said reinforcing studs are secured to the other said panel and wherein each of said reinforcing studs comprises; 
 a web defining a free edge which is not embedded in a said panel;    a triangular tube formation formed on said free edge, having a first angled tube wall, a second transverse tube wall, and a return tube wall;    a free edge of said return tube wall being fastened to said web;    an embedment flange portion formed along the opposite edge of said web;    a retention edge strip formed on said embedment flange portion; and,    a plurality of spaced apart flange openings formed in said embedment flange portion; said embedment edge strip and edge flange being embedded in said one panel, and said triangular tube portion being secured to said other panel.    
     
     
         36 . A composite construction member having a first thin panel of cast material, and a second thin panel of cast material spaced from said first panel, and a reinforcing grid of sheet metal studs comprising parallel studs wherein said reinforcing studs have embedment portions which are embedded into one said cast panel, and said reinforcing studs are secured to the other said panel and wherein each of said reinforcing studs comprises; 
 a web defining a free edge which is not embedded in said panel;    a triangular tube formation formed on said free edge, having a first angled tube wall, a second transverse tube wall, and a return tube wall;    a free edge of said return tube wall being fastened to said web;    a series of generally V-shaped web portions extending from said free edge;    an apex on each of said V-shaped web portions;    an embedment portion formed on each said apex; and,    each said apex having an embedment opening formed therein; wherein said apex on each said V-shaped portion is embedded in said one panel, and wherein said tubular portion is secured to the other said panel.    
     
     
         37 . A composite construction member as claimed in  claim 36  and including web openings of generally circular shape formed through said web in said V-shaped web portions and edges of said circular openings being formed out of the plane of said web, into a continuous annular ring.  
     
     
         38 . A composite construction member as claimed in  claim 37  and including generally circular depressions formed in said V-shaped web portions between said web openings and said triangular formation, and semi-circular openings formed within said depressions.  
     
     
         39 . A reinforcement stud for use in forming a composite construction panel wherein the panel is formed with a thin panel of cast material, and a reinforcing grid of sheet metal studs wherein said reinforcement studs have embedment portions which are embedded in the cast panel, and wherein each of said reinforcement studs comprises; 
 a web defining a free edge, which is not embedded in the panel;    right angular flange formed on said free edge;    an angular edge strip formed along the free edge of said right angular flange    an embedment flange portion formed along the opposite edge of said web, opposite to said free edge, and having a retention edge strip shaped in section as a semi-arcuate profile, formed along said embedment flange portion; and,    a plurality of spaced apart embedment flange openings formed in said embedment flange portion.