Steel Thermal Stud And Method Of Manufacture Thereof

Abstract

Disclosed herein is a steel thermal stud and method of manufacturing thereof. The steel thermal stud of the present invention can be used in load bearing and non-load bearing applications as a direct replacement for wood studs, however installed the same as traditional steel studs. The steel thermal stud is able to be insulated with a variety of insulation products depending on the application, and the stud discloses a superior thermal and acoustic properties while being much lighter than wood studs.

1 . A steel thermal stud, said stud comprising:
 a pair of top and bottom flanges with webs AA, wherein each flange with respective webs includes a flange continuing to an inner web at a bend on both sides, said inner web continuing to a step on the both sides, an outer web continuing from said step terminates at a specified distance in an opposite direction of said step on the both sides, a plurality of slots located on said outer web on the both sides, and a plurality of aligned slots provided over said flange;   multiple pairs of opposing formed plates AC, configured to be spaced along length of said pair of top and bottom flanges with webs AA, hence to hold together said top and bottom flanges with webs AA; and   an insulation AB, adapted to be located inside of said stud, wherein said insulation AB is securely contained in place via said pair of top and bottom flanges with webs AA and said multiple pairs of opposing formed plates AC.   
     
     
         2 . The stud of  claim 1 , wherein said plurality of aligned slots are configured to make said bend by merely rolling each of said top and bottom flanges with webs AA over. 
     
     
         3 . The stud of  claim 1 , wherein said pair of top and bottom flanges with webs AA may allow a fastener to penetrate in order to prevent the movement of said fastener in any direction, to prevent deformation of the stud wall material, to prevent said fastener from backing out by having additional contact with less potential movement, to provide more pull-out strength and more strip resistance of said fastener during installation. 
     
     
         4 . The stud of  claim 1 , wherein said each formed plate AC is comprised of a web and a pair of formed ends, and termination of said formed ends and an inner surface of said web tightly contact the inside and outside of said outer web of said top and bottom flanges with webs AA. 
     
     
         5 . The stud of  claim 1 , wherein said plurality of slots are configured to stuck in each formed end of each of said formed plates AC. 
     
     
         6 . The stud of  claim 1 , wherein said formed plates AC may help isolate and absorb vibration and thermal transfer, and assist with structural strengths. 
     
     
         7 . The stud of  claim 1 , may further comprise a secondary flange AD which is configured to be located within said top, or said bottom, or said top and bottom flanges with webs AA, to provide additional penetration locations for mounting screws or fasteners, in order to allow multiple connection points on said screws or fasteners hence to make said screws or fasteners cantilevered to support loads. 
     
     
         8 . The stud of  claim 7 , wherein said secondary flange AD is comprised of a pair of legs and a web. 
     
     
         9 . The stud of  claim 1 , may further comprises additional holes, slots, ribs or other shapes for running conduits, pipes, tubes, insulation and other mechanisms through, and to assist with fastener drifting as well as allowing easier penetration for pointed or self-drilling fasteners. 
     
     
         10 . A method of manufacturing a steel thermal stud, said method comprising steps of:
 decoding of strip slack sections to form a pair of top and bottom flanges with webs AA;   forming of a step on each side of said strips of said top and bottom flanges via a roll-forming;   forming of a bend on each side of said strips of said top and bottom flanges via a plurality of aligned slots;   foaming an insulation AB and forming of a plurality of slots;   installing multiple pairs of opposing formed plates AC through said plurality of slots to hold together said top and bottom flanges; and   stacking and packaging of said steel thermal stud.   
     
     
         11 . The method of  claim 10 , wherein said stud may be made by employing a forming process that includes a use of compression around the different stud components, and use of electro-magnetic to control the positioning of said top and bottom flanges with webs AA during a formed plate installation to ensure proper alignment with minimal tolerances to install said formed plates AC simultaneously at all locations on said stud, along with alignment electronic controls. 
     
     
         12 . The method of  claim 10 , wherein said manufacturing process may allow the final bends at aligned perforations to be over-bent, pushing into said insulation AB, and recovering or springing-back to the correct angle, wherein said insulation AB may assist in maintaining the shape of said stud, both during the forming process and once said stud is ready for use. 
     
     
         13 . The method of  claim 10 , wherein said steel stud may install a plastic spacer before forming of the final bend to prevent over-bending of the last-formed web when using light density insulation within said stud. 
     
     
         14 . The method of  claim 10 , wherein said steel stud may be made using galvanized steel in coil form, and manufactured on roll forming machines with various in-line punches, dies, top and bottom rollers, wheels, shears, etc. 
     
     
         15 . The method of  claim 10 , wherein said steel stud may also be made with multiple machines such as a turret press and brake press. 
     
     
         16 . The method of  claim 10 , wherein said formed plates AC may be made up of a material such as stainless steel, snap-in fiber reinforced plastic pultrusions, injection molded and extruded plastics. 
     
     
         17 . The method of  claim 10 , wherein said formed plates AC may have a plastic or other coating to help prevent vibration and acoustic transfer between said top and bottom flanges with webs AA and said formed plates AC.