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  Metal stud punch systemUSPTO Application #: 20060201225Title: Metal stud punch system Abstract: A portable metal stud punching system with a controller. The punch system may be set for a desired number of punches, N. When N equals 0, N may be reset though the entry of a code to reset N or increase the value of N to a number greater than 0. (end of abstract)
Agent: Carl D. Crowell - Salem, OR, US Inventor: Joseph Kariakin USPTO Applicaton #: 20060201225 - Class: 072325000 (USPTO) Related Patent Categories: Metal Deforming, With Cutting, By Composite Tool (e.g., Piercing) The Patent Description & Claims data below is from USPTO Patent Application 20060201225. Brief Patent Description - Full Patent Description - Patent Application Claims
CROSS-REFERENCE TO RELATED APPLICATIONS [0001] This application is a continuation-in-part of Application Ser. No. 10/917,028, Filed 08/11/2004 by the present inventor. FIELD OF THE INVENTION [0002] This invention relates generally to building construction, and more particularly to the construction of and method of manufacturing tabbed structural members for tilt-up style wall construction and the control of thereof. BACKGROUND OF THE INVENTION [0003] Tilt-up building construction is well known in the construction industry. Tilt-up thin-shell construction is a method of construction where the walls or panels are formed horizontally on a building slab or foundation from light gauge metal framing embedded in thin (1.5'' to 2'') concrete. Thin-shell construction is distinguished from traditional tilt-up construction which uses steel rebar inside of 6'' to 8'' thick concrete walls, rather than thinner concrete with external steel. There are obvious advantages to the newer thin-shell systems in material savings and ease of transporting and handling lighter panels. When the panels are dried and finished they are simply tilted up to become vertical walls. [0004] Another method employs pre-fabrication of the building panels that can be either constructed on or off-site and then moved into a specific position to form the walls, floors and roofs of a building structure These pre-fabricated panels are reinforced and joined to each other by metal studs and joists embedded in the panels. [0005] It is generally recognized that the overall strength of a prefabricated building panel is, in large part, dependent upon the integrity of the bond that is created between the metal stud and the concrete panel after the concrete has hardened. For example, a stud edge surface in simple contact with the surface of the concrete panels results in a relatively weak bond and, therefore, a relatively weak panel. Accordingly, it has become a common technique to provide projections on the edge of the metal stud that extend into the wet concrete therefore securely anchoring the metal stud to the concrete panel when the concrete hardens. [0006] By way of example, projections can be provided directly on the flange of a metal stud to anchor the stud to the panel. In one know method, the metal stud is shaped like a common "C" channel and has a planar central web and a pair of substantially perpendicular edge flanges. However, one edge flange has a series of spaced, longitudinally shaped cut-outs along its length, thereby permitting the cut-out portion of the edge flange to bend upwards and form a projection which can be embedded within the concrete material of the panel. A reinforcing mesh or the like can be mechanically attached to the projections so that the mesh is positioned at the proper depth within the panel. The drawback with these cutouts in the studs is that common "C" channel must be either specially modified or specially manufactured which adds to the cost of labor and material of the finished panel. One solution is the SteelCrete Punch Press available from Simple Building Systems, Inc., 27280 Jefferson Avenue, Suite 202, Temecula, Calif. 92590. The SteelCrete Punch Press has a series of hydraulic punches that when a length of C channel is inserted into the press, the cutouts or tabs are punched and formed. The problem with this system is that the SteelCrete Punch Press is so large that it is prohibitive to take to the job site, because of the heavy Punch Press the studs have to be shipped twice. From the stud manufacture to the Punch Press, unloaded, punched, reloaded and shipped to the client. This extra shipping and handling significantly raises costs. Additionally, the higher cost of this press makes it not feasible for the smaller scale contractor. [0007] Simple Building Systems, Inc. does supply pre-punched studs however, since the studs are specially modified or manufactured at an off-site manufacturing facility, the studs are not readily susceptible to further modifications or adjustments to meet unusual or special needs which may arise in the field. [0008] Pre-punched studs also suffer from the additional storage space requirements and difficulties in stacking and shipping. With the pre-punched studs, the cut outs created prevent orderly stacking, increase the required volume for materials storage, are easily damaged or bent and make the normally linear metal stud difficult to handle. [0009] Prior methods of forming metal studs for use with tilt up construction include sequentially cutting and then shaping tabs on metal studs. Such methods are generally not portable and not usable at a job site, as the linear travel required to have both cutting stations and shaping stations in sequence mechanically requires a travel greater than the width of a conventional vehicle and trailer. As the metal studs being punched may be of any length, it is desirable to be able to punch the studs in a manner so as not to interfere with a vehicle towing a punching unit, making prior art portable units impractical. [0010] Another potential solution is described in a patent issued to Ruiz et al., U.S. Pat. No. 5,414,972 where a reinforced structural member is a two-piece assembly comprising a structural member and a reinforcing member. The reinforcing member is fastened to the structural member such that a series of projections extend from the reinforcing member are engaged in the building panel. Although this is a partial solution to the shipping problem, since less material is shipped, it requires significant additional labor to fasten the reinforcing member to the structural member raising costs. [0011] Accordingly, there exists a need for a system and method of manufacturing a structural member that is a modification of a standard C channel metal stud used in the manufacture of thin shell tilt-up style construction panels that is easily and economically punched to form the tabs needed for embedment and attachment to the concrete. [0012] Further there is a need for a system of economically punching tabs in a C channel metal stud that is compact, simple to operate and portable such that it may be readily used on a job site. [0013] There is further need to be able to control the use of such a system to permit only licensed or authorized use of such and to be able to remotely adjust the available usage of such a system. SUMMARY OF THE INVENTION [0014] The present invention provides a system and method of modifying a standard C channel stud used in the manufacture of tilt-up style construction. By punching and forming a tab or series of tabs on one of the two parallel sides of the C channel, the tab becomes a concrete embedment with known engineering values of withdrawal and shear force. The tab also provides a ready point for reinforcing mesh to be easily attached and held in place with the tabs prior to pouring the cement or other wall construction material. [0015] In the preferred embodiment, the entire device is such that a single punch and die are manipulated by a pair of hydraulic units such that the device may be readily mounted on a portable station, such as a trailer and towed and used as needed at a job site. [0016] In the preferred embodiment, the operation of the device, including the operation of the hydraulic units is enabled or disabled by a controller. The controller records the number of punches that have been made and allows the metal stud punching system to make subsequent punches until a determined numerical limit is reached. The numerical limit is set based on a code entered into the controller's keypad. This allows the owner of the device to sell a specified number of punches to the device's operators. This also permits the remote entry of an authorizing code to adjust numerical limit of available punches. [0017] The metal stud punching system of the preferred embodiment of the present invention has an alignment frame with an adjustable infeed alignment port in a first side and an adjustable outfeed alignment port in an opposite side. There is a punch and die positioned within the alignment frame. A length of metal stud is inserted through the infeed alignment port, the ports are wide enough for different stud widths with one vertical side of the metal stud disposed between the punch and the die. A first hydraulic unit is attached to the punch and moves a first direction thereby inserting the punch into the die and punching a tab out of the vertical side of the metal stud. A second hydraulic unit moves the punch assembly in a direction perpendicular to the first direction of the first hydraulic unit. After the tab has been punched, the second hydraulic unit advances the metal stud by sliding the punch assembly a distance equal to the desired space between tabs. With the perpendicular movement, the punch inserted in the metal stud is dragging in the stud and pushing it out the outfeed alignment port. In the preferred embodiment, the die has one open side allowing the tab to slide through the die enabling the die to remain stationary rather needing to retract both the punch and the metal stud to avoid the tab. The punch is retracted by the first hydraulic unit and the punch assembly is returned to its original position by the second hydraulic unit. BRIEF DESCRIPTION OF THE DRAWINGS [0018] The above description and other objects, advantages, and features of the present invention will be more fully understood and appreciated by reference to the specification and accompanying drawings, wherein: [0019] FIG. 1 is a cross-sectional view of the punch, die, and steel stock demonstrating the step-by-step punching and forming of the tab on the steel stock according to the preferred embodiment of the present invention. Continue reading... Full patent description for Metal stud punch system Brief Patent Description - Full Patent Description - Patent Application Claims Click on the above for other options relating to this Metal stud punch system patent application. ###  How KEYWORD MONITOR works... a FREE service from FreshPatents1. Sign up (takes 30 seconds). 2. Fill in the keywords to be monitored. 3. Each week you receive an email with patent applications related to your keywords. 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