NZ237299A - Sheet metal stud with wall panel securing prongs. - Google Patents

Description

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Patents Form No. 5 NEW ZEALAND PATENTS ACT 1953 COMPLETE SPECIFICATION WALL FRAME ELEMENTS WITH INSULATING PANEL ANCHORING PRONGS It CAROLD PICHETTE, a Canadian citizen of 163, de l'Eglise Street, Chateau-Richer Province of Quebec, CANADA GOA 1N0 hereby declare the invention, for which I pray that a patent may be granted to me, and the method by which it is to be performed, to be particularly described in and by the following statement: (followed by page la) I M.Z. PATEN i OFFICE I -4 MAR 1991 F,i:.Cr.lV~D 237 2 99 FIELD OF THE INVENTION The present invention relates to wall structural elements with insulating panel anchoring prongs. Some of said elements serve to prevent sagging of flexible and compressible 5 insulating panels located in hollow walls, while other elements serve to fix rigid insulating panels in a wall.

BACKGROUND OF THE INVENTION In applicant's own prior U.S. Patent number 4,761,928, 10 issued August 19, 1988, a sheet metal stud serving as part of the frame of the hollow wall, is described, comprising several pairs of prongs with lateral teeth partially struck out from the web of the stud. The prongs of each pair can be bent transversely to the web alternately on each side of the same just prior to the 15 installation of the insulating panels. Then the latter are engaged over the prongs, which prevent sagging of the panels on each side of the stud. One drawback of the patented stud is the fact that an inexperienced workman can bend all the prongs, or at least the two prongs of one or of several pairs, towards the same 20 side of the stud web, thereby destroying the required alternating direction of successive prongs to obtain a good anchoring of the insulating panels on each side of the stud. If the workman tries to correct his error by bending back the prongs through the web opening which has resulted from the die-cutting of the prong, the 25 retaining zone of the prong to the stud can break under the la (followed by Pa9e 2) 237 2 99 action of a second bending.

Another drawback of the patented stud relates to the possibility that the workman will set the prong to an oriented 5 position other than its optimum anchoring position. In the above-mentioned U.S. patent, there are no means enabling the workman to automatically position the prong in its optimum anchoring orientation.

OBJECTS OF THE INVENTION The principal object of the invention is therefore to provide a stud of the character described, in which each of the prongs can be bent only in one direction, the prongs capable of being bent in alternating fashion on both sides of the stud. 15 Another object of the present invention is to provide simple means to stop the prongs at an operative limit position normal to the stud and which is the optimum position for the anchoring and retention of the insulating panels.

Another object of the present invention relates to 20 plates and bars used as elements of wall frames, which are provided with prongs having the above-mentioned characteristics.

SUMMARY OF THE INVENTION In accordance with the invention, there are provided 25 hollow wall frame elements having means for retaining against sagging, compressible insulating panels located inside the wall. 2 237299 These elements include studs and plates. There are also provided wall elements formed of bars used for fixing rigid insulating panels in exterior walls.

All of these elements are made of sheet metal and are 5 provided with prongs struck out from a flat portion of the metal sheet and leaving in this flat portion an opening of the same shape as the prong. Each prong is elongated with a pointed outer end, teeth protruding from at least one side of the prong, the latter having an inner end integral with the sheet metal portion 10 along a bending line transverse to the prong. The prong can be bent into an operative position generally normal to the sheet metal portion and on one side of the latter starting from an inoperative position nearly parallel to said sheet portion.

The invention provides a sheet metal element with a i5 flat portion having a first and a second face and provided with a prong struck out from said flat sheet metal portion which has a resulting similarly shaped opening, said prong of elongated shape with a pointed free end, teeth protruding from at least one side and having an inner end integral with said sheet 20 portion about a bending line transverse to said prong, bendable between an operative position substantially normal to said sheet portion and on one side of the latter from an inoperative position nearly parallel to said sheet portion, characterized in that said prong, in its inoperative position, protrudes from 2 5 said first face and has a part which overlaps an edge of said 3 19 NOV 1993 237299 opening, such that the prong cannot be bent through said opening, because said part then abuts against said opening edge.

In accordance with a first characteristic of the invention, each prong, in its inoperative position, slightly protrudes from one of the opposite faces of said sheet portion and has a part which overlaps the edge of said aperture, whereby the prong cannot be bent through said opening, because said part will then abut against the edge of the opening.

In accordance with a second characteristic of the invention, each prong has, in the vicinity of its bending line, a boss, or stop, which protrudes from said first face and which abuts against said sheet portion in the operative position of the prong.

The sheet metal element can be a stud, or post, which is a structural element of the frame of a hollow wall. In this 3a (follp^-^7or; f 237299 case, the tongues are disposed in pairs longitudinally spaced along the stud and the prongs of each pair are close to each other and in their inoperative position, protrude from opposite faces of the web of the stud and can be bent only in opposite 5 directions on the opposite sides of the stud, in order to anchor insulating panels at regular intervals along the stud and on each side of the same.

The sheet metal elements can also be in the form of plates provided with the above-mentioned prongs, and these plates can be fixed to studs made of wood or of sheet metal. These plates can be installed on the already-existing studs of erected walls, thereby avoiding the need to dismantle the wall frame and requiring removal of the dry wall panels on only one side of the wal 1 .

The invention is also directed to prongs provided with teeth on each side and which can be used to anchor insulating panels inserted from any side of the wall. The invention is also directed to bars used for retaining rigid insulating panels and provided with anchoring prongs.

BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 is a perspective view of a hollow wall broken to show the inside and with a frame including sheet metal studs with the prongs of the invention; Figure 2 is a perspective view, on an enlarged scale, of the inside of the stud of Figure 1; 4 237 2 99 Figure 3 is a plan view of the outside of the stud of Figure 2; Figure 4 is a section along line 4-4 of Figure 3; Figure 5 is an enlarged view of the prong shown in the 5 area delimited by the ellipse 5 of Figure 3; Figure 6 is a longitudinal section taken along line 6-6 of Figure 3; Figure 7 is an enlarged view of the area delimited by the circle 7 in Figure 6; Figure 7A is a view similar to that of Figure 7 but showing the prong in its right angular position, namely its operative position; Figure 8 is a plan section of a part of the wall showing how an insulating panel is anchored; Figure 9 is a section taken along line 9-9 of Figure 8; Figure 10 is a section on an enlarged scale, taken along line 10-10 of Figure 5; Figure 11 is an elevation of a plate provided with anchoring prongs; Figure 12 is a side elevation of a wooden stud to which two plates in accordance with Figure 11 are secured; Figure 13 is a section taken along line 13-13 of Figure 12; Figure 14 is an elevation of a plate provided with 25 another embodiment of the prongs in accordance with the invention; 237 2 99 Figure 15 is a partial section taken along line 15-1! of Figure 14; Figure 16 is a view similar to that of Figure 15, but showing the prong in its bent operative position; Figure 17 is a section taken along line 17-17 of Figure 16; Figure 18 is an enlarged vieew of the area within circle 18 in Figure 14; Figure 19 is an enlarged view of the area within circle 10 19 of Figure 15; Figure 20 shows a stud having prongs in accordance with Figure 14; Figure 21 is a partial section taken along line 21-21 of Figure 20; Figure 22 is an elevation of a stud provided with another prong arrangement serving to retain insulating panels; Figures 23 and 24 are sections taken along line 23-24, 23-24 of Figure 22, showing two ways of bending the prongs; Figure 25 is a plan view of a portion of the stud of 20 Figure 22, showing a prong on an enlarged scale; Figure 26 is a section taken along line 26-26 of Figure ; Figure 27 is a section similar to that of Figure 26, but showing the prong in operative position; Figure 28 is a partial elevation of a plate provided with the prongs of Figure 25; 257299 Figure 29 is a section taken along line 29-29 of Figure 28; Figure 30 is a partial view showing the prong of either Figure 25 or Figure 28, but provided with a modified stop; 5 Figure 31 is a view similar to that of Figure 30 but showing the prong in operative position; Figure 32 is an elevation of a plate provided with the prongs of Figure 30 and provided with hooks to fix the plate to a sheet metal stud; Figure 33 is an enlarged view of the area in circle 33 of Figure 32; Figure 34 is a partial section taken along line 34-34 of Figure 33; Figure 35 is a perspective view of a sheet metal stud 15 provided with holes to receive the hooks of the plate of Figure 32; Figure 36 is an enlarged view of the area 36 in Figure ; Figure 37 is a perspective of a conventional metal 20 stud provided with holes for fixing plates similar to that of Figure 28; Figure 38 is a partial vertical section of the stud of Figure 35 to which is secured the plate of Figure 32 on each of its two sides; Figure 39 is an enlarged section taken within area 39 of Figure 38; 237 2 99 Figure 40 is a section taken along line 40-40 of Figure 39; Figure 41 is a broken perspective showing an exterior building wall incorporating Z-shaped bars in accordance with the 5 invention, used for retaining rigid insulating panels; Figure 42 is a section taken along line 42-42 of Figure 41; Figure 43 shows in section, in a, b, c, d four possible positions of the Z-bar, these sections being all taken within 10 area 43 in Figure 42; Figure 44 is an end view of the Z-bar; Figure 45 is a partial elevation of the Z-bar, taken along line 45-45 of Figure 44; Figure 46 is a plan view of the Z-bar and taken along 15 line 46 of Figure 45; and Figure 47 is a section taken along line 47-47 of Figure 46.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS OF THE 20 INVENTION Referring to Figures 1 and 2, wall M includes a rigid frame or armature made of sheet metal elements. These elements include spaced upright studs, indicated at 22, the lower end of which is inserted within and fixed to a floor channel 23 which is 25 secured to floor S and the upper end of which, not shown, is inserted within and is fixed to a ceiling channel, not shown. 8 t ♦ Studs 22 can be reinforced by transverse bars 23A, in the form of channels, which extend through square-shaped openings of several studs 22. These studs are also provided with circular holes for the passage of conduits 23B for electric wires or for plumbing.

Each stud 22 has a U-shaped cross-section and comprises a web 22a and two flanges 22b and 22c. Dry wall panels P are secured to the flanges 22b, 22c or to only one set of such flanges in the case it is not desired to completely close the wall. Each stud 22 is provided with a series of pairs of prongs 24 and 26, which, 10 in their operative position, are bent at right angle with respect to web 22a and on each side of the latter and serve to anchor and retain flexible and compresssible panels, indicated at 28, more particularly, batts of glassfiber, which are positioned in the spaces between successive studs 22. Each prong 24 and 26 (see 15 Figures 1 to 10) is obtained by partial stamping or die-cutting of the web 22a of the stud 22. Each prong has an elongated generally rectangular shape, with two longitudinal free sides 32, 34; an external free pointed end 36; and an internal end 38 integrally retained to the web 22a. Each prong 24, 26 is in an 20 inoperative position nearly parallel to the web 22a. Prong 24, as shown in Figure 6, protrudes from the inside face of the web 22a, namely the face exposed between the two flanges 22b and 22c, whereas prong 26 protrudes from the exterior face of web 22a. Each prong 24, 26 can be bent from its inoperative position, 25 indicated hereinabove, down to an operative position perpendicular to web 22a, as shown, for example, in Figures 2, 237299 7a, and 8. Each prong is pivoted to its operative position about a bending line, indicated at B in Figure 5, which approximately corresponds to the inner ends of the die-cutting which has formed the longitudinal sides 32 and 34. The die-cutting of the prongs 5 24 and 26 results in the formation of correspondingly-shaped openings 40 in web 22a.

The longitudinal side 32 is straight, whereas the opposite side 34 forms several teeth 42, each having a straight edge 42a inclined opposite tip 36. This tip facilitates 10 insertion within insulating panel 28. Each prong 24, 26 is provided with a longitudinal central reinforcing rib 44 which protrudes from the prong on the side of the inner face of the web 22a, whereas each prong 26 is provided with a similar rib 46, which protrudes on the side of the external face of web 22a, as 15 clearly shown in Figure 6. The inner ends of the ribs 44 and 46 are located in the vicinity of the bending line B, which is itself in the flat part of web 22a. On the opposite side of the bending line B, a boss 48 or 49 is formed in the web 22a in alignment with the ends of the ribs 44, 46,respectively, and on 20 the same side as the latter with respect to the plane of web 22a. More specifically, boss 48 protrudes on the same side as rib 44, whereas boss 49, associated with branch 26, protrudes on the same side as rib 46. In practice, the punch and die used for stamping the prong 24 operates in an opposite direction with respect to 25 the punch and die used for stamping prong 26. The ribs 44 and 46 cooperate with the bosses 48 and 49 and abut one one another in 237299 the operative position of the prong, namely the position in which the prong makes a 90-degree angle with respect to web 22a, as shown in Figure 7a.

In accordance with a principal characteristic of the 5 invention, means are provided to prevent prongs 24 or 26 from being bent above bending line B in a direction which would cause the prong to move through opening 40 made in web 22a. In the embodiment shown in Figure 5, during die-cutting, the metal in the zone 38 and of the bending line B, is stretched unequally 10 transversely of the prong and, therefore, the latter, once cut, is longitudinally as well laterally shifted through an angle indicated by alpha and, therefore, the prong edge 32 and the teeth 42 are shifted opposite the corresponding edges of opening 40 and makes an interference therewith. 15 The arrangement of the prongs 24 and 26 is as in the previously-mentioned U.S. patent, namely the prongs are arranged in spaced pairs longitudinally of the stud and the prongs of each pair are adjacent each other, the longitudinal axis of each prong is inclined in the same direction with respect to the 20 longitudinal axis of stud 2, and also the bending line B is inclined relative to the longitudinaz1 axis of prong 24 or 26; the teeth 42 of the prongs are disposed on the same side of the latter.

Therefore, in its operative position, the prong assumes 25 a double inclination with respect to the stud. A first inclination, as shown in Figure 8, wherein each prong is inclined 11 237 2 99 towards the flange 22b in a plance perpendicular to the plane of the web 22a; and a second inclination, shown in Figure 9, wherein each branch is transversely inclined with respect to the longitudinal axis of the stud 22.

In practice, to install insulating panels, especially batts of glassfibers 28 within hollow walls, one proceeds as shown in Figures 8 and 9. The prongs 24 and 26 must be oriented towards the workman, that is towards the side of the wall where the dry wall panel P is not yet in position, and it is necessary 10 that the teeth 42 be directed towards the workman, that is towards the open side of the wall; and that the teeth be directed upwardly, as shown in Figure 9. It is then very easy to postion the insulating panel 28 by pushing its side edge against the pointed tips of the prongs in accordance with arrow F of Figure 8 15 and by a nearly simultaneous movement, pushing the insulating panel 28 against the already-installed wall panel P, in accordance with arrow Fa of Figures 8 and 9.

The prong inclination towards the workman not only facilitates anchoring the panels 28 but also causes the prongs 24 20 and 26 to pierce several easily-detachable glassfiber laminations of the panel 28, these laminations being generally parallel to the wall panels P. A better retention of the glassfibers against sagging is obtained. The retention is still improved because the glassfiber batts under their weight tend to slip towards the back 25 in the direction of arrow Fa of Figure 9 to finally rest against the right-hand panel P of Figure 9. 12 257299 If the workman has made sure to install the studs 22 with the tips of the prongs 24 and 26 in their inoperative position directed upwardly, as shown in Figures 1 and 2, and that he has first fixed the dry wall panels P against the flanges 22c 5 of the studs 22 opposite the direction of the teeth 42, it will then be impossible for him to make a mistake in choosing the proper bending direction of the tongues 24, 26 of each pair, since these tongues can only be bent in the proper direction. Also, the optimum operative position is obtained, namely at 90 10 degrees with respect to the web 22a, by simply bending the tongues until they attain their limit position, where, as shown in Figure 7a, the inner end of reinforcing rib 44 or 46 abuts against boss 48 or 49. Also, due to these stopping means, the prongs will not tend to move downwardly with time under the 15 weight of the glassfiber panels 28.

Figure 11 and 13 show a rectangular plate 54 provided with holes 52 to fix the plate by nails or the like to each of the two opposite faces of a wooden stud or upright D (Figure 12) or to each of the opposite faces of the web of a conventional 20 sheet metal stud when the latter is made of a thicker than normal metal sheet and which will not permit bending of the prongs without the use of a tool. Plate 54 is provided with two pairs of prongs 24' 26'. The prongs of each pair are at the same level and diverge in the direction of their tip. It is only the 25 longitudinal internal side of each prong which is provided with teeth 42', similar to teeth 42, and which face one another in the 13 2 3 7 2^9 inoperative position of the prongs. Each prong 26' is provided with a rib 46', the inner end of which is in the vicinity of bending line B, whereas a boss 38' is provided on the other side of the. bending line, said bosses being common to the two prongs 5 24' 26*. In their inoperative position, all of the prongs 24' 26' slightly protrude from the external face of the plate 54. Boss 38' and also the ribs 46' also protrude from the exterior face of plate 54. A plate 54 is secured to each of the opposite faces of wooden stud D, with the pointed tips of the prongs 26' 10 upwardly directed and with the prongs on the outside of the stud. The workman selectively bends that one of the prongs 24' and 26' of each pair, the teeth 42' of which are directed towards himself and upwardly inclined in the same direction as was described with respect to Figures 8 and 9. The prongs cannot be bent other than 15 in the external direction of the plate, because the prongs are laterally and longitudinally offset with respect to the opening 40' formed in the plate by the die-cutting of the prongs. The prongs are positively maintained in their operative position normal to the plate 54. ;20 Figures 14 to 19 show a plate 54* which is positioned in the same manner as plate 54 on the opposite faces of either a wooden stud D or of the web of a conventional sheet metal stud. Plate 54' has holes 52 for securing the same. Each pair of prongs 24' 26' is replaced by a single prong 56, having a series 25 of teeth 58a, 58b on each of its two longitudinal sides and which is also provided with a central longitudinal reinforcing rib 59, 14 237 2 99 the inner end of which is adjacent the bending line B'. Plate 54' has a boss 38" on the opposite side of the bending line. The width of the prong 56 decreases in the direction of its bending line, except its pointed end portion. This pointed end is 5 provided with an extension 60, in the form of a boss, which overlaps a distance OS the corresponding edge of opening 40" which was formed during die-cutting of the prong 56. The extension 60 prevents the prong from being bent through the opening 40". The sides of the prong and the teeth 58a and 58b 10 are diverging and inclined with respect to plate 54'. In the inoperative position of the prong 56, the teeth extend through opening 40", as shown in Figure 15. In its operative position shown in Figures 16 and 17, prong 56 is maintained in its horizontal position normal to plate 54' by a boss 38" and by the 15 abutting inner end of rib 59. As for plate 54, it is not necessary to choose which side of the hollow wall is to be left open for installation of the insulating panels, since there is always one series of teeth which face the workman. Moreover, these teeth are upwardly inclined towards the workman, as in 20 Figure 8, and also because the prongs decrease in width, the teeth are inclined towards the workman in a plane perpendicular to the plane of the plate 54' in a manner similar to the teeth of the prongs 24 and 26 in Figure 8.

Prongs 56 are all bent on the same side to extend 25 outwardly of plate 54' in their operative position.

The same type of prongs is shown in Figures 20 and 21, 2 3 7 2 ? wherein they are used in association with a stud 22' analogous to the stud 22 of Figures 1 to 11. In this latter, prongs 54' are arranged in pairs, the prongs of each pair being adjacent to each other and the prongs of the same pair capable of bending in 5 opposite directions only (Figure 21) and are maintained normal to the web of the stud by means of the reinforcing ribs of these prongs together with the bosses 38", as in the plate of Figure 14. Prongs 56' are also provided with extensions 60' to prevent them from being bent through the corresponding opening in the 10 stud web. Therefore, the workman will be obliged to pivot the prongs 56' in alternate manner on each side of the stud. The stud provided with prongs 56' has the same advantage as those defined in relation with prongs 56 of plate 54' of Figure 14.

Figures 22 to 27 show a sheet metal stud 62 provided 15 with longitudinally-spaced groups of two pairs of prongs. The prongs of the first pair are indicated at 64 and 64a, while the prongs of the second pair are indicated at 66 and 66a. The prongs of each pair are arranged in a manner analogous to the prongs 26' of Figure 11. Prongs 64 and 64' can be bent only 20 towards the inside of the stud 62, while the prongs 66, 66a can only be bent towards the exterior of the stud 62. More specifically, the prongs of the same pair are disposed azt the same level along the stud 62. They are diverging towards their pointed end 68 and their inner ends are defined by the respective 25 bending lines B". Each prong of the same pair has a series of teeth 70 on its inner side and which face the other prong of the 16 237299 same pair. The prongs are laterally offset during die-cutting, such that the edge of opening 72 resulting from the die-cutting of the prong will interfere with the corresponding prong.

Referring to Figure 22, prongs 66 and 66a protrude from 5 the exterior face of web 62a in their inoperative position, while prongs 64, 64a protrude from the inside face of the same web 62a. In the same manner, reinforcing ribs 74 of prongs 64,64a are recessed with respect to the exterior face of web 62a, while the reinforcing ribs 76 of prongs 66, 66a protrude from said external 10 face. If the insulating panels are to be inserted in the direction of the arrow 78 (Figure 23), the workman will bend the superposed prongs 64, 66 to their operative position, such that their teeth 70 will face the workman and with the prongs laterally inclined towards the latter, as in Figure 8. If the 15 insulating panels are to be installed from the opposite direction, as shown by arrows 80, (Figure 24) the workman will then only bend the prongs 64a and 66a.

Referring to Figures 25 to 27, each reinforcing rib 74 or 76 extends centrally of the prong and its inner end 82 is open 20 at 84 at the level of the bending line B". This inner end forms a stop for maintaining the prong in operative position at 90 degrees with respect to the web 62a, as shown in Figure 27. In this case, it is not necessary to form a boss on the web on the other side of the bending line B".

Figures 28 and 29 show a plate 86, similar to the plate of Figure 11, and which has the same purpose. It is provided at 17 237299 two different levels with pairs of prongs 88, which are similar to prongs 26' of Figure 11, except that the stop means for maintaining the prongs in their operative 90-degree position. These stop means consist of ribs 76a outwardly protruding from 5 the outside of the plate and the inner end of which abuts against the plate 86 in the operative position of the prong. A hole 84 is formed at the inner end of rib 7 6a.

Figures 30 and 31 show a prong 90 provided with a stop 92 which ends at the level of the bending line B" as for the 10 prongs 88 of Figure 28, but these stops 92 are much shorter than reinforcing ribs 76a and are open at both ends. The stop 92 is used when the metal sheet is sufficiently thick as to obviate the necessity of having reinforcing ribs in the prongs 90. Stop 92 directly abuts against the plate 62a or 86 in the operating 15 position of the prong, as shown in Figure 31. Such a prong 90 can be used not only for plates but also for the webs of metallic studs.

Figure 32 shows a plate 94 provided with prongs 96 disposed in diverging pairs, as in the plate 54 of Figure 11. 20 Plate 94 has the same purpose as plate 54. Each prong is laterally shifted to prevent its passage through opening 98 of the plate. Each prong 96 is provided with a stop 100, identical to stop 92 of Figure 29. Prongs 96 can be bent along the bending lines B". Plate 94 is characterized by the provision of two 25 hooks 102 spacedly disposed along the centerline of the plate 94. These hooks are bent back to protrude from the internal face of 18 2 3 7 2 8f the plate 94 and are partially die-cut within an opening 104 formed in the plate during die-cutting of the hooks 102. Each hook has a downward leg 106, the height of which is equal to 1.3 times the distance J between the lower end 108 of the leg 106 and 5 the lower edge 110 of the opening 104. The top edge 112 of opening 104 is equal to the height of the leg 106, that is to 1.3 times J.

A conventional sheet metal stud 114, shown in Figure 35, is characterized by the fact that its web 116 is provided 10 with pairs of rectangular holes 118 spacedly disposed along the centerline of web 116 a distance from each other indicated by Y and which is equal to the distance Y between the hooks 102 of the plate 94. These holes 118 are rectangular and, as shown in Figure 36, their width is approximately equal to 2.2 times the 15 thickness T of plate 94, while the height of hole 118 is equal to about 1.2 times the total height C of hook 102.

As shown in Figures 38 to 40, two plates 94 can be positioned back to back on each side of the web 116 with their hooks 102 disposed side by side and extending through a common 20 opening 118 and through the opening 104 of the other plate 94. The height of all these openings is sufficient for insertion of a hook while the plate is in raised position and to allow the subsequent lowering of the plate for the hook leg to engage the opposite face of the web 116 of the stud 11.

Figure 37 shows a conventional stud 119, made of sheet metal and similar to stud 114, but in which the openings 118 have 19 237299 been replaced by round holes 120, which can be made on the building site or at the stud manufacturing plant and which serve to fix anchoring plates, such as plates 54 of Figure 11, in opposite directions by means of metal screws.

Figures 41 to 46 show a wall structural element 122, which is a bar of Z-shape cross-section, adapted to be positioned horizontally. This bar is formed by a central web 124 and two flanges 126, 128 at right angles to the web and oppositely directed. Web 124 and flange 126 are each provided at uniform 10 distances along the bar, with prongs 130 and 132 respectively. Prongs 130, which are obtained by die-cutting the flange 126, are very similar to prongs 24, 26 of Figures 1 to 11. They are provided with teeth 134 on only one longitudinal side. Prongs 122, which are die-cut in web 124 are similar to prongs 132, 15 except that they are provided with teeth 136 on both sides of the prong. Prongs 130, 132 are lazterally and longitudinally offset during die-cutting, such as to interfere with the edge of the opening formed during die-cutting. Prongs 130 and 132 can therefore be bent towards or only one side of the web or of the 20 flange. Prongs 132, made in web 124, can only be bent to their operative position in a direction opposite to a boss 138 formed in web 124 by die-cutting and which provides a sharp edge 140 facing flange 126, that is the flange provided with prongs 130. Each prong 130, 132 is provided with a central longitudinal 25 reinforcing rib 141, 144, the inner end 146, 148 of which abuts against a boss 150, 152 in the operative positiion of the prong, 237299 in order to positively maintain the latter in a plane perpendicular to web 124 and to flange 126 respectively.

Figure 41 and 42 show how the bar 122 is used. It serves to retain in position rigid insulating panels 154 used in 5 external building walls. These rigid panels are generally made of polyurethane foam or of compressed glass fibers. Figure 41 also shows the inside of the wall, including the insulating panels 28 of non-compressed glass fibers and which are flexible and compressible. These panels 28 are located between studs 22. 10 The interior side of the exterior wall is finished by dry wall panels P.

Figure 41 shows a concrete floor 156 of a building with the studs 22 inserted within a floor channel 23 secured to the floor and inserted within a sealing channel 160. The exterior 15 edge of floor 156, as well as the exterior of the hollow wall, is covered by rigid insulating panels 162 to which are secured the horizontal Z-bars 122. The vertical distance between the various Z-bars 122 is equivalent to the height of the panels 154, the latter having standard dimensions.

In the position of the bar 122, shown in Figure 41 and also in Figure 43-b, flange 126, provided with prong 130, is directed upwardly and directly fixed to the panels 162. Panel 154 is installed from the external side of the wall first by inserting the top edge of the panel 154 between the flange 128 25 and the panel 162 and by raising the panel in accordance with arrow 164, such that it will be anchored by prongs 132, having a 21 237 2 9 e double set of teeth. The lower edge of the panel is simply pushed against the prongs 130 of flange 136 in the direction of arrow 166 and the lower edge portion of the panel is hooked not only by the prong teeth 134 but also by the retaining edge 140 of 5 boss 138.

The bars 122 can also be installed in the position shown in Figure 43-c. In this position, the bar has been turned half a turn in clockwise direction with respect to the position shown in Figure 43-b. The panels 154 are again installed from 10 the exterior of the building wall by first inserting the lower edge of the panel in the subjacent bar in accordance with the arrow 168, such that this lower edge will become anchored by the prongs 132 and then the upper edge of the panel is pushed against prongs 130 in the direction of arrow 166.

The same bar 122 can also be fixed in either one of the positions shown in Figures 43-a and 43-b for the installation of the panels 154 from the inside of the building in accordance with arrows 170. In the position of Figure 43-a, one starts to anchor the lower edge of the panel 154 in accordance with arrow 168, 20 whereas in the position of Figure 43-d, one starts by anchoring the top edge of the panel in accordance with arrow 164. 22

Claims (19)

WHAT We CLAIM IS:- 2i7z99

1. A sheet metal element with a flat portion having a first and a second face and provided with a prong struck out from said flat sheet metal portion which has a resulting similarly shaped opening, said prong of elongated shape with a pointed free end, teeth protruding from at least one side and having an inner end integral with said sheet portion about a bending line transverse to said prong, bendable between an operative position substantially normal to said sheet portion and on one side of the latter from an inoperative position nearly parallel to said sheet portion, characterized in that said prong, in its inoperative position, protrudes from said first face and has a part which overlaps an edge of said opening, such that the prong cannot be bent through said opening, because said part then abuts against said opening edge.

2. A sheet metal element as defined in claim 1, further including a stop integral with said prong and protruding from said first face in the zone of said bending line and abutting against said sheet portion in the operative position of said prong.

3. A sheet metal element as defined in claim 2, wherein said pointed end has an extension which forms said part. 23 237299

4. A sheet metal element as defined in claim 1, further including two stops integrally formed with said prong and with said sheet portion, respectively, on each side of said bending line and in the vicinity of the latter, said two stops abutting each other in the operative position of said prong.

5. A sheet metal element as defined in claim 1, wherein said prong has a 1ongtidudinal reinforcing rib protruding from said first face and having an inner end in the vicinity of said bending line and forming a stop, abutting against said sheet portion in the operative position of said prong.

6. A sheet metal element as defined in claim 1, wherein said prong has a longitudinal central reinforcing rib with an inner end located in the vicinity of said bending line, said rib protruding from said first face, said rib inner end abutting against said sheet portion in the operative position of said prong, each longitudinal edge of said prong having teeth, said teeth inclined with respect to said sheet portion and extending through said opening in the inoperative position of said prong, said prong having a width which decreases in the direction of said bending line.

7. A sheet metal element as defined in claim 6, wherein said pointed end has an extension which forms said part. 24 J9W01 IS 93 237 2 99

8. A sheet metal element as defined in claim 7, further including two stops integral with said prong and with said sheet portion, respectively, protruding from said first face and located on each side of said bending line adjacent the latter, said two stops engaging each other in the operative position of said prong.

9. A sheet metal element as defined in claim 1, forming a stud for a hollow wall, said stud having a cross-sectional CJ-shape, defining a web and two legs against which dry wall panels are adapted to be fixed with said web normal to said dry wall panels, said sheet portion constituting said web, said prongs arranged in pairs spaced longitudinally of said stud, the prongs of each pair protruding from opposite faces of said web in their inoperative position, such that said prongs can be only bent in opposite directions with respect to said web and extend on each side of said web in their operative position.

10. A sheet metal element as defined in claim 9, wherein the longitudinal axis of each prong is inclined with respect to the longitudinal axis of said stud.

11. A sheet metal element as defined in claim 10, wherein said bending line is inclined with respect to the longitudinal axis of said stud and to the longitudinal axis of said prong. 25 237299

12. A sheet metal element as defined in claim 9, wherein the longitudinal axis of said prong is parallel to the longitudinal axis of said stud and said bending line is transverse to said stud longitudinal axis, said prong having teeth on each of its longitudinal edges the width of said prong decreasing in the direction of said bending line and said longitudinal edges and teeth being inclined with respect to the plane of said web and extending through said opening in the inoperative position of said prong.

13. A sheet metal element as defined in claim 1, forming a substantially rectangular plate provided with means to fix said plate against a structural post of a hollow wall structure.

14. A sheet metal element as defined in claim 13, wherein said plate has a pair of said prongs located substantially at the same level relative to the length of said plate, said prongs having teeth on only one of their longitudinal sides, the teeth of any one prong extending towards the other prong, the longitudinal axes of said prongs of said pair diverging in the direction of the pointed end of said prongs.

15. A sheet metal element as defined in claim 6, forming a substantially rectangular plate, with the longitudinal axis of said prong located lengthwise of said plate. 237299

16. A sheet metal element as defined in claim 1, forming a substantially rectangular plate with at least two prongs located at the same level lengthwise of said plate, said two prongs diverging in the direction of their pointed ends when in inoperative position, each prong having teeth located only on that one of its longitudinal sides which faces the other prong, each prong provided with a stop protruding from said first face in the zone of said bending line, said plate provided with hooks spaced along its longitudinal axis, adapted to enter apertur'es made in a sheet metal structural studs of a hollow wall.

17. A sheet metal element as defined in claim 9, wherein the teeth of each prong of said pair are disposed on only one longitudinal side of the prong and face in the same direction.

18. A sheet metal element as defined in claim 17, further including an additional pair of prongs in the vicinity of the first-mentioned pair of prongs and similar to the latter, except that their teeth are directed in a direction opposite to the teeth of the prongs of the first pair.

19. A sheet metal element as defined in claim 1, in the form of an elongated bar, of Z-shaped cross-section, including a web and two oppositely-directed flanges depending from the opposite sides of the web, one flange being a prong-free flange, said web and the other flange provided with said prongs 27 i^P-arr/rro^l-'fc 19 NOV 1993 Rece?v-D 2 3 "* 2 9 9 longitudinally spaced along the same, the prongs depending from said web extending in the same direction as said prong free flange and the prongs depending from said other flange extending in the same direction as said web with respect to said other flange, in the operative positions of said prongs. CAROLD PICHETTE U.AnjiAr&uO a J By His Attorneys / / BALDWIN SON & CAREY