Top Flange Hanger with Strengthening Embossment

Structural connector for connecting first and second structural members has a substantially planar first flange and an embossment in the first flange, and the embossment in the first flange is formed with first and second sections.

Structural connector for connecting first and second structural members has a substantially planar first flange and an embossment in the first flange, and the embossment in the first flange is formed with first and second sections.

The first section generally extending uniformly to a first level above the top surface of the substantially planar first flange, that is different from a level to which the second section generally uniformly extends, the first and second sections being joined to each other at a distinct transition portion where the embossment sharply descends from the level of the first section to the level of the second section. The structural connector can be made with a bend that forms a first member adjacent the first flange and the embossment can extend through the bend into the first member.

The structural connector of the present invention has particular application in the field of structural hangers where an elongated, generally horizontally disposed structural member is hung from a supporting structure, both being part of thestructural frame of a building.

In light frame construction, it is common to hang the joists supporting the floors of the building from horizontally disposed members often called headers, beams or ledgers. The joists can be supported by hangers which are attached to theheaders, beams or ledgers. One type of hanger used is called a top flange hanger. A top flange hanger has a portion or member that rests on the top surface of the supporting structure, increasing the strength of the connection.

Unfortunately, the presence of the top flange can interfere with the setting of the sub-flooring members on top of the joists and the headers and ledgers. The top flanges create an unevenness in the surface upon which the sub-flooring isinstalled.

Preferably, the flat top surfaces of the joists, headers and ledgers will all be uniformly level and set at the same elevation, once the members are set in place, although deviations are often made to allow for shrinkage of members made from woodor having wood sub-components. Also, preferably, the sub-flooring used is made up of large sheets of relatively thin planar material, such as plywood or oriented strand board, that can be laid down on the level top surfaces of the headers and ledgersresulting in a uniformly flat surface for laying down the flooring.

Thus, it is desirable to minimize the thickness of any members, such as fasteners, fastener heads or hanger components that will project above the level of the top surfaces of the ledges, headers and joists. When such members project above theultimate top level of the structural members of the flooring, they create unevenness in the surface for the subflooring, commonly known as reveal problems.

Thus, when top flange hangers are used, it is desirable to make the material of the top flange as thin as possible. However, the top flange must still be strong enough to carry the desired loads imposed on the hanger. One means of strengtheningthe top flanges of hangers is to create embossments or deformations in the top flange hanger that extend into the back members of the hangers. The problem with typical strengthening deformations or embossments is that too much of the material of the topflange is deformed to too great a height, thus creating reveal problems.

It is a specific object of the present invention to provide a structural hanger for supporting a structural member from a supporting member, where the structural hanger is made with a top flange that rests on the top surface of the supportingmember, and the top flange of the hanger is formed with strengthening deformations that increase the strength of the structural hanger while minimizing the profile of the top flange of the hanger.

It is a further object of the present invention to provide that the level of the first section of the embossment of the structural connector is higher above the top surface of the first flange than the level of the second section of theembossment, and the higher first level is closer to the bend between the first flange and the first member than the second section. The inventors have found embossments which are taller near the edge of the first structural member or supportingstructural member and then decrease in height but continue to extend a substantial distance along the top flange, can provide sufficient strength to structural hangers made from light gauge steel, while providing minimal interference with the laying ofthe subflooring.

Provide a top flange hanger made from galvanized sheet steel or stainless steel that does not need to be welded, and, therefore, does not need to be painted to protect the hanger from corrosion.The top flange hanger with low-profile strengthening deformations in its top flange or flanges that can be formed from sheet steel material on a fully automated die press with no secondary orfinal bend operations being necessary.