U.S. patent application number 09/932192 was filed with the patent office on 2002-04-18 for metal channel for wall panels.
Invention is credited to Cherry, Jonathan, Humpage, Roy.
Application Number | 20020043040 09/932192 |
Document ID | / |
Family ID | 9897769 |
Filed Date | 2002-04-18 |
United States Patent
Application |
20020043040 |
Kind Code |
A1 |
Cherry, Jonathan ; et
al. |
April 18, 2002 |
Metal channel for wall panels
Abstract
A metal channel for positioning and retaining metal studding and
wall panels to form partition walls, comprising a central web with
retaining flange portions along its opposite sides. The web is
segmented, being divided along its length into discrete segments by
transverse slots. One of the flange portions is similarly divided
into segments by transverse slots aligned with the slots. Adjacent
segments of the flange portions are however connected together by
expansible bridges and optionally by frangible bridges. The other
of the flange portions is provided with lines of perforation
aligned with the slots and defining flexure zones. The channel is
formed straight but can be bent into smooth curves by expansion of
the expansible bridges.
Inventors: |
Cherry, Jonathan; (West
Bridgeford, GB) ; Humpage, Roy; (Smethwick,
GB) |
Correspondence
Address: |
Alix, Yale & Ristas, LLP
750 Main Street
Hartford
CT
06103-2721
US
|
Family ID: |
9897769 |
Appl. No.: |
09/932192 |
Filed: |
August 17, 2001 |
Current U.S.
Class: |
52/702 ;
52/712 |
Current CPC
Class: |
E04B 2002/7481 20130101;
E04B 2/82 20130101; E04C 2003/0434 20130101; E04C 2003/0421
20130101; E04B 2/7453 20130101; E04C 3/07 20130101; E04C 2003/0473
20130101 |
Class at
Publication: |
52/702 ; 52/712;
52/731.5; 52/731.9 |
International
Class: |
E04C 003/32 |
Foreign Application Data
Date |
Code |
Application Number |
Aug 17, 2000 |
GB |
0020247.3 |
Claims
What is claimed is:
1. A metal channel for the positioning and retention of metal
studding and wall panels to form straight, angled or curved
partition walls, the channel comprising a straight longitudinal web
adapted for anchoring to a floor or ceiling of a building, the web
having oppositely disposed first and second longitudinal edges and
first and second flange portions extending from the first and
second longitudinal edges of the web, respectively, the first and
second flange portions being adapted for abutting opposite sides of
metal studding for supporting a wall panel, the web defining a
plurality of longitudinally spaced transverse slots dividing the
web into discrete segments, the first flange portion defining a
plurality of transverse slots dividing the first flange portion
into discrete segments, the slots of the first flange portion being
aligned with the slots of the web, adjacent segments of the first
flange portion being connected together by an expansible bridge of
metal, and the second flange portion having a flexure zone aligned
with the transverse slots of the web and the first flange portion,
wherein bending the channel around any of the flexure zones causes
widening of the associated transverse slots in the web and in the
first flange portion, with associated expansion of the bridge of
metal across the widened transverse slot in the first flange
portion.
2. A channel according to claim 1, wherein each of the expansible
bridges of metal are formed by a pattern of apertures in the first
flange portion of the channel.
3. A channel according to claim 1, wherein the expansible bridges
have a modulus of expansion which increases with increasing
expansion.
4. A channel according to claim 1, wherein the wall panels are
conformable to a curve having a predetermined minimum radius and
the expansible bridges are adapted to have a limit of expansion
which is substantially equal to the minimum radius of the
curve.
5. A channel according to claim 1, wherein the first flange portion
has a distal edge laterally spaced from the first longitudinal edge
of the web and adjacent segments of the first flange portion are
attached to one another at or proximate to the distal edge of the
first flange portion by frangible bridges of metal.
6. A channel according to claim 1, wherein the second flange
portion defines a plurality of perforations, a line of the
perforations forming each flexure zone.
7. A channel according to claim 1, wherein the second flange
portion has a distal edge laterally spaced from the second
longitudinal edge of the web and defines a plurality of transverse
slots dividing the second flange portion into discrete segments,
one of the slots forming each flexure zone, adjacent segments of
the second flange portion being attached to one another at or
proximate to the distal edge of the second flange portion by
frangible bridges of metal end at a position intermediate the
distal edge of the second flange portion and the second
longitudinal edge of the web by expansible bridges of metal.
8. A channel according to claim 2, wherein the channel is formed by
bending sheet metal and each pattern of apertures is stamped into
the sheet metal before the sheet metal is bent.
Description
BACKGROUND OF THE INVENTION
[0001] The invention relates to metal channels for positioning and
retaining partition wall systems, and provides a novel channel
member for use as a head or base channel for straight or curved
partition wall systems.
[0002] Partition panels for the creation of divided walls in office
and industrial premises has made it possible for architects to
design buildings with completely open-plan interiors which can then
be internally divided in virtually any format according to the
working practices of the end user. Furthermore, the partition
panels once installed can be modified or removed and replaced as a
user's demands change or whenever the building is occupied by
another user with different requirements.
[0003] Typically the partition systems comprise double-skinned wall
panels which are supported at the sides by metal studding and above
and below in metal channels. One metal channel, the base channel,
is secured fast to the internal floor of the building, and another
metal channel, the head channel, is secured to the ceiling
vertically above the first channel. Vertical metal stud rails are
then fitted between the head and base channels, and partition wall
panels are then secured to the studs and form the partition
extending between the head and base channels. It should be
understood that in the context of such partition system it is the
mounting channels and studding that are essentially metal, and not
the wall panels. The wall panels themselves may be made of metal,
or from any other wall-boarding material, such as plasterboard.
[0004] The construction of the head and base channels is perfectly
simple for straight wall sections. The channels are generally
U-shaped, with a central longitudinal web from opposite edges of
which are formed upstanding or depending flanges. The central web
is secured to the floor or ceiling, and the wall panels held in
place between the two flanges.
[0005] A more labor-intensive system of assembly is needed for the
construction of curved walls. Typically curved timber head and sole
plates are prepared, cut to the precise radius of the intended
curve.
[0006] The sole and head plates are first secured to the floor and
ceiling of the interior of the building that is to be partitioned
and then the vertical metal stud rails are secured directly to head
and sole plates. There are no continuous metal head and base
channels extending around the curve of the head and sole plates.
The process is labor-intensive and there is a need for a simpler
and cheaper method for the positioning and anchorage of curved
partition walls.
SUMMARY OF THE INVENTION
[0007] The invention provides a metal channel for the positioning
and retention of metal studding and wall panels to form straight,
angled or curved partition walls, comprising a straight
longitudinal web for anchorage to a floor or ceiling of a building
and first and second flange portions upstanding or depending (as
appropriate to floor or ceiling mounting respectively) from
opposite longitudinal edges of the web for abutting opposite sides
of metal studding supporting a partition wall panel, wherein the
web is divided along its length into discrete segments spaced each
from the next by a transverse slot, and the first flange portion on
one side of the web is similarly divided along its length into
discrete segments spaced each from the next by a transverse slot
with each pair of adjacent segments being connected together by an
expansible bridge of metal, and the second flange portion on the
other side of the web has a flexure zone aligned with the
transverse slots in the web and in the first flange portion, so
that bending the channel around any of the flexure zones causes
widening of the associated transverse slots in the web and in the
first flange portion, with associated expansion of the bridge of
metal across the widened transverse slot in the first flange
portion.
[0008] The expandible bridge of metal may be created by a suitable
pattern of stamping apertures in the sheet metal from which the
channel is formed, before bending it into channel section. For
example, a plurality of slots stamped out of the metal of the first
flange portion, each having a length slightly less than the height
of the first flange portion and each overlapping appreciably in
transverse extent and location from the immediately adjacent slot
or slots can leave a sinusoidal bridge of metal connecting together
the segments of the flange on opposite sides of the bridge. Or the
bridge may have the form of a circular or oval or rectangular or
diamond-shaped annulus of metal connected at opposite sides to the
adjacent segments, and capable of distortion as the segments are
moved apart.
[0009] The expansible bridges preferably have a modulus of
expansion which increases with increasing expansion. Such a modulus
ensures that if a length of channel is bent into a curve, each
bridge will expand by approximately the same amount so that the
curve naturally conforms, approximately, to the arc of a circle. It
will be understood of course that the actual shape will be a series
of interconnected straight channel sections, but is has been found
that the overall shape is visually indistinguishable from a true
circle if the transverse slots and bridges in the web and first
flange are about 75 mm apart.
[0010] Advantageously the expansible bridges have a limit of
expansion which defines the radius of the smallest curve to which
the associated metal wall partition panels can conform. For
example, with all bridges expanded to their ultimate limit the
channel could desirably have a 600 mm radius.
[0011] The flexure zone in the second flange portion could simply
be a straight and unperforated transverse portion of the flange
portion aligned with the slots in the web and first flange portion.
Advantageously however, a line of weakness across the second flange
portion defines each flexure zone. For example, a line of
perforations across the height of the second flange portion would
define a clear and accurate flexure line. Such a line of
perforations would also create a clear guide for cutting the
channel to length in situ.
[0012] In one modification of the invention, the segments of the
first flange portion may be temporarily attached to one another at,
or near, their edge distal to the web by frangible bridges of
metal. Such a channel would retain its straight configuration until
the frangible bridges were severed, for example by a hacksaw or
other cutting tool. Such a channel could be used as supplied for
straight partition walls. For curved walls a number of the
frangible bridges could be severed corresponding to the length of
the arc of the curve, and the resulting wall would then run
smoothly from straight to curved and again to straight. Or for a
single obtuse angle in the wall, only one of the frangible bridges
would be cut.
[0013] For curved walls, always the first flange portion of the
channel, with its expansible bridges, lies on the outside of the
curve. A sinusoidal wall can therefore be created by securing to
the floor and ceiling of the building lengths of channel in
end-to-end abutment, each length being inverted relative to the
next so that the expansible bridges always lie on the outside of
the curve. If sinusoidal walls form a significant use of the
channel, however, it may be desirable to form identical slots and
expansible bridges in both flange portions, preferably both
accompanied by the frangible bridges described above. Cutting the
frangible bridges on one flange portion therefore permits the
expansion of the expansible bridges on that flange portion,
permitting that flange portion to lie on the outside of the curved
wall, while the associated expansible bridges and uncut frangible
bridges on the other flange portion define the flexure zones and
permit that other flange portion to lie on the inside of the curved
wall. By a judicious pattern of severing the frangible bridges
along the length of the channel, the function of first and second
flange portions can thus alternate along the channel to create from
a single channel length a support for a sinuous wall.
[0014] It is an object of the invention to provide a channel system
for such a simpler and cheaper anchor system, which can be used for
either straight or curved partition wall anchorage.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] The present invention may be better understood and its
numerous objects and advantages will become apparent to those
skilled in the art by reference to the accompanying drawings in
which:
[0016] FIG. 1 is a perspective view of a short length of a first
embodiment of a channel according to the invention;
[0017] FIG. 2 is a plan view of the channel of FIG. 1, with the
flange portions beneath the plane of the paper;
[0018] FIG. 3 is a side elevation of the first flange portion of
the channel of FIG. 1;
[0019] FIG. 4 is a side elevation of a second flange portion of the
channel of FIG. 1;
[0020] FIG. 5 is a transverse section through the channel of FIG. 1
;
[0021] FIG. 6 is a side elevation of an expansible bridge formation
of a second embodiment of a channel according to the invention;
[0022] FIG. 7 is a side elevation of an expansible bridge formation
of a third embodiment of a channel according to the invention;
and
[0023] FIG. 8 is a side elevation of an expansible bridge formation
and associated frangible bridge of a fourth embodiment of a channel
according to the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0024] Referring first to FIGS. 1 to 5, a channel according to the
invention is illustrated in an orientation suitable for floor
fixing, to create the base channel locating and retaining metal
studding to support a partition wall. The same channel section can
be inverted to form the head channel for the same wall. The channel
comprises a central web 1 bounded on its opposite sides by first
and second flange portions 2 and 3. The web 1 is divided into
discrete segments 4 longitudinally of the channel by transverse
slots 5 spaced apart by equal distances of 75 mm. The web 1 is
longitudinally profiled (see FIGS. 1 and 5) for added rigidity, and
has preformed holes 6 for fastening the channel to the floor or
ceiling of a building.
[0025] The first flange portion 2 is similarly divided into
discrete segments by transverse slots 7 aligned with the slots 5,
the significant difference between the slots 5 and 7 being that the
slots 7 do not extend completely through the first flange portion 2
whereas the slots 5 do extend completely through the web 1. The
slots 7 leave two short anchorage portions 8 of the first flange
portion connecting adjacent segments 9 of the first flange portion
2 to an expansible metal bridge 10. The expansible bridge 10 is in
the form of an oval-shaped annulus of metal joined to the segments
9 by the anchorage portions 8 across its short axis. Expansion of
the bridge, as described below, causes extension of that short axis
and deformation of the oval annulus until ultimately the oval is
reformed with its long axis connecting together the anchorage
portions 8.
[0026] The second flange portion 3 has a line of perforations 11
defining a flexure line or flexure zone aligned with each of the
slots 5 and 7.
[0027] The channel is formed by first punching the appropriate
apertures from a straight strip of metal and then forming the metal
into the channel shape shown.
[0028] The metal of the channel is preferably made by the
ULTRASTEEL.TM. process which is a processes protected by inter
alia, Patents GB-B-2063735 and GB-B-2095595 in the name of Hadley
Industries PLC.
[0029] In use, the channel may be kept straight as it is secured to
the floor and ceiling, and used to position and retain metal
studding and partition panels to form straight walls. Or it may be
bent into curves, each bending being accompanied by flexure of the
second flange portions 3 along the flexure zones and expansion of
the expandible bridges 10 as the slots 5 and 7 widen.
[0030] FIG. 6 shows another possible shape for the expansible metal
bridge 10. FIG. 7 shows a further possible shape, illustrating how
the adjacent segments 9 of the first flange portion 2 may be
connected together by more than one expansible bridge 10.
[0031] FIG. 8 illustrates how a temporary and frangible bridge 12
may be left in the manufacturing process, connecting together the
adjacent segments 9 of the first flange portion 2 at its end remote
from the web 1. If the frangible bridges 12 are left intact, the
channel is straight and can be used for the positioning and
retention of straight walls where the majority of partition walls
are expected to be straight. Whenever a curved wall section is
desired, however, the frangible bridges 12 can be severed by a
hacksaw or by tinsnips, and the channel formed into an appropriate
curve. The slot 7, frangible bridge 12 and expansible bridge 10
formation of FIG. 8 can advantageously be repeated on the second
flange portion 3 to create the flexure zones of the second flange
portion, so that the functions of first flange portion (supporting
the outer curve of a curved wall) and the second flange portion
(supporting the inner curve) can alternate along the length of the
channel to support an undulating wall.
[0032] While preferred embodiments have been shown and described,
various modifications and substitutions may be made thereto without
departing from the spirit and scope of the invention. Accordingly,
it is to be understood that the present invention has been
described by way of illustration and not limitation.
* * * * *