U.S. patent application number 11/146534 was filed with the patent office on 2006-12-21 for structural members with gripping features and joining arrangements therefor.
Invention is credited to William Andrews.
Application Number | 20060283130 11/146534 |
Document ID | / |
Family ID | 36764692 |
Filed Date | 2006-12-21 |
United States Patent
Application |
20060283130 |
Kind Code |
A1 |
Andrews; William |
December 21, 2006 |
Structural members with gripping features and joining arrangements
therefor
Abstract
A joining arrangement is provided for use in the construction of
stud frame which includes a releasable attachment/detachment
feature. The first member (plate) includes in at least one side
wall a formation which, when members are joined, engages a
corresponding formation in at least one wall of the second member
(stud). The formation, such as a V-shaped protrusion, is/are
disposed at an angle to the longitudinal axis of the member and the
formation on the second member is disposed generally parallel to
its longitudinal axis such that upon engagement of the first and
second members, the respective formations in the first and second
members engage such that they are in alignment, thereby, securing
the first member to the second. Additionally, a plurality of
protrusions, which provide a gripping feature, may be formed on the
upper surface of web for inhibiting the stud from sliding,
slipping, moving and/or migrating within the plate.
Inventors: |
Andrews; William;
(Camberwarra, AU) |
Correspondence
Address: |
STETINA BRUNDA GARRED & BRUCKER
75 ENTERPRISE, SUITE 250
ALISO VIEJO
CA
92656
US
|
Family ID: |
36764692 |
Appl. No.: |
11/146534 |
Filed: |
June 7, 2005 |
Current U.S.
Class: |
52/633 |
Current CPC
Class: |
E04B 2/7459 20130101;
Y10T 403/46 20150115; Y10T 403/7043 20150115; E04B 2/767
20130101 |
Class at
Publication: |
052/633 |
International
Class: |
E04C 3/02 20060101
E04C003/02 |
Claims
1. A system for interconnecting and framing studs, comprising: a
first structural member adapted to be positioned atop a surface in
a horizontal orientation, said first member having a channel-shaped
cross-section including a first planar web side with a plurality of
protrusions formed on an upper surface thereof, and a pair of
opposing parallel vertical walls integrally connected to said first
planar web side, each vertical wall having an inwardly directed
male protrusion formed continuously along a substantial length of
said first member, each inwardly directed male protrusion
integrally formed and directly positioned adjacent a respective
longitudinal edge of said first planar web; and at least one second
structural member having a first and second terminus end, said
first end adapted to be transversely interconnected to said first
member in a vertical and perpendicular orientation to said first
member, each second member having a channel-shaped cross-section
including a vertically oriented second planar web side and a second
pair of opposing parallel vertical walls integrally connected to
said second planar web side, each vertical wall having an inwardly
projecting flange integrally formed to an outer edge of said
vertical wall such that said flanges are coplanar with each other,
and an inwardly protruding female recess integrally formed directly
adjacent to said first and second terminus ends of said second
member in each vertical wall and extending substantially the entire
width of said vertical wall; wherein one of said first or second
terminus ends of said at least one second structural member is
adapted to be interconnected within said first structural member by
inserting a selected terminus end into said first structural member
and twisting said second member until said inwardly directed male
protrusions of said first member are received, aligned and
interconnected with said inwardly protruding female recesses of
said second member to form a perpendicularly interconnected
structural framing joint between said first and second structural
members; wherein said plurality of protrusions formed on the upper
side of said first planar web are provided for inhibiting said at
least one second structural member from sliding within said first
structural member.
2. The system according to claim 2 further comprising a third
structural member adapted to be positioned atop said second
terminus end of said at least one second structural member in a
horizontal orientation, said third member having a channel-shaped
cross-section and including a third planar web side including a
plurality of protrusions formed on a lower side thereof, and a
third pair of opposing parallel vertical walls integrally connected
to said third planer web, each vertical wall having an inwardly
directed male protrusion formed continuously along a substantial
length of said third member, each inwardly directed male protrusion
integrally formed and directly positioned adjacent a respective
longitudinal edge of said third planar web; wherein the other of
said first and second terminus ends of said at least one second
structural member is adapted to be interconnected within said third
structural member by inserting the respective other terminus end
into said third structural member and twisting said second member
until said inwardly directed male protrusions of said third member
are received, aligned and interconnected with said inwardly
protruding female recesses of said second member to form a
perpendicular interconnected structural framing joint between said
third and second structural members; and wherein said plurality of
protrusions disposed on said lower side of said web of said third
structural member are provided for inhibiting said at least one
second structural member from sliding within said third structural
member.
3. The system according to claim 2, wherein said inwardly directed
male protrusions and inwardly protruding female recesses have
V-shaped cross-sections which are adapted to be received by each
other.
4. The system according to claim 1, wherein said second planar web
side of said at least one second structural member includes at
least one opening for accommodating conduits.
5. The system according to claim 1, wherein said at least one
second structural member includes a telescopic feature allowing
said at least one second structural member to be either lengthened
or shortened in the longitudinal direction to accommodate floor to
ceiling height misalignments.
6. The system according to claim 1, wherein each second structural
member comprises an inner and outer element, wherein said inner
element is adapted to closely fit within and interface with said
outer element such that said inner element is may slidably move
within said outer element.
7. The system according to claim 6, wherein crushed regions are
formed on said inwardly projecting flanges substantially proximate
said inwardly protruding female recesses on said second structural
member.
8. A system for interconnecting and framing studs, comprising: a
first longitudinal structural member adapted to be positioned atop
a surface in a horizontal orientation, said first member having a
channel-shaped cross-section including a first planar web side
defined by a pair of opposing parallel edges, wherein a plurality
of protrusions are formed on an upper surface of said first planar
web side, and a pair of opposing parallel vertical walls are
integrally connected to said pair of opposing parallel edges, each
vertical wall having an inwardly directed male V-shaped protrusion
formed therein, said V-shaped protrusion positioned adjacent each
opposing edge of said first planar web and extending a substantial
length of said first member; and at least one second longitudinal
structural member having a first and second terminus end, said
first end adapted to be transversely interconnected to said first
member in a vertical and perpendicular orientation to said first
member, each second member having a channel-shaped cross-section
including a vertically oriented second planar web side defined by a
pair of vertically oriented parallel edges and a second pair of
opposing parallel vertical walls integrally connected to said pair
of vertically oriented opposing parallel edges defining said second
planar web side, each vertical wall having an outer edge with an
inwardly projecting planar flange integrally formed to said outer
edge such that each flange is coplanar with each other and opposes
said second planar web in a parallel manner, and an inwardly
protruding V-shaped female recess integrally formed adjacent to
said first terminus end of said second member in each vertical wall
in a perpendicular orientation with respect to said second planar
web, said female recess extending substantially the entire width of
said vertical wall; wherein said first terminus end of said at
least one second structural member is interconnected within said
first structural member by inserting said first terminus end into
the open ended side of said first structural member and twisting
said second member until said inwardly directed V-shaped male
protrusions of said first member are received, aligned and
interconnected with said inwardly protruding V-shaped female
recesses of said second member to form a perpendicularly
interconnected structural framing joint between said first and
second structural members; wherein said plurality of protrusions
formed on the upper side of said first planar web are provided for
inhibiting said at least one second longitudinal structural member
from sliding within said first longitudinal structural member.
9. The system according to claim 8 further comprising an inwardly
protruding V-shaped female recess integrally formed adjacent to
said second terminus end of said second member in each vertical
wall in a perpendicular orientation with respect to said second
planar web, said female recess extending substantially the entire
width of said vertical wall.
10. The system according to claim 9 further comprising a third
longitudinal structural member adapted to be positioned atop said
second terminus end of said at least one second structural member
in a horizontal orientation, said third member having a
channel-shaped cross-section and including a third planar web side
defined by a third pair of opposing parallel edges, said web
including a plurality of protrusions formed on a lower side
thereof, and a third pair of opposing parallel vertical walls
integrally connected to said pair of opposing parallel edges, each
vertical wall having an inwardly directed V-shaped male protrusion
having a generally V-shaped cross-section integrally formed in said
vertical wall adjacent each opposing edge of said third planar web
and extending a substantial length of said third member; wherein
said second terminus end of said at least one second structural
member is interconnected within said third structural member by
inserting said second terminus end into the open ended side of said
third structural member and twisting said second member until said
inwardly directed V-shaped male protrusions of said third member
are received, aligned and interconnected with said inwardly
protruding female recesses of said second member to form a
perpendicular interconnected structural framing joint between said
third and second structural members; and wherein said plurality of
protrusions disposed on said lower side of said web of said third
longitudinal structural member are provided for inhibiting said at
least one second longitudinal structural member from sliding within
said third longitudinal structural member.
11. The system according to claim 8, wherein said second planar web
side of said at least one second structural member includes at
least one opening for accommodating conduits.
12. The system according to claim 8, wherein said at least one
second structural member includes a telescopic feature allowing
said at least one second structural member to be either lengthened
or shortened in the longitudinal direction to accommodate floor to
ceiling height misalignments.
13. The system according to claim 12, wherein each second
structural member comprises an inner and outer element, wherein
said inner element is adapted to closely fit within and interface
with said outer element such that said inner element is may
slidably move within said outer element.
14. The system according to claim 12, wherein crushed regions are
formed on said inwardly projecting flanges substantially proximate
said inwardly protruding female recesses on said second structural
member when said female recesses are formed on said first and
second terminus ends of second structural member.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application is related to pending U.S. patent
application Ser. No. 09/979,214, filed May 14, 2002, entitled
"STRUCTURAL MEMBERS AND JOINING ARRANGEMENTS THEREFOR", the content
of which is expressly incorporated by reference herein in its
entirety.
STATEMENT RE: FEDERALLY SPONSORED RESEARCH/DEVELOPMENT
[0002] Not Applicable
BACKGROUND
[0003] 1. Field of the Invention
[0004] The present invention relates to joining systems and to
structural members for use in such joining systems. More
particularly, the present invention relates to structural members
which have gripping features formed on the lower and upper base
plates which inhibit the vertically oriented stud from inadvertent
slippage, movement and/or migration within the lower and upper base
plates.
[0005] 2. Background of the Invention
[0006] Traditionally, light weight construction of metal stud
frames employs steel or aluminum stud members which are generally
channel shaped and wherein the ends of the stud members engage
channel shaped plate members. A standard form metal stud frame will
usually comprise a series of spaced apart stud members which each
engage via their ends respective opposing top and bottom plate
members. According to conventional methodology, the frames are
generally assembled on the ground. Typical frame construction
involves placement of top and bottom plate members in spaced apart
opposing relationship whereupon stud members are connected to the
top and bottom plates which traditionally involves engaging the
ends of the stud with tech screws or the like. These frames may or
may not be braced but in the case where they are not braced with
bracing members reliance for bracing is placed on tech screws.
Unlike external frames, internal frames used in partitioning are
not generally braced during construction as bracing is affected by
wall cladding fixed to the frame. During construction, stud frames
are structurally weak and in the case of internal frames, they are
not effectively braced until the wall cladding is affixed to the
frame. A small number of holding screws may be used to fix some
studs to the top and bottom plates. Although a weak form of bracing
is created by the conjunction between stud and plate members which
are screwed, no reliance can be placed on the bracing of the frame
as the unscrewed joins do not offer sufficient strength and
resistance against slewing in the circumstance when the frame is
lifted into position.
[0007] Installers screw the members together at the point of
overlap between stud and plate but engagement of studs to plates
with limited screwing will not of itself provide adequate bracing.
The profiles of the known studs and plates are channel shaped with
a planar base and sidewalls extending from and continuous with the
edges of said base. Typically, a stud mates with a plate by
insertion of the end of the stud into the throat of the plate. The
fit is essentially friction grip and there is no resistance against
separation of stud from plate until such time as tech screws are
inserted.
[0008] Another method of affixation of studs to top and bottom
plates involves a tab and slot arrangement in which tabs located at
the extremity of the walls of the top and bottom plates engage a
corresponding slot in each wall of the stud members following which
the tradesman hammers the tabs so they are oriented at an angle
other than normal to the walls of the stud members thereby locking
the stud members against the top and bottom plates.
[0009] One advantage of this method is that more material is
required to form the channel shaped top and bottom plates.
Secondly, additional labor is required to bend the tabs into their
locking position which can be awkward due to the position of the
protruding tabs inside the channel shaped studs. Although the tab
and slot method of connection of studs to plates is effective in
securing the members, it is tedious and time consuming for
tradesman to bend the tabs four times for each stud. The insertion
of tech screws, although used in holding studs to plates during
construction and until the cladding material is affixed to the stud
frame is likewise time consuming and does not provide effective
temporary bracing until all or the majority of the joins are
screwed. Other methods of affixation of studs to plates have been
used such as riveting, welding or clinching of each stud, all of
which methods involve additional labor.
[0010] A further prior art method of joining structural members for
a stud frame involves the use of cooperating and corresponding
engaging formations in the walls of both stud and plates. The
formations in the plate consist of a securing notch formed in the
walls of the mating stud and plates. To facilitate stud location,
the wall extremities of the plate are abbreviated by upturning of a
lip formed at the extremities at the position where the stud mates
with the plate. The additional material required to form the lip
adds to material costs and necessitates a securing clip which adds
to costs in labor and assembly. Another disadvantage of this mode
of connection is that the surface area of engagement is low
resulting in low resistance to relative rotation, twisting, and
pulling out between stud and plate.
[0011] Another prior art method involves the engagement between a
formation in the walls of the top and bottom plates and a
corresponding formation in stud members. The formations are
produced by pressing out of a region of the wall of each member so
that the formations mate in snap fit male/female relationship.
While this system works well, it necessitates an additional
punching step during production which increases production time of
the constituent structural members but it does not provide a useful
and more convenient alternative to the tab system described above.
All of the above systems rely on pre-punching and limits or removes
entirely the ability of the installer to move the studs relative to
plates once fitted and where adjustment may be required during
construction to accommodate fit and finish errors or window or door
size irregularities.
[0012] Another problem arising particularly in internal stud frame
construction is irregularity in floor to ceiling height in
buildings caused by poor concrete finishing and out of alignments
which often necessitates cutting of stud members in regions of
reduced height. In a normal stud frame, the stud members would be
the same height or length but where there are irregularities in the
ceiling or floor, the frame will not fit unless stud heights are
suitably cut to accommodate those differences. This is time
consuming and adds additional labor costs to the installation.
Finally, another disadvantage of the known prior art is that the
vertically oriented studs are prone to sliding, slipping, movement
and/or migration within the lower base plate and upper base plate,
particularly, while routing conduit through conduit ports. For
instance, when the conduit is being pulled through the conduit
ports formed in the vertically oriented studs, the conduit tends to
catch and pull the studs from their predetermined spacing.
Therefore, it would be beneficial to provide a gripping feature or
the like, which will inhibit such unwanted sliding, slipping,
movement and/or migration within the lower base plate and upper
base plate.
BRIEF SUMMARY OF THE INVENTION
[0013] The present invention seeks to ameliorate the shortcomings
of the prior art arrangements by providing an alternative method of
joining structural members used in the formation of metal stud
frames and the like for use in modular construction of stud frames.
Preferably, the arrangements are adapted to suit internal non-load
bearing stud frame partitioning. Due to the labor and additional
material costs in implementation of the known methods, there is a
need to provide a joining system which allows quick and efficient
joining of structural members of a stud wall frame without having
to use any tools such as a hammer, as previously described, and
allowing quick, efficient and infinite positioning of the stud. The
joining arrangements, according to the present invention, further
allows convenient, releasable fixation of a stud to a plate without
any further operation to secure the members after initial joining.
The joining arrangements obviate the need for additional bracing
once the frame is assembled and have the advantage that each
stud/plate join is effectively braced due to the interengagement of
profiled parts formed in the studs and plates.
[0014] The present invention also provides a stud member including
an adjustable extension member which enables the length of the stud
to be adjusted to accommodate on site height variations avoiding
the need for installers to cut studs to accommodate
misalignments.
[0015] In another broad form, the present invention comprises: a
joining arrangement for use in the construction of stud frames
wherein a first structural member is releasably attached to a
second structural member; wherein, the first member has side walls
which include a formation which when members are to be joined,
engages a corresponding formation on the second member;
characterized in that the formation in the side walls of the first
member is disposed at an angle to its longitudinal axis and the
formation on the member is disposed generally parallel to its
longitudinal axis such that upon engagement of the first and second
members, the respective formations in the first and second members
engage, such that they are generally in alignment.
[0016] In another broad form, the present invention comprises: a
joining arrangement for use in the construction of stud frames and
for releasable attachment of a first member to a second structural
member forming part of the stud frame; wherein, the first member
includes in at least one side wall a formation which, when members
are to be joined, engages a corresponding formation in at least one
wall of the second member characterized in that the formation in
the wall(s) of the first member is/are disposed at an angle to the
longitudinal axis of the member and the formation in the second
member is disposed generally parallel to its longitudinal axis such
that upon press fitting engagement of the first and second members,
the respective formations in said first and second members engage
to secure the first member to the second member. According to a
preferred embodiment, the respective formations in the first and
second members allow relative movement between the first and second
members in the direction of the longitudinal axis of the second
member. Preferably, the joining arrangement is used in the
construction of internal stud frames in such applications as
partitioning.
[0017] In another broad form, the present invention comprises: a
joining arrangement enabling releasable attachment of first and
second structural members used in the construction of a stud frame,
wherein the joining arrangement comprises a formation in the first
member disposed at an angle to the longitudinal axis of the member
and which engage a corresponding formation in the second member
which is disposed generally in alignment with the longitudinal axis
of the second member such that the respective formations in the
first and second members cooperate to releasably attach the first
member to the second member, wherein the joining arrangement allows
relative movement between the first and second members. According
to a preferred embodiment, the relative movement enables movement
of the first member along a direction parallel to the longitudinal
axis of the second member.
[0018] In another broad form of the present invention comprises: a
joining arrangement for joining structural members for use in
construction of a stud frame wherein the arrangement comprises: a
formation in opposing walls of the first member which engages a
corresponding formation opposing walls of the second member;
wherein the formation in the walls of the first member are disposed
normally to the longitudinal axis of the member and the formation
in the walls of the second member are disposed in alignment with
the longitudinal axis of the second member such that the respective
formations in the first and second members upon engagement align
and allow the first member freedom of movement relative to and in
the direction of the longitudinal axis of the second member.
[0019] According to the preferred embodiment, the first member is
rotated into its position of engagement with the second member and
can be released by rotation in the opposite direction. Preferably,
the formations in the first and second members comprise inwardly
directed recesses which interfit it male/female engagement.
[0020] In another form of the present invention comprises: a
structural member for use in a stud frame and which joins with top
and bottom plates of the stud frame; characterized in that the
member is a stud which includes an extension element capable of
relative movement thereby allowing adjustment to the length of the
stud to accommodate floor to ceiling height variations.
[0021] Preferably, the adjustment is telescopic wherein the
extension member may be extended and retracted to adjust the length
of the member to suit floor to ceiling height.
[0022] The ends of the elements may be adapted with any of the
foregoing joining systems herein described but ideally would
include an extension member which allows for relative longitudinal
movement of a first member relative to a second member.
[0023] In its broadest form of the method aspect, the present
invention comprises: a structural member for use in a building
structure such as a stud frame, wherein the member comprises at
least a web and sidewalls depending from the web; characterized in
that the structural member further includes a formation in at least
one of the walls which engages a corresponding formation in at
least a second mating structural member to releasably secure the
structural member to the mating member.
[0024] Preferably, the formations are disposed either parallel or
normal to the longitudinal axis of the structural member and
comprise a recess in the external face of at least one wall and a
projection on an inside face of at least one wall wherein the
internal projection is formed by the external recess.
[0025] Preferably each of the walls of said structural member have
at least one formation which are the same length as one dimension
of said walls. According to one embodiment, the formations are
parallel to the longitudinal axis of the structural member.
Preferably, the formations are located proximate the web and on
opposing faces of said walls with each at the same distance from
the web.
[0026] According to one embodiment, the formations are normal to
the longitudinal axis of the structural member and are located at
or near one or both ends of the structural member. Preferably, when
the formations are parallel to the longitudinal axis of the member,
the member is capable of mating with a mating member with
formations which are normal to the longitudinal axis of the member,
such that the members are detachably fixed to each other. According
to a preferred embodiment, the structural member is telescopic and
includes an outer member and an inner member, wherein the members
move relative to each other such that one of the members moves
between a retracted states in which is it nested in the other
member and an extended states in which the member is partially or
fully extended relative to said other member. Preferably, one of
the members is an extension member which includes a formation which
is capable of engaging a mating member. The extension member is
preferably substantially shorter than the other member.
[0027] In another broad form according to the method aspect, the
present invention comprises: a method of construction of a stud
frame using stud frame using structural members each comprising at
least a web and sidewalls depending from the web; characterized in
that the members include a formation in at least one of the walls
of a first of the members which engages a corresponding formation
in a second member to secure the structural member to the mating
member; the method comprising the steps of:
[0028] a) taking the first structural member including a formation
in at least one of the sidewalls;
[0029] b) taking the second structural member the same or similar
to the first structural member;
[0030] c) taking a third structural member and setting it in
opposing relationship to the first member;
[0031] d) taking the second structural member, including a
formation in at least one wall of the member and which is normal to
the longitudinal axis the second member;
[0032] e) placing a first end of the second member into engagement
with the first member and a second end of the second member into
engagement with the third member such that respective formations on
the first and second and the third and second members mutually
engage to hold the members in detachable engagement;
[0033] f) taking a fourth and subsequent members and joining a
first end of the fourth and subsequent members with the first
structural member;
[0034] g) engaging a second end of the fourth and subsequent
members with the third structural member;
[0035] Preferably, the method includes the further steps of
repeating steps f) and g) until a stud frame of predetermined
length is formed.
[0036] Preferably, the method includes the further step prior to
engagement of any one or more of the fourth and subsequent members
of telescopically extending the length of one or more of the fourth
and subsequent members to accommodate height variations in a space
defined by the first and third members. Preferably, the first and
second ends of the fourth and subsequent members are positively
rotated into snap fit engagement with the first and third
members.
[0037] In another embodiment of the present invention, a plurality
of protrusions are formed on the upper side of the web of at least
one of the lower and upper base plate. The protrusions are provided
to inhibit the vertically oriented stud from inadvertent slippage,
movement and/or migration within the lower and upper base plates.
Other exemplary embodiments and advantages of the present invention
may be ascertained by reviewing the present disclosure and the
accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0038] The present invention will now be described according to
preferred but non-limiting embodiments and with reference to the
accompanying illustrations wherein:
[0039] FIG. 1 shows an exploded view of a joining arrangement for
two structural members including respective formations in the walls
of the members according to a preferred embodiment of the
invention;
[0040] FIG. 2 shows a perspective view of respective ends of a
typical stud and plate according to one embodiment of the invention
prior to engagement;
[0041] FIG. 3 shows an assembled view of the arrangement in FIGS. 1
and 2;
[0042] FIG. 4 shows an elevational view of a typical stud and plate
frame according to a preferred embodiment of the invention;
[0043] FIG. 5 shows a perspective view of an engagement between an
intermediate stud and bottom plat in the frame of FIG. 4;
[0044] FIG. 6 shows an end view of the arrangement of FIG. 5;
[0045] FIG. 7 shows an isometric view of a telescopic stud member
according to a preferred embodiment of the invention;
[0046] FIG. 8 shows an isometric view of a telescopic stud member
according to an alternative embodiment;
[0047] FIG. 9 shows an abbreviated perspective section of a stud
frame showing mating between telescopic studs and plate according
to a preferred embodiment of the invention;
[0048] FIG. 10 shows an isometric view of a stud member according
to an alternative embodiment;
[0049] FIG. 11 shows an isometric view of a stud member including
an extension member with a flared end for biased engagement with a
plate;
[0050] FIG. 12 shows an isometric view of another embodiment of a
plate which includes a plurality of protrusions formed on the upper
side of the web, according to an aspect of the present
invention;
[0051] FIG. 13 shows a top view of the plate from FIG. 12; and
[0052] FIG. 14 shows a side view of the plate from FIG. 12.
DETAILED DESCRIPTION
[0053] The particular shown herein are by way of example and
purposes of illustrative discussions of the embodiments of the
present invention only and are presented in the cause of providing
what is believed to be the most useful and readily understood
description of the principles and conceptual aspects of the present
invention. In this regard, no attempt is made to show structural
details of the present invention in more detail than is necessary
for the fundamental understanding of the present invention, the
description taken with the drawings make it apparent to those
skilled in the art how the several forms of the present invention
may be embodied and practiced.
[0054] Referring to FIG. 1, there is shown an exploded view of an
assembly 1 for joining two structural members 2 and 3 according to
a preferred embodiment of the invention. Structural member 2 is
preferably channel shaped and includes a web 4 to which is
connected opposing walls 5 and 6 which terminate in respective
flanges 7 and 8.
[0055] Wall members 5 and 6 have formed therein respective
formations 9 and 10 which each define inwardly directed recesses.
Formations 9 and 10 may be introduced into member 2 by means of a
roll forming step during production of member 2. In the preferred
embodiment, the formations 9, 10 have a generally V-shaped
cross-section. Member 2 is preferably employed as a stud for use in
metal frame construction and is adapted for releasable attachment
to member 3 which acts as either a top or bottom plate in a metal
stud frame. Member 3 is generally channel shaped and includes web
11 to which is connected opposing walls 12 and 13 which terminate
in free ends 14 and 15. Walls 12 and 13 include formations 16 and
17 defining respective inwardly directed male protrusions 18 and 19
and external female recesses 20 and 21. In the preferred
embodiment, the male protrusions 18 and 19 (and external female
recesses 20 and 21) have a generally V-shaped cross-section.
Although respective formations 9, 10, 16 and 17 are inwardly
directed, it will be appreciated by those skilled in the art that
the formations may be reversed such that the male formations would
project outwardly relative to the walls in which they are formed.
Furthermore, the aforementioned protrusions may have other
cross-sectional shapes such as semicircular, notches, or the
like.
[0056] Referring to FIG. 2, there is shown the stud and plate
arrangement of FIG. 1 showing the rotation of a stud 2 relative to
plate 3 prior to mutual engagement thereof. The arrangement shown
is typical of engagement between a stud and bottom plate.
Engagement takes place by rotation of stud 2 in the general
direction of arrow 22 to allow stud 2 to be urged into position by
press fit in the direction of arrow 23. FIG. 3 shows the final
engagement positions of stud 3 and plate 3. The arrangement shown
in FIG. 3 is the typical engagement which would occur at locations
24 and 25 of frame 26 shown in FIG. 4.
[0057] On site, stud frames are generally assembled on the floor
according to engineering plans which indicate to the assembler the
positions of the stud members. The positions of the studs are
critical to ensure elimination of cumulative error along the length
of the frames, even spacing and to allow for locations of doors and
windows. Location of the stud members is also critical to ensure
that frame members match the location of joins in cladding affixed
to the frames to ensure that the cladding joins are rigidly
supported. Where the top and bottom plates of a stud frame are
prefabricated with formations which dictate the exact location of
the studs, there is no inherent flexibility in the positioning of
the studs to accommodate misalignment of a cladding join with a
stud. Correcting stud location for this misalignment is difficult,
if not impossible, with the tab and slot joining systems and also
with the existing systems employing corresponding formations
pressed into the walls of the plate and stud members as relative
movement between stud and plate is not available once the members
are fitted.
[0058] According to the invention, the joining arrangement allows
for the relative movement between stud members and top and bottom
plate members to adjust for any misalignments between cladding and
studs and where fine adjustments may be required to accommodate
windows and doors. This is achieved by means of a snap fit
connection between stud and plate which provides a strong
connection yet allowing relative movement between stud and plate
members so the stud may be relocated at any position along the
length of the plate members. The formation in the walls of the stud
may travel the full length of the member or they may be
intermittent. In the latter case, the studs will be adjustable
along the length of the plate over the full length of the
formation. With this choice for the formation, the movement
flexibility of the studs relative to the plates will either be
absolute along the full length of the plate or over a predetermined
distance in the stud location. In the latter case, the formation in
the walls of the plate will occur over a short distance in the
region of a predetermined stud position.
[0059] FIG. 5 shows a perspective view of a typical intermediate
joint 27 of the frame 26 of FIG. 4 in which intermediate stud 28
engages plate 3. Stud 28 is able to move longitudinally along plate
3 in the direction of arrow 29, thereby allowing fine adjustments
to the position of the stud 3 to accommodate stud spacing
requirements, joins in cladding or positions of windows or
doors.
[0060] FIG. 6 shows an end view of the arrangement of FIG. 5 and
the nature of the mating engagement between stud 28 and plate 3.
According to one embodiment, stud 28 includes an opening 30 formed
therein which accommodates material such as, but not limited to,
service conduits. A common problem which exists in frame
installation is ceiling to height irregularities in buildings. This
may occur where concrete finishing is uneven creating fit problems
for stud frames. According to present methodology, this problem is
addressed by cutting individual studs to fit the distance between
bottom and top plates. This is time consuming during construction
of frames and adds to labor costs. This problem is overcome
according to one aspect of the present invention by providing an
extendible stud which eliminates the need for cutting to suit
ceiling to height irregularities. According to one embodiment,
there is provided a telescopic stud which includes an extension
member which moves between a retracted state in which the stud is a
first minimum length and an extended state in which the stud is
extended from the minimum length up to a maximum length.
[0061] FIG. 7 shows an isometric view of a structural member 40
according to a preferred embodiment including telescopic elements
41 and 42 which enable extension and retraction to a predetermined
distance. Elements 41 and 42 are channel shaped and are arranged
such that element 42 fits inside a channel formed by element
41.
[0062] In the event of floor to ceiling height misalignments in a
structure to which a stud frame is to be fitted, member 40, due to
its telescopic extension capability eliminates the need for an on
site measuring and cutting where studs are formed to be too long or
too short. This reduces on site time and labor costs.
[0063] According to the embodiment shown in FIG. 7, element 42
includes formations 43 and 44 and element 41 includes formations 45
and 46. These mate with corresponding top and bottom plate members
according to the arrangements previously described allowing
longitudinal adjustment relative to the plates in addition to
vertical adjustment in the direction of arrow 47. During the cold
forming of element 42, flanges 48 and 49 are crushed at regions 50
and 51 as formations 43 and 44 are introduced into element 42.
Likewise, flanges 52 and 53 are crushed in the regions of 54 and 55
as formations 45 and 46 are introduced into element 41.
[0064] FIG. 8 shows a telescopic stud element 60 according to an
alternative embodiment. Stud 60 comprises elements 61 and 62 which
are capable of telescopic adjustment in the direction of the arrow
63. Stud 60 further comprises an element 62, formations 64 and 65
which engage corresponding formations in a plate in a manner
previously described. Likewise, element 61 comprises formations 66
and 67 which will engage a bottom plate as previously
described.
[0065] FIG. 9 shows a section of the frame of FIG. 4 defined by
line X-X and include junction 70 and end junction 71. Junction 71
is formed by mating of telescopic stud 72 and top plate 73. As
telescopic stud 72 comprises telescopic elements 74 and 75, stud 72
may extend to increase the local height of the frame. Likewise,
intermediate stud 76 which comprises elements 77 and 78 may also
extend in which case that portion of the frame can be extended or
retracted in the direction of arrows to accommodate height
variations.
[0066] FIG. 10 shows an alternative stud 90 comprising telescopic
elements 91 and 92. This is a more conventional stud profile
without formations in the ends of elements 91 and 92 to engage with
corresponding plate profiles as previously described. Element 92
includes a tab 93 which provides a bearing shoulder for urging
element 92 in a direction of arrow 94 to accommodate height
variations.
[0067] FIG. 11 shows stud 90 of FIG. 10 including flared ends on
element 92. This arrangement allows element 92 to engage a top
plate with a positive bias thereby increasing frictional fit
between stud and plate. This arrangement can also be introduced
into the end of element 91 which would engage a bottom plate.
[0068] FIGS. 12-14 show an alternative embodiment of the present
invention which provides a plurality of protrusions or knurls 102
formed on the upper or exposed side of web I 1 of the plate 100
which function as gripping or frictional features. Preferably, the
protrusions 102 are punched from the bottom side of the web through
the top side of the web such that they form a gripping surface on
the top side of web 11. It is noted, however, that the protrusions,
knurls or the like 102 may be formed by any other metal forming
method which accomplishes the same effect. The protrusions 102 are
formed in the web 11 in order to inhibit the studs 2, 40, 60, 90 or
the like (see FIGS. 1-11) from sliding, slipping, moving and/or
migrating. For instance, the protrusions 102 will substantially
prevent unwanted slippage, migration and/or movement when conduit
is being run through at the opening 30 provided in the vertically
oriented studs 2. It is further noted that the height, size,
spacing, number protrusions per area unit may be adjusted to
increase the frictional and gripping effect that the
protrusions/knurls 102 provide.
[0069] It will be recognized by persons skilled in the art that
numerous variations and modifications may be made to the invention
as broadly described herein without departing from the overall
spirit and scope of the invention. The particular shown herein are
by way of example and purposes of illustrative discussions of the
embodiments of the present invention only and are presented in the
cause of providing what is believed to be the most useful and
readily understood description of the principles and conceptual
aspects of the present invention. In this regard, no attempt is
made to show structural details of the present invention in more
detail than is necessary for the fundamental understanding of the
present invention, the description taken with the drawings make it
apparent to those skilled in the art how the several forms of the
present invention may be embodied and practiced.
[0070] Although the invention has been described with reference to
several exemplary embodiments, it is understood that the words that
have been used are words of description and illustration, than
words of limitation. Changes may be made within the preview of the
appended claims, as presently stated and as amended, without
departing from the scope and spirit of the invention and its
aspects. Although the invention has been described with reference
to particular means, materials and embodiments, the invention is
not intended to be limited to the particulars disclosed; rather,
the invention extends to all functionally equivalent structures,
methods and such uses are within the scope of the appended
claims.
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