U.S. patent application number 11/787022 was filed with the patent office on 2008-07-03 for structural members and joining arrangements therefor.
Invention is credited to William Andrews.
Application Number | 20080159807 11/787022 |
Document ID | / |
Family ID | 3814722 |
Filed Date | 2008-07-03 |
United States Patent
Application |
20080159807 |
Kind Code |
A1 |
Andrews; William |
July 3, 2008 |
Structural members and joining arrangements therefor
Abstract
A joining arrangement for use in the construction of stud frames
and for releasable attachment of a first structural member to a
second structural member forming part of the frame. The first
member includes in at least one side wall a female recess which,
when the members are joined, engages a corresponding male
protrusion in at least one wall of the second member. The
respective formations in the first and second members engage such
that they are generally in alignment thereby securing the first
member to the second member and wherein the first member is a stud
and the second member is a plate.
Inventors: |
Andrews; William; (Nowra,
AU) |
Correspondence
Address: |
STETINA BRUNDA GARRED & BRUCKER
75 ENTERPRISE, SUITE 250
ALISO VIEJO
CA
92656
US
|
Family ID: |
3814722 |
Appl. No.: |
11/787022 |
Filed: |
April 13, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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09979214 |
May 14, 2002 |
7223043 |
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PCT/AU00/00500 |
May 14, 2002 |
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11787022 |
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Current U.S.
Class: |
403/363 ;
52/745.19 |
Current CPC
Class: |
F16B 9/09 20180801; Y10T
403/4605 20150115; F16B 7/0486 20130101; E04B 2/7459 20130101; F16B
7/10 20130101; Y10T 403/46 20150115; F16B 2200/30 20180801; E04B
2/766 20130101; E04B 2/789 20130101; E04B 2/767 20130101; Y10T
403/7043 20150115 |
Class at
Publication: |
403/363 ;
52/745.19 |
International
Class: |
E04B 2/58 20060101
E04B002/58 |
Foreign Application Data
Date |
Code |
Application Number |
May 21, 1999 |
AU |
AU/PQ0521 |
Claims
1-28. (canceled)
29. A method of construction of a stud frame using structural
members comprising a web and sidewalls depending from the web, the
member including a formation in at least one of the sidewalls which
engages a corresponding formation in a mating structural member to
secure the structural member to the mating structural member, the
method comprising the steps of: a) providing a first structural
member including the formation in at least one of the sidewalls,
the formation extending a substantial length of the first
structural member along a longitudinal axis of the first structural
member, the formation initiating juxtaposed to the web of the first
structural member; b) providing a second structural member; c)
setting the first structural member in opposing relationship to the
second structural member; d) providing a third structural member
including a formation being disposed at a first end portion of the
third member and having a substantially similar configuration
compared to the formation of the first structural member, the
formation of the third structural member sized and configured to
slide against the formation of the first structural member; e)
placing the first end portion and a second end portion of the third
member into engagement with the first and second members,
respectively, the respective formations in the first and third
members mutually interlock to hold the first and third members
together; and f) sliding the formation of the third member against
the formation of the first member in a direction parallel to the
longitudinal axis of the first member to position the third member
on the first member.
30-39. (canceled)
40. A frame of a building comprising: an elongate first member
defining a longitudinal axis, the first member comprising; a web;
and a pair of opposing walls connected to the web of the first
member, the walls of the first member including inwardly directed
V-shaped protrusions generally parallel to the longitudinal axis of
the first member, the inwardly directed V-shaped protrusions having
a first retaining portion that initiates juxtaposed the web of the
first member; and an elongate second member defining a longitudinal
axis, the elongate second member having a first distal end portion,
the first distal end portion having inwardly directed V-shaped
recesses generally transverse to the longitudinal axis of the
elongate second member, the inwardly directed V-shaped protrusions
of the first member disposed within the inwardly directed V-shaped
recesses of the second member for transversely interconnecting the
elongate first member to the elongate second member.
41. The frame of claim 40 further comprising a radiused portion,
the web of the first member being directly connected to the
radiused portion, and the first retaining portion being directly
connected to the radiused portion.
42. The frame of claim 41 wherein the first retaining portion being
at an acute angle with respect to the web of the first member.
43. A frame of a building comprising: an elongate first member
defining a longitudinal axis, the first member comprising; a web;
and a pair of opposing walls connected to the web of the first
member, the walls including inwardly directed protrusions extending
a substantial length of the first member, the inwardly directed
protrusions generally parallel to the longitudinal axis of the
first member, the inwardly directed protrusions being closer to the
web of the first member compared to an upper distal end of the
walls of the first member; and a second member having a first
distal end portion, the first distal end portion having inwardly
directed recesses, the inwardly directed protrusions of the first
member disposed within the inwardly directed recesses of the second
member for transversely interconnecting the first and second
members.
44. The frame of claim 43 wherein the inwardly directed protrusions
and inwardly directed recesses have a complimentary V shaped
configuration.
45. A frame of a building comprising: elongate opposed first
members, at least one of the elongate opposed member comprising: a
web defining a longitudinal axis; a pair of opposing walls having a
retaining first portions, the retaining first portion extending
inwardly toward the opposing wall and extending a substantial
length of the first member, the retaining first portion connected
to the web at an angle less than 90 degrees and greater than zero
degrees; an elongate second member having opposed end portions
respectively attached to the opposed first members, the elongate
second member transversely attached to the opposed first members,
at least one of the opposed end portions having an inwardly
directed recesses, the retaining first portions of the first member
disposed within the inwardly directed recesses for interconnecting
the first and second members.
46. The frame of claim 45 wherein the walls of the first member
further has a second portion extending away from the opposing wall
and connected to the first portion at an angle greater than 90
degrees and less than 180 degrees.
47. The frame of claim 46 wherein the retaining first portions are
generally flat and the retaining second portions are generally
flat.
48. The frame of claim 45 wherein the inwardly directed protrusions
and inwardly directed recesses have a complimentary V shaped
configuration.
49. The method of claim 29 wherein the providing the first
structural member step comprises the steps of: forming an inwardly
directed V shaped protrusion in both of the sidewalls of the first
structural member.
50. The method of claim 49 wherein the providing the third
structural member step comprises the steps of: forming inwardly
directed recess that are sized and configured to slideably
interlock with the inwardly directed V shaped protrusions of the
first structural member in the first end portion of the third
structural member.
51. The method of claim 50 wherein the forming the inwardly
directed recess step comprises the step of forming the inwardly
directed recess to have a V shape.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional application of U.S. patent
application Ser. No. 09/979,214, filed May 14, 2002, now U.S. Pat.
No. 7,223,043, which was the National Stage of International
Application No. PCT/AU00/00500, filed May 14, 2002, which claims
the benefits of AU/PQ0521, filed in Australia on May 21, 1999.
STATEMENT RE: FEDERALLY SPONSORED RESEARCH/DEVELOPMENT
[0002] Not Applicable
BACKGROUND
[0003] 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
for use in releasable joining arrangements formed by such
structural members whereby an end of a first structural member
includes a formation which may be joined by engagement with a
corresponding formation on a second structural member such that the
members may be joined at any location along the length of the
second member and without the need for fasteners. Although the
present invention in all its forms has multiple applications, the
invention will be primarily described with reference to its
application in joining structural members for use in particular
thought not exclusively in stud frames.
[0004] 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 studs 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 1 bracing is effected
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.
[0005] 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.
[0006] 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 orientated at an angle
other than normal to the walls of the stud members thereby locking
the stud members against the top and bottom plates.
[0007] One disadvantage 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 joins are screwed.
Other methods of affixation of studs to plates have been used such
as riveting, welding or clinching each of each stud, all of which
methods involve additional labor.
[0008] 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 the stud and plates.
[0009] 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.
[0010] 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 problem with this arrangement lies in the alignment
between stud and plate formations requiring some squeezing and
manipulation of the stud by the assembler to secure it in position
which adds to assembly time and therefore labor costs.
[0012] 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 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.
[0013] 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.
BRIEF SUMMARY
[0014] 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.
[0015] 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.
[0016] 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, said 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 said first
member is disposed at an angle to its longitudinal axis and the
formation on said second member is disposed generally parallel to
its longitudinal axis such that upon engagement of the first and
second members, the respective formations in said first and second
members engage, such that they are generally in alignment.
[0017] 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 said stud frame; wherein, said 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
said wall/s of said first member is/are disposed at an angle to the
longitudinal axis of the member and the formation in said 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 each said 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.
[0018] 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 engages 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 said
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.
[0019] 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.
[0020] In another broad form 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 in 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.
[0021] 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.
[0022] Preferably the formations in the first and second members
comprise inwardly directed recesses which interfit in male/female
engagement.
[0023] In another form 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.
[0024] 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.
[0025] The ends of the elements may be adapted with any of the
forgoing 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.
[0026] 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 said web; characterized in
that the structural member further includes a formation in at least
one said walls which engages a corresponding formation in at least
a second mating structural member to releasably secure said
structural member to said mating member.
[0027] Preferably, the formations are disposed either parallel or
normal to the longitudinal axis of said structural member and
comprise a recess in the external face of said at least one wall
and a projection on an inside face of said at least one wall
wherein the internal projection is formed by the external
recess.
[0028] Preferably each said walls of said structural member have at
least one said formations 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 said web and on
opposing faces of said walls with each at the same distance from
the web.
[0029] According to one embodiment the formations are normal to the
longitudinal axis of said structural member and are located at or
near one or both ends of said structural member.
[0030] Preferably, when the formations are parallel to the
longitudinal axis of said member, the member is capable of mating
with a mating member with formations which are normal to the
longitudinal axis of said member, such that the members are
detachably fixed to each other.
[0031] 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 state in which it is nested in
the other member and an extended state in which said member is
partially or fully extended relative to said other member.
Preferably, one of said 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 said
other member. In another broad form according to the method aspect
the present invention comprises: a method of construction of a stud
frame using structural members each comprising at least a web and
sidewalls depending from said web; characterized in that the
members include a formation in at least one said walls of a first
of said members which engages a corresponding formation in a second
member to secure said structural member to said mating member; the
method comprising the steps of: a) taking the first said structural
member including a formation in at least one said sidewalls; b)
taking the second structural member the same or similar to said
first structural member; c) taking a third structural member and
setting it in opposing relationship to said first member; d) taking
the second structural member including a formation in at least one
wall of said member and which is normal to the longitudinal axis of
said second member; e) placing a first end of said second member
into engagement with said first member and a second end of said
second member into engagement with said third member such that
respective formations on said first and second and said third and
second members mutually engage to hold said members in detachable
engagement; f) taking a fourth and subsequent members and joining a
first end of said fourth and subsequent members with said first
structural member g) engaging a second end of said fourth and
subsequent members with said third structural member; Preferably
the method includes the further steps of repeating steps f) and g)
until a stud frame of predetermined length is formed. Preferably,
the method includes the further step prior to engagement of any one
or more of said fourth and subsequent members, of telescopically
extending the length of one or more said, fourth and subsequent
members to accommodate height variations in a space defined by said
first and third members. Preferably, said first and second ends of
said, fourth and subsequent members are positively rotated into
snap fit engagement with said first and third members.
[0032] In another embodiment of the invention, a system for
interconnecting and framing studs consists of a first longitudinal
structural bottom member, at least one second longitudinal
structural member, and a third longitudinal structural top
member.
[0033] The first longitudinal structural bottom member may be
adapted to be positioned atop a surface in a generally horizontal
orientation. The first bottom member may have a channel-shaped
cross-section and a first pair of terminus ends. The first bottom
member may further consist of a lower horizontally oriented and
substantially flat planar web side, a first pair of opposing,
parallel, longitudinal and inwardly directed male protrusions, and
a first pair of opposing, parallel, longitudinal, substantially
flat and vertically oriented side walls.
[0034] The lower horizontally oriented and substantially flat
planar web side may be defined by a first pair of opposing,
parallel and longitudinal edges which are each of a prescribed
length and a first pair of opposing terminus edges.
[0035] The first pair of opposing, parallel, longitudinal and
inwardly directed male protrusions may be continuously formed along
the lengths of respective ones of the first pair of opposing,
parallel and longitudinal edges. Each protrusion may have a
V-shaped cross-section and consisting of a first lower inclined
side integrally connected to a first upper inclined side along a
common longitudinal edge to form a respective one of said inwardly
directed male protrusions. The first lower inclined side being
positioned proximal to and integrally connected to a respective one
of said first pair of opposing, parallel, and longitudinal edges of
the lower planar web side.
[0036] The first pair of opposing, parallel, longitudinal,
substantially flat and vertically oriented side walls may each be
integrally connected to a respective first upper inclined side of a
respective one of said inwardly directed male protrusions.
[0037] The at least one second longitudinal structural member may
be adapted to be transversely interconnected to said first bottom
member in a generally vertical and perpendicular orientation with
respect to said first bottom member. The at least one second member
may have a channel-shaped cross-section and a second pair of
terminus ends. The at least one second member may further consist
of a telescopic feature, a vertically oriented and substantially
flat planar web side, a second pair of opposing, parallel,
longitudinally, substantially flat and vertically oriented side
walls, a pair of longitudinal and vertically oriented and
substantially flat planar flanges, and at least one opening
disposed through said vertically oriented planar web side for
receiving conduits.
[0038] The telescopic feature consists of an inner longitudinal
element and outer longitudinal element. The inner element being
adapted to closely interfit within and interface with said outer
element such that said inner element is adapted to slidably move
within said outer element.
[0039] The vertically oriented and substantially flat planar web
side may be defined by a second pair of opposing, parallel,
longitudinal and vertically oriented edges, and a second pair of
horizontally oriented opposing terminus edges.
[0040] Each wall of the second pair of opposing, parallel,
longitudinal, substantially flat and vertically oriented side walls
is integrally connected to a respective one of said second pair of
opposing vertically oriented edges of said vertically oriented
planar web side. Each of said second pair of vertical side walls
being further defined by a distal, longitudinal and vertically
oriented edge. A first pair of horizontally oriented opposing side
edges which are each of a prescribed length and connect to a
respective one of said second pair of horizontally oriented
opposing terminus edges in a perpendicular manner.
[0041] Each flange of the pair of longitudinal and vertically
oriented and substantially flat planar flanges is integrally
connected to a respective one of said distal, longitudinal and
vertically oriented edge of said second pair of vertically oriented
side walls such that each flange is coplanar with each other and
opposes said vertically oriented planar web side in a parallel
manner.
[0042] Each of said second pair of terminus ends of said at least
one second member includes a pair of opposing, parallel and
inwardly directed female recesses continuously formed along the
lengths of respective ones of said first pair of horizontally
oriented opposing side edges. Each recess has a V-shaped
cross-section adapted to receive a respective one of said inwardly
directed male protrusions disposed on said first bottom member.
Each of said pair of female recesses is positioned in a horizontal
and perpendicular orientation with respect to said vertically
oriented web side. Each female recess comprises an outer distal
inclined side integrally connected to an inner inclined side about
a common horizontally oriented side edge to form a respective one
of said inwardly directed female of recesses. The outer distal
inclined side is integrally formed therewith a respective one of
said first pair of horizontally oriented opposing side edges
defined by said second pair of opposing vertically oriented side
walls.
[0043] The third longitudinal structural top member is adapted to
be positioned atop the other of said second pair of terminus ends
of said at least one second structural member in a generally
horizontal orientation. The third upper member has a generally
channel-shaped cross-section and a third pair of terminus ends. The
third bottom member further consists of an upper horizontally
oriented and substantially flat planar web side, a second pair of
opposing, parallel, longitudinal and inwardly directed male
protrusions, and a third pair of opposing, parallel, longitudinal,
substantially flat and vertically oriented side walls.
[0044] The upper horizontally oriented and substantially flat
planar web side is defined by a third pair of opposing, parallel
and longitudinal edges which are each of a prescribed length and a
third pair of opposing terminus edges.
[0045] The second pair of opposing, parallel, longitudinal and
inwardly directed male protrusions is continuously formed along the
lengths of respective ones of the third pair of opposing, parallel
longitudinal edges. Each protrusion has a V-shaped cross-section
and consists of a second upper inclined side integrally connected
to a second lower inclined side along a common longitudinal edge to
form a respective one of said inwardly directed male protrusions.
The second upper inclined side being positioned proximal to and
integrally connected to a respective one of said opposing,
parallel, and longitudinal edges of said upper planar web side.
[0046] Each wall of the third pair of opposing, parallel,
longitudinal, substantially flat and vertically oriented side walls
which is integrally connected to a respective second lower inclined
side of a respective one of said inwardly directed male
protrusions.
[0047] A lower one of said second pair of terminus ends of said at
least one second structural member is adapted to be interconnected
within said first structural bottom member by inserting said lower
one of said second pair of terminus ends into an open ended side of
said first structural bottom member and twisting said lower one of
said second pair of terminus ends of said at least one second
structural member until said pair of inwardly directed male
protrusions of said first structural member are received, aligned
and interconnected with a respective one of said pair of inwardly
directed female recesses of said second structural member to form a
perpendicularly interconnected structural framing joint between
said first bottom member and said at least one second structural
member.
[0048] An upper one of said second pair of terminus ends of said at
least one second structural member is adapted to be interconnected
within said third structural top member by inserting said upper one
of said second pair of terminus ends into an open ended side of
said third structural top member and twisting said upper one of
said second pair of terminus ends of said at least one second
structural member until said pair of inwardly directed male
protrusions of said third structural member are received, aligned
and interconnected with a respective one of said pair of inwardly
directed female recesses of said second structural member to form a
perpendicularly interconnected structural framing joint between
said third top member said at least one second structural
member.
[0049] The telescopic feature is adapted to allow said at least one
second structural member to be either lengthened or shortened in
the longitudinal and vertical direction to accommodate floor to
ceiling height misalignments.
[0050] In another embodiment, each V-shaped protrusion may be
shaped by retaining first portion of the plate wall that extends
inward from said longitudinal edge of the plate web toward the
opposing wall at an acute angle to the plate web. The longitudinal
edge may be in a common plate to the plate wall. A second portion
of the plate wall that extends from the first portion of the plate
wall to a third portion of plate wall may be perpendicular to the
plate web. The second portion of the plate wall may have an obtuse
angle to the third portion of the plate wall for engagement with a
retainable portion of a stud wall of the stud member.
[0051] The stud wall may include V-shaped recesses at a first end
of the stud wall. The V-shaped recesses may be disposed generally
normal to a longitudinal axis of the stud wall for engagement with
corresponding V-shaped protrusions in the opposing walls of the
metal plate member.
[0052] Each V-shaped recess may be shaped by a retainable first
portion of the stud wall that extends inward from the first end of
the stud wall toward the opposing stud wall at an acute angle to
the longitudinal axis of the stud wall. A second portion of the
stud wall may extends from the first portion of the stud wall to a
third portion of the stud wall that is perpendicular to the stud
web. The second portion of the stud wall may be at an obtuse angle
to the third portion of the stud wall for engagement with the first
retaining portion of said plate wall of the metal late member.
BRIEF DESCRIPTION OF THE DRAWINGS
[0053] The present invention will now be described according to
preferred but non limiting embodiments and with reference to the
accompanying illustrations wherein;
[0054] FIG. I 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;
[0055] 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.
[0056] FIG. 3 shows an assembled view of the arrangement in FIGS. I
and 2.
[0057] FIG. 4 shows an elevation view of a typical stud and plate
frame according to a preferred embodiment of the invention.
[0058] FIG. 5 shows a perspective view of an engagement between an
intermediate stud and bottom plate in the frame of FIG. 4.
[0059] FIG. 6 shows an end view of the arrangement of FIG. 5.
[0060] FIG. 7 shows an isometric view of a telescopic stud member
according to a preferred embodiment of the invention.
[0061] FIG. 8 shows an isometric view of a telescopic stud member
according to an alternative embodiment;
[0062] 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.
[0063] FIG. 10 shows an isometric view of a stud member according
to an alternative embodiment;
[0064] FIG. 10A shows a close up view of the stud member of FIG.
10; and
[0065] FIG. 11 shows an isometric view of a stud member including
an extension member with a flared end for biased engagement with a
plate.
DETAILED DESCRIPTION
[0066] Referring to FIG. 1 there is shown an exploded view of an
assembly I 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.
[0067] Wall members 5 and 6 have formed therein respective V-shaped
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. 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 V-shaped protrusions 18 and 19 and external
female V-shaped recesses 20 and 21. Although respective formations
9,10 and 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.
[0068] Referring to FIG. 2 there is shown the stud and plate
arrangement of FIG. I 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 position of stud 2 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.
[0069] 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.
[0070] 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.
[0071] FIG. 5 shows a perspective view of a typical intermediate
joint 27 of the frame 26 of FIG. 4 in which intermediate stud 2
engages plate 3. Stud 2 is able to move longitudinally along plate
3 in the direction of arrow 29, thereby allowing fine adjustments
to the position of stud 2 to accommodate stud spacing requirements,
joins in cladding or positions of windows or doors.
[0072] FIG. 6 shows an end view of the arrangement of FIG. 5 and
the nature of the mating engagement between stud 2 and plate 3.
According to one embodiment stud 2 includes an optional 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 providing an optional 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.
[0073] 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.
[0074] 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 on site
measuring and cutting where studs are found to be too long or too
short. This reduces on site time and labor costs.
[0075] 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.
[0076] 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 in 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.
[0077] FIG. 9 shows a section of the frame of FIG. 4 defined by
line X-X and includes junction 70 and end junction 71. Junction 71
is formed by mating of telescopic stud 72 and top plate 73. Outer
telescopic stud 72 may comprise first telescopic element 74 and
second telescopic element 75. The outer telescopic stud 72 may
extend to increase the local height of the frame. Likewise,
intermediate stud 72 which may also comprise elements 74 and 75 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. 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 (see FIGS. 10 and 10A) which provides
a bearing shoulder for urging element 92 in a direction of arrow 94
to accommodate height variations.
[0078] FIG. 11 shows stud 90 of FIG. 10 including flared ends on
element 98. This arrangement allows element 98 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.
[0079] One major advantage of the joining arrangement using the
formations described is that the formations in the plate members
are fabricated during the rolling phase without any steps
additional to those already involved in the manufacture of the
plates. The formation in the studs require an additional forming
step but when the system is used in the field additional labor
steps such as turning down tabs are eliminated rendering the
invention more economic than the known methods.
[0080] In an aspect of the wall frame, referring to FIG. 6, the
structural member 3 may comprise opposing plate walls. Each of the
plate walls may comprise first portion 95, second portion 97 and
third portion 99. The first and second portions 95, 97 may define
the formations 9 and 10. Additionally, the first portion and the
plate web 11 may be at an acute angle 101 with respect to each
other. Also, the second and third portions 97, 99 may be at an
obtuse angle 103 with respect to each other.
[0081] 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.
* * * * *