AU1359900A - Steel frame structural members - Google Patents

Description

r/IUUU II 2/5/ Y Regulation 3.2(2)

AUSTRALIA

Patents Act 1990

ORIGINAL

COMPLETE SPECIFICATION STANDARD PATENT at a. a a a

S**

ooo o Application Number: Lodged: Invention Title: STEEL FRAME STRUCTURAL MEMBERS a 0 The following statement is a full description of this invention, including the best method of performing it known to us 1 STEEL FRAME STRUCTURAL MEMBERS The present invention relates to steel frame members for use in the construction of steel frame housing. More particularly the application relates to a method of production, and apparatus for the production of steel framework components, and joining of said members.

Prior art methods of production include rolling machines to roll metal strips or bands into members which are shaped in order to give the member strength, and structural rigidity, generally in specific planes.

Generally the shapes produced by conventional rolling methods include U, C and Z shapes, which are generally bolted or welded together to produce structural members. Prior art rolling apparatus have only been able to produce "Open" sections, that is where the longitudinal sides of the metal bands do not meet.

A disadvantage of the prior art results from the need to join by welding, 15 screwing, bolting or riveting the studs to the lower and upper plates. By making such a connection, a great deal of time and energy is expended, generally as the such connections require clamping first, then the use of hardware and energy to achieve securement.

By conventional formation methods and by the use of C shaped members to 20 form roof trusses, such trusses have to be bolted or welded in order for the trusses to bear weight. Such constructions are time consuming to produce by their manner of securing the individual members. The resultant constructions are generally noisy S"when they expand and contract.

The C sections used to produce the stud members are such that the sides permit plasterboard sheeting to be secured thereto. To properly drill hex screws through the plasterboard and the C section is difficult because the screw can wander across the face of the C section, until the drill tip on the screw bites in. This results in damage to the plaster board as the screw moves through the plaster board until the screw bites into the metal.

Conventionally formed stud members are sometimes required to be joined back to back or mouth to mouth in order to provide a double stud which is generally used at either side of a door or window opening. If placed back to back, the backs can be bolted, screwed or welded together. However, a back to back orientation can be useless in door and window openings, as a flat face is generally required. When a front to front combination is used, tack welding is generally all that is used. However, whilst twice the strength is provided, twice the size also results.

It is an object of the present invention to provide a methods, apparatus and products which overcome at least one disadvantage of the prior art.

Summary of the Invention According to a first aspect of the present invention there is disclosed a method of producing a channel member for use as a member of a building frame said method including: a) Forming a central member with two side members depending substantially perpendicularly therefrom; then 15 b) Forming deformations on said central member in the regions located between one tenth to one third inwards from either edge of said member.

According to a second aspect of the present invention there is disclosed a channel member for use as a structural beam of a building frame said member having a central portion and two side portions depending substantially 20 perpendicularly therefrom and at least one deformation located on said central member in a region that extends inwards between one tenth of the width of the central member inwards of the edge and one third of the central member inwards of the edge.

The first and second aspects result in a much stronger beam than that previously produced by a roll method. The deformations help to strengthen the central portion against buckling.

According to a third aspect there is disclosed a structural member for use in construction of a building frame said member including at least a central portion and two side portions depending substantially perpendicularly from opposing edges of said central portion, at least one said portions being characterised by a plurality of spaced deformation adapted to assist a drill bit to engage said frame member.

3 The third aspect allows a plasterboard fixer to find a line which extends vertically upwards, across the width of the stud such that should drill bit of the screw not bite immediately, it will move only a short distance before the bite is enhanced.

According to a fourth aspect of the present invention there is disclosed an elongate member with a substantially constant cross sectional arrangement including at least a first set of two substantially perpendicular portions whereby in use said first set of two substantially perpendicular portions are adapted to interlock with a first set of two substantially perpendicular portions of a second elongate frame member of substantially constant cross section whereby said interlocking provides a structurally sound frame member with at least a partially hollow cross section for use in construction of a building frame.

According to a fifth aspect of the present invention there is disclosed a hollow sectional frame member for use in construction of a building frame said beam including at least two interlocked elongate members of substantially constant cross section each said member having at least a first set of two S. substantially perpendicular portions adapted to interlock with said first set of °...•substantially perpendicular portions of said alternate member whereby said interlocking provides a structurally sound beam.

By providing the C shaped member with different length sides such that the short side is nestable in the long side, an Rectangular Hollow Section (RHS) or Square Hollow Section (SHS) can be formed without the need of welding, riveting, bolting or securing.

Brief Description of the Drawings Examples of the present invention will now be described with reference to the accompanying drawings in which: Figure 1A illustrates a plan view of a roll forming machine for use with an aspect of the present invention; Figure 1B illustrates a covered elevational view of the apparatus of Figure 1; Figure 2 illustrates the fifteenth stage of the roll forming equipment of Figure 1; Figure 3a, 3b and 3c illustrate the sixteenth, seventeenth and eighteenth states of the apparatus of Figure 1; Figure 4 details how a stud member can be attached to a bottom wall plate; Figure 5 illustrates how a nogging and stud are assembled; Figure 6A illustrates how bottom wall plates are spliced together; Figure 6B illustrates how top wall plates are spliced together; Figure 7 illustrates a chord member (top and bottom) as produced by the apparatus of Figure 1; Figure 8 illustrates the construction of a wall stud member; Figure 9A illustrates an end elevation of the construction of the bottom plate member; ~Figure 9b illustrates a plan view of the apparatus of Figure 9A; Figure 10 illustrates how the member of Fig. 8 can be combined to form 15 the stronger stud sections at door and window openings and the like; .ooo•i Figure 11 illustrates a C section beam member; and Figure 12 illustrates in perspective view of a typical wall junction.

o **Detailed description of the preferred embodiment Illustrated in Figure 1 is a roll forming machine 30 which has a series of rolling stages marked with the numerals 1 to 20. As is well understood by the skilled addressee, each stage produces a modified shape in a metal sheet passing through the machine 30. At stage 1 the flat metal sheet of any suitable thickness is passed through in the flat condition through the first roller.

Depending upon the shape of the rollers A the structural member which issues from stage 20 will be capable of bearing stresses applied to it after it has been constructed into a framework or other article.

Stages 1 to 11 are powered by belt driven means 31. However, stages 12 to 14 inclusive and 16 to 18 inclusive are idling rollers, and are not powered by the belt drive means 31.

Each of the rollers 1 to 11, 15, 19 and 20 revolve around a substantially horizontal axis. Rollers 12 to 14 and 16 to 18 revolve around a non-horizontal axis and in the preferred embodiment herein described the axis more approximates the vertical. However, the angle of orientation will depend upon the process required. As the idling rollers are not powered, the power to pass the material to be deformed is supplied by the roller stages 1 to 11 which push the metal sheet through the idling rollers, and by stages 15, 19 and 20 which pull the material being deformed through the idling rollers. The idling rollers revolving around a vertical axis are able to achieve a greater level of pressure applied to the metal being deformed than rollers revolving around a horizontal axis.

A closed structural member 70 of figure 2 may be formed by the rollers of figure 1. The closed member is formed by folding member 71 through 180 degrees. The movement through 180 degrees is done in stages as the material passes through preferably six vertically axled rollers. Figure 3a through figure 3c illustrate the stages that the extended member 71 may pass through.

To form the chord member 70 of Figure 2 roller stages 12 to 15 bend overhanging member 71, which enters roller 12 in the vertical orientation, through approximately 900. By the time the chord 70 exits roller 18 the member 71 has been folded through 1800 from its original starting point. Member 71 is pressed against metal sheet section 72 by high pressure exerted by the roller of figure 3c at least. These rollers hold the members 71 and 72 in firm location relative to each other.

20 No securing between members 71 and 72 need take place other than the pressure applied to member 71 because during use of the chord member bolts or screws or other fixing means which are used to fix the member into place pass through the flange section 73.

The invention is not limited to a chord member and other closed structural members may be formed according to the disclosed method of forming a member through 1800 so as to secure the opposing edges of metal sheet material.

The roller of figure 3a is the roller of stage sixteen of figure 1 and it rotates about a vertical axis. The operating face of this roller is angled at 750 to the vertical axis. This roller operates on member 71 when it exits stage 15 to form it through a further 150 to the horizontal.

The roller of figure 3b is the roller of stage seventeen of figure 1 and it rotates about a vertical axis. The operating face of the roller is angled at 300 to the vertical axis. It operates on the member 71 as it exits roller sixteen to form it through to an angle of 600 to the horizontal.

The roller of figure 3c is the roller of stage eighteen of figure 1 and it rotates about a vertical axis. The operating face of the roller is parallel to the vertical axis. It operates on the member 71 as it exits stage seventeen and forms it through the final 300 so that member 71 has been formed through 1800.

In another preferred embodiment six rollers are used. Each roller forms the member 71 through a 150 increment. A similar set of vertically axled rollers may be used to form member 71 through the first 900 to stage By utilising the chord member 70 and fine threaded screws to secure the truss braces, a stronger and quieter truss results. By varying the rollers the output product of the forming machine 30 can be varied according to the need required. The one machine can be utilised to manufacture all the different sections required in wall frame and roof truss construction.

Illustrated in Figures 4, 8, 9A and 9B are details of the stud 80 and bottom or top wall plate 90 arrangements. In Figure 8 is the construction of the stud member 80 whilst Figures 9A and 9B illustrate the top and bottom wall plate 90 construction. These are both illustrated in Figure 4 showing the method of joining. Illustrated in Figure 4 is a bottom wall plate 90 to which is 20 being perpendicularly attached, stud member 80. The stud member 80 has formed in it, on side walls 81 and 82, recesses or slits 83 which allow the entry of tab members 91 and 92 on bottom wall plate 90 to pass therethrough. The oooo tab members 91 and 92 are respectively on side walls 93 and 94 of bottom wall plate 90. The tabs may alternatively be located on the stud member 80 and the recess may be located on the wall plate 90. A combination of tabs and recesses may be located on each of the wall plate 90 and the stud member By bending tab members 91 and 92 downward (or upward in respect of the top plate stud joint) the stud 80 is secured to the stud 90 and is prevented from translation. Such a joint provides all the necessary strength without riveting, gluing, welding, bolting or screws.

The tabs are located at intermittent lengths along the wall plate 90 so the stud member may have a plurality of locations along the wall plate or so that a plurality of studs may be located to the one wall plate.

The method of joining is not limited to wall plate and stud members and it may be utilised to join other members of a building frame.

Illustrated in Figure 5 is the stud member 80 which has a U shaped noggin member 85 which passes through it. By crimping the sides of the nogging on both sides of the wall stud the wall stud 80 is satisfactorily braced to help it to resist buckling under vertical loading.

Illustrated in Figure 6A and 6B is the method of joining, or splicing bottom wall plates 90A and 90B, and top wall plates 90D and 90C, respectively.

As a piece of stud section has an outside length equivalent to the inside width of wall plate members 90A,B,C and D the stud or splicing members 80A and B snugly fits therebetween. By then Tek screwing into the sides of the bottom wall plates, or from the top in the case of the top wall plate the splicing or joint can be completed. Illustrated in Figure 9A and 9B the top and bottom wall plates are shown as having the half round tab members 91 and 92 being in a 15 substantially parallel orientation relative to the central portion 95 of the top and bottom wall plate. Alternatively the tab members 91 and 92 can be in the vertical orientation and only bent over when it is desired to connect a stud member 80 thereto or other member. The shape of the tab members 91 and 92 can be any appropriate shape such as rectangular or square. If the tabs 91 and 20 92 are maintained in the vertical orientation, a larger recess 83 needs to be 9*e9 formed in the sides of the stud Illustrated in Figure 12 is of a detail three-way join of a wall junction whereby a stud section 117 is utilised to assist in the joining of the three-wall sections A, B and C.

Illustrated in Figure 11 is the cross section of a 150mm C shaped beam produced by the roll forming machine of apparatus 30 of Fig. 1.The deformations 114 and 115 help to strengthen the beam 110 by preventing buckling occurring across the length of the beam and between side walls 111 and 112.

The beam is preferably of a substantially C shape construction having side walls 111 and 112 and on the central portion 113 there are located two longitudinally shaped, or deformed recesses 114 and 115. Such recesses may be applied to other members of a building frame to achieve increases in the members strength.

These recesses are preferably located in a region of some 15 to away from the sides 111 and 112 in the direction of arrows A and B respectively. Outside of these regions the strength benefit which is derived from the location of the deformations 114 and 115 is decreased. To locate the deformations 114 and 115 towards the centre in the region of 50mm or greater away from side walls 111 and 112 will in fact weaken the beam and not give any benefit to the strength.

The recesses 114 and 115 can be suitably deformed into the central portion 113 by the rolling machine 30 during production of this substantially C shaped member. Conventional 150mm beams which don't have deformations 114 and 115 are normally allowed to span only a maximum length of 3.6m carrying a maximum weight of 600kg. By the present method and construction the beam 110 can span a length of 4.6m and carry some 800kg.

Use of such spaced deformations to obtain increased strength advantages is not limited to C shaped frame members and it may be applied to any building frame member.

Illustrated in Figure 8, as previously described, is a stud member 20 which has reinforcing deformations 84 which are produced in a similar manner to that of the product of Fig. 11. The side walls 81 and 82 each have longitudinally extending deformations which allow Tek screws to be located as they drill through the metal of sides 81 and 82. Recesses of other shapes and orientations on the surface of the stud may also be used, provided they encourage the tek screw to engage the surface of the member rather than wandering across its surface. Such recesses may also be applied to the surface of other frame members that are required to receive Tek screws.

Frame members whose cross sectional shape is at least partially hollow may be produced by two or more interlocking members who's cross sectional shape is substantially constant along their length. These members interlock due to the provision of perpendicular sections on each member. These perpendicular sections of each member overlap when the members are arranged to form a said further member whose cross sectional shape is at least 9 partially hollow. By the overlapping portions, the members lock into place and form a structurally sound member which does not require fixing screws, welds or the like to hold the member, which is at least partially hollow in cross section, together.

The members used to form the hollow members may be of any suitable shape, however, it is preferred that a C shaped channel member of figure 10 be used to form Rectangular Hollow Sections or Square Hollow Sections.

The side walls 81 and 82 of figure 9 and figure 10 are of a dimension which is different from each other. The side wall member 81 is some 2.5 mm shorter than that of side 82. Preferably the side 81 is some 35.5 mm whilst the side 82 is 37.5 mm.

By such a construction, the stud members 80 are nestable within each other as is illustrated in Figure 10. In Figure 10 there are three stud members 80A, 80B and 80C. Members 80A and 80B are back to back whilst member 80C is nested within member or stud section 80B. 80B and 80C are nested S• such that the opening between the side walls face each other and substantially oo rectangular hollow section is produced.

Because of the inwardly pointing flanges being inwardly angled to the horizontal, in the direction of the central portion, and the sizes and dimensions 20 of the sides, the members 80B and 80C can be joined without need of fixing screws or the like.

However, as it is common that the plaster board or other internal wall 0.

sheeting is attached by Tek screwing or hex screws the members 80B and will generally have a Tek screw also helping them not to separate.

Claims (26)

1. A method of producing a channel member for use as a member of a building frame said method including: a) Forming a central member with two side members depending substantially perpendicularly therefrom; then b) Forming deformations on said central member in the regions located between one tenth to one third inwards from either edge of said member.

2. A method of producing a channel member as claimed in claim 1 wherein said deformations are longitudinal recesses.

3. A method as claimed in claim 2 wherein said longitudinal recesses extend along the length of said member. A method as claimed in claim 2 or 3 wherein said longitudinal recesses are parallel. 4 5. A method as claimed in any one of claims 1 through 4 wherein said deformations are substantially arcuate in cross section.

6. A method as claimed in claim 5 wherein said cross section is semi-circular.

7. A method as claimed in claim 5 or claim 6 wherein a radius of said cross section is less than or equal to one eighth of the width of the central member.

8. The method of any preceding claim wherein step a) further includes forming flange members substantially parallel to said central member and depending from each said side member and extending internally from each of said side member. 11

9. A channel member for use as a structural beam of a building frame said member having a central portion and two side portions depending substantially perpendicularly therefrom and at least one deformation located on said central member in a region that extends inwards between one tenth of the width of the central member inwards of the edge and one third of the central member inwards of the edge. A channel member as claimed in claim 9 wherein said deformations are longitudinal recesses.

11. A channel member as claimed in claim 10 wherein said longitudinal recesses extend along the length of said member. o° 12. A channel member as claimed in claim 10 or 11 wherein said longitudinal recesses are parallel.

13. A channel member as claimed in any one of claims 9 through 12 wherein said deformations are substantially arcuate in cross section. ooo•

14. A channel member as claimed in claim 13 wherein said cross section is semi-circular. ogoo A channel member as claimed in claim 13 or claim 14 wherein a radius of said cross section is less than or equal to one eighth of the width of the central member.

16. The channel member of any one of claims 9 through 15 wherein said channel member further includes flange members formed substantially parallel to said central member and depending from each said side member and extending internally from each said side member.

17. A structural member for use in construction of a building frame said member including at least a central portion and two side portions depending substantially perpendicularly from opposing edges of said central portion, at least one said portion being characterised by a plurality of spaced deformations adapted to assist a drill bit to engage said frame member.

18. A frame member as claimed in claim 17 wherein said deformations are longitudinal recesses.

19. A frame member as claimed in claim 18 wherein said longitudinal recesses are parallel. A frame member as claimed in claim 18 or claim 19 wherein said recesses extend substantially along the length of said portion.

21. A frame member as claimed in any one of claims 17 through 20 wherein said portion comprises between five and seven deformations.

22. An elongate member with a substantially constant cross section including at least a first set of two substantially perpendicular portions whereby in use said first set of substantially perpendicular portions are adapted to interlock with a first set of two substantially perpendicular portions of a second elongate frame member of substantially constant cross section whereby said interlocking provides a structurally sound frame member with at least a partially hollow cross section for use in construction of a building frame.

23. An elongate member as claimed in claim 22 whereby a first portion of said first set of substantially perpendicular portions of said elongate member abuts a portion of said first set of substantially perpendicular portions of said second elongate member adjacent a portion of the second elongate member that abuts the second portion of said elongate member. 13

24. An elongate member as claimed in claim 22 or claim 23 wherein said elongate member further includes at least a second set of substantially perpendicular portions of different dimension to a first set of substantially perpendicular portions whereby in use in said interlocking arrangement said first set of substantially perpendicular portions of said elongate member interlocks with said second set of substantially perpendicular portions of said second elongate member and said second set of substantially perpendicular portions of said elongate frame member interlocks with said first set of substantially perpendicular portions of said second elongate frame member. An elongate member as claimed in claim 23 wherein the difference in dimensions between said first and second sets of substantially perpendicular portions is substantially the thickness of each said portions whereby in use in said interlocking arrangement said first and second portions of alternate interlocking members abut. ,26. An elongate member as claimed in claim 24 whereby said second elongate member is of substantially similar cross section to said elongate member and whereby in use in said interlocking arrangement said second elongate member is oo o rotated with respect to said elongate member.

27. An elongate member as claimed in any one of claims 24 through 26 wherein said elongate member includes a central portion and two side portions depending substantially perpendicularly from opposing edges of said central portion and S* wherein at least one flange member depends substantially perpendicularly from at least one said side portion whereby said flange and said side portion comprise said first set of substantially perpendicular portions.

28. An elongate member as claimed in claim 27 wherein said side portions are of differing lengths whereby two substantially channel shaped elongate members can interlock whereby said interlocking produces a structurally sound hollow sectional member. 14

29. A hollow sectional frame beam for use in construction of a building frame said beam including at least two interlocked elongate members of substantially constant cross section each said member having at least a first set of two substantially perpendicular portions adapted to interlock with said first set of substantially perpendicular portions of said alternate member whereby said interlocking provides a structurally sound beam. A hollow sectional frame beam as claimed in claim 29 whereby a first portion of said first set of substantially perpendicular portions of said elongate member abuts a portion of said first set of substantially perpendicular portions of said second elongate member adjacent a portion of the second elongate member that abuts the second portion of said elongate member.

31. A hollow sectional frame beam as claimed in claim 29 or claim wherein each said elongate member further includes at least a second set of substantially perpendicular portions of different dimension to a first set of :substantially perpendicular portions whereby in use each said first set of substantially perpendicular portions of said elongate frame member interlocks with said second set beam of substantially perpendicular portions of said second elongate frame member and said second set of substantially perpendicular portions of said elongate frame member interlocks with said first set of substantially perpendicular portions of said second elongate frame member.

32. A hollow sectional frame beam as claimed in claim 31 wherein the difference in dimensions between said first and second sets of substantially perpendicular portions is substantially the thickness of each said portion whereby in use in said interlocking arrangement said first and second portions of alternate interlocking members abut.

33. A hollow sectional frame beam as claimed in claim 32 whereby said second elongate member is of substantially similar cross section to said elongate member and whereby in use in said interlocking arrangement said second elongate member is rotated with respect to said elongate member.

34. A hollow sectional frame beam as claimed in any one of claims 29 through 33 wherein said elongate member includes a central portion and two side portions depending substantially perpendicularly from opposing edges of said central portion and wherein at least one flange member depends substantially from at least one said side portion whereby said flange and said side portion comprise said first set of substantially perpendicular portions. A hollow sectional frame beam as claimed in claim 34 wherein said side •portions are of differing lengths whereby two substantially channel shaped elongate members can interlock whereby said interlocking produces a structurally sound hollow sectional beam. DATED this 2 0 th day of January, 2000. NEW DIMENSIONS (AUST) PTY LTD WATERMARK PATENT TRADEMARK ATTORNEYS UNIT 1 THE VILLAGE RIVERSIDE CORPORATE PARK

39-117 DELHI ROAD NORTH RYDE NSW 2113 AUSTRALIA PNF:MP:GL P14292AU01