AU2006201344A1 - Structural members and joining arrangements therefor - Google Patents

Description

31/03/2006 10:51 +61-2-95522894 WALSH AND ASSOCIATES PAGE 04/29 STRUCTURAL MEMBERS AND JOINING ARRANGEMENTS THEREFOR

BACKGQ

The present joining syste releasable jc structural n correspondit any locatior Although th primarily de particular th PRIOR IAR Traditionally members wti channel shaf of spaced bottom plat assembled o members in top and bot screws or th braced with.

frames, inte bracing is eJ structurally cladding is studs to the conjunction bracing of th

LIND

invention relates to joining systems and to structural members for use in such ms. More particularly, the present invention relates to structural members for use in ining arrangements formed by such structural members whereby an end of a first ember includes a formation which may be joined by engagement with a ig formation on a second structural member such that the members may be joined at along the length of the second member and without the need for fasteners.

present invention in all its forms has multiple applications, the invention will be scribed with reference to its application in joining structural members for use in >ught not exclusively in stud frames.

,light weight construction of metal stud frames employs steel or aluminium stud ich are generally channel shaped and wherein the ends of the stud members engage ed plate members. A standard form metal stud frame will usually comprise a series art stud members which each engage via their ends respective opposing top and Smembers. According to conventional methodology, the frames are generally Sthe ground. Typical frame construction involves placement of top and bottom plate spaced apart opposing relationship whereupon stud members are connected to the om plates which traditionally involves engaging the ends of the studs with tech elike. These frames may or may not be braced but in the case where they are not bracing members reliance for bracing is placed on tech screws. Unlike external mal frames used in partitioning are not generally braced during construction as mected by wall cladding fixed to the frame. During construction, stud frames are veak and in the c;se of interal frames, they are not effectively braced until the wall Lffixed to the frame. A small number of holding screws may be used to fix some top and bottom plates. Although a weak form of bracing is created by the between stud and plate members which are screwed no reliance can be placed on the e frame as the unscrewed joins do not offer sufficient strength and resistance against 1 COMS ID No: SBMI-03189877 Received by IP Australia: Time 10:46 Date 2006-03-31 31/03/2006 10:51 +61-2-95522894 WALSH AND ASSOCIATES PAGE 05/29 slewing in t] together at f limited scre' plates are ct the edges of the throat o separation o Another me arrangement engage a co hammers thi members th One disadva and bottom position whi shaped stud: securing the for each stu construction consuming a screwed. Ot or clinching method of j correspondir The formatil and plates.

upturning of ie circumstance when the frame is lifted into position. Installers screw the members ie point of overlap between stud and plate but engagement of studs to plates with ving will not of itself provide adequate bracing, The profiles of the known studs and annel shaped with a planar base and sidewalls extending from and continuous with said base. Typically, a stud mates with a plate by insertion of the end of the stud into F the plate. The fit is essentially friction grip and there is no resistance against fstud from plate until such time as tech screws are inserted.

thod of affixation of studs to top and bottom plates involves a tab and slot in which tabs located at the extremity of the walls of the top and bottom plates rresponding slot in each wall of the stud members following which the tradesman Stabs so they are orientated at an angle other than normal to the walls of the stud reby locking the stud members against the top and bottom plates.

ntage of this method is that more material is required to form the channel shaped top plates. Secondly, additional labour is required to bend the tabs into their locking ch can be awkward due to the position of the protruding tabs inside the channel Although the tab and slot method of connection of studs to plates is effective in members, it is tedious and time consuming for tradesman to bend the tabs four times d. The insertion of tech screws, although used in holding studs to plates during and until the cladding material is affixed to the stud frame is likewise time nd does not provide effective temporary bracing until all or the majority of joins are ter methods of affixation of studs to plates have been used such as riveting, welding each of each stud, all of which methods involve additional labour. A further prior art )ining structural members for a stud frame involves the use of cooperating and g engaging formations in the walls of both the stud and plates.

mns in the plate consist of a securing notch formed in the walls of the mating stud ro facilitate stud location, the wall extremities of the plate are abbreviated by 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 COMS ID No: SBMI-03189877 Received by IP Australia: Time 10:46 Date 2006-03-31 31/03/2006 10:51 +61-2-95522894 WALSH AND ASSOCIATES PAGE 06/29 clip which connection i rotation, twi Another pro requiring so which adds engagement formation in of each met system wor increases pri more convei pre punchinj to plates one fit and finishI Another pro ceiling heigi necessitates stud membe: or floor, thi differences.

adds to costs in labour and assembly. Another disadvantage of this mode of s that the surface area of engagement is low resulting in low resistance to relative rting, and pulling out between stud and plate.

blem with this arrangement lies in the alignment between stud and plate formations ne squeezing and. manipulation of the stud by the assembler to secure it in position :o assembly time and therefore labour costs. Another prior art method involves the between a formation in the walls of the top and bottom plates and a corresponding stud members. The formations are produced by pressing out of a region of the wall iber so that the formations mate in snap fit male/ female relationship. While this cs well it necessitates an additional punching step during production which )duction time of the constituent structural members but it does provide a useful and ient alternative to the tab system described above. All of the above systems rely on Sand limits or removes entirely the ability of the installer to move the studs relative e fitted and where adjustment may be required during construction to accommodate errors or window or door size irregularities.

lem arising particularly in internal stud frame construction is irregularity in floor to t in buildings caused by poor concrete finishing and out of alignments which often cutting of stud members in regions of reduced height. In a normal stud frame, the s would be the same height or length but where there are irregularities in the ceiling frame will not fit unless stud heights are suitably cut to accommodate those this is time consuming and adds additional labour costs to the installation.

LNVENflOlti The present providing ar stud frames arrangement labour and a provide a jo invention seeks to ameliorate the shortcomings of the prior art arrangements, by alternative method of joining structural members used in the formation of metal and the like for use in modular construction of stud frames. Preferably the s are adapted to suit internal non load bearing stud frame partitioning. Due to the iditional material costs in implementation of the known methods, there is a need to ining system which allows quick and efficient joining of structural members of a 3 COMS ID No: SBMI-03189877 Received by IP Australia: Time 10:46 Date 2006-03-31 31/03/2006 10:51 +61-2-95522894 WALSH AND ASSOCIATES PAGE 07/29 stud wall fr allowing qu to the preset any further obviate the each stud/ p the studs an The present which enabl avoiding th form, the pr frames whe: wherein, sai be joined, e formation ir and the form such that ui first and sec In another I construction member fon wall a forms least one wi first membe formation ir upon press i first and see a preferred relative mov ;me without having to use any tools such as a hammer as previously described and ck, efficient and infinite positioning of the stud. The joining arrangements according t invention further allows convenient, releasable fixation of a stud to a plate without operation to secure the members after initial joining. The joining arrangements leed for additional bracing once the frame is assembled and have the advantage that ate join is effectively braced due to the inter engagement of profiled parts formed in i plates.

invention also provides a stud member including an adjustable extension member es the length of the stud to be adjusted to accommodate on site height variations need for installers to cut studs to accommodate misalignments. In another broad ssent invention comprises: a joining arrangement for use in the construction of stud ein a first structural member is releasably attached to a second structural member, I first member has side walls which include a formation, which when members are to igages a correspcmding formation on the second member, characterised in that the the side walls of said first member is disposed at an angle to its longitudinal axis iation on said second member is disposed generally parallel to its longitudinal axis on engagement of the first and second members, the respective formations in said >nd members engage, such that they are generally in alignment.

road form the present invention comprises: a joining arrangement for use in the of stud frames and for releasable attachment of a first member to a second structural ning part of said stud frame; wherein, said first member includes in at least one side tion which, when members are to be joined, engages a corresponding formation in at 1 of the second member, characterised in that the formation in said wall/s of said r is/are disposed at an angle to the longitudinal axis of the member and the said second member is disposed generally parallel to its longitudinal axis such that itting engagement of the first and second members, the respective formations in said md members engage to secure the first member to the second member. According to mabodiment, the respective formations in each said first and second members allow ement between the first and second members in the direction of the longitudinal axis 4 COMS ID No: SBMI-03189877 Received by IP Australia: Time 10:46 Date 2006-03-31 31/03/2006 10:51 +61-2-95522894 WALSH AND ASSOCIATES PAGE 08/29 of the seconl member Preferably the joining arrangement is used in the construction of internal stud frames In another b a joining at used in the i in the first engages a alignment A said first ar member; w.

second men According 1 member alo: In another structural m a formation opposing w are disposec the second such that th< allow the fil axis of the a According engagement Preferably t which interf In another fi which joins stud which adjustment t n such applications as partitioning.

oad form the present invention comprises; angement enabling releasable attachment of first and second structural members onstruction of a stud frame; wherein the joining arrangement comprises a formation nember disposed at an angle to the longitudinal axis of the member and which orresponding formation in the second member which is disposed generally in th the longitudinal axis of the second member such that the respective formations in I second members cooperate to releasably attach the first member to the second .erein, the joining arrangement allows relative movement between the first and )ers.

a preferred embodiment, the relative movement enables movement of the first g a direction parallel to the longitudinal axis of the second member.

)road form the present invention comprises; a joining arrangement for joining mnbers for use in construction of a stud frame wherein the arrangement comprises: :n opposing walls of the first member which engages a corresponding formation in Us of the second member; wherein the formation in the walls of the first member normally to the longitudinal axis of the member and the formation in the walls of lember are disposed in alignment with the longitudinal axis of the second member respective formations in the first and second members upon engagement align and it member freedom of movement relative to and in the direction of the longitudinal 'cond member.

o the preferred embodiment, the first member is rotated into its position of with the second member and can be released by rotation in the opposite direction.

e formations in the first and second members comprise inwardly directed recesses t in male/ female engagement.

nn the present invention comprises: a structural member for use in a stud frame and with top and bottom plates of the stud frame; characterised in that the member is a includes an extension element capable of relative movement thereby allowing Sthe length of the stud to accommodate floor to ceiling height variations.

COMS ID No: SBMI-03189877 Received by IP Australia: Time 10:46 Date 2006-03-31 31/03/2006 10:51 +61-2-95522894 WALSH AND ASSOCIATES PAGE 09/29 Preferably, 1 retracted to The ends o described bt movement o In its broad4 for use in a l and sidewal includes a f least a seco mating mere Preferably, i structural m projection 01 the external Preferably e are the sare formations formations a same distan According t structural mi Preferably, member is c longitudinal According t member and the member he adjustment is telescopic wherein the extension member may be extended and Ldjust the length of the member to suit floor to ceiling height.

the elements may be adapted with any of the forgoing joining systems herein t ideally would include an extension member which allows for relative longitudinal Fa first member relative to a second member.

st form of the method aspect the present invention comprises; a structural member uilding structure such as a stud frame, wherein the member comprises at least a web Is depending from said web; characterised in that the structural member further irmation in at least one said walls which engages a corresponding formation in at id mating structural member to releasably secure said structural member to said ber.

he formations are disposed either parallel or normal to the longitudinal axis of said amber and comprise a recess in the external face of said at least one wall and a 1 an inside face of said at least one wall wherein the internal projection is formed by recess.

ach said walls of said structural member have at least one said formations which e length as one dimension of said walls. According to one embodiment the are parallel to the longitudinal axis of the structural member. Preferably the re located proximate said web and on opposing faces of said walls with each at the e from the web.

o one embodiment the formations are normal to the longitudinal axis of said mrber and are located at or near one or both ends of said structural member.

when the formations are parallel to the longitudinal axis of said member, the apable of mating with a mating member with formations which are normal to the axis of said member, such that the members are detachably fixed to each other.

a preferred embodiment the structural member is telescopic and includes an outer an inner member wherein the members move relative to each other such that one of Smoves between a retracted state in which it is nested in the other member and an 6 COMS ID No: SBMI-03189877 Received by IP Australia: Time 10:46 Date 2006-03-31 31/03/2006 10:51 +61-2-95522894 WALSH AND ASSOCIATES PAGE 10/29 extended st Preferably, capable of e than said oti In another b of construct sidewalls de least one sa second mi comprising 1 a) takin sidewalls; b) takin c) takin member; d) takin member and e) placi second end formations c said membe f) takin subsequent g) enga member, Preferably tl predetermin engagement te in which said member is partially or fully extended relative to said other member.

one of said members is an extension member which includes a formation which is igaging a mating member. The extension member is preferably substantially shorter er member.

*oad form according to the method aspect the present invention comprises: a method ion of a stud frame using structural members each comprising at least a web and pending from said web; characterised in that the members include a formation in at d walls of a firsi of said members which engages a corresponding formation in a :mber to secure said structural member to said mating member; the method he steps of: g the first said structural member including a formation in at least one said g the second structural member the same or similar to said first structural member; g a third structural member and setting it in opposing relationship to said first g the second structural member including a formation in at least one wall of said which is normal to the longitudinal axis of said second member, ng a first end of said second member into engagement with said first member and a Yf said second member into engagement with said third member such that respective n said first and second and said third and second members mutually engage to hold s in detachable engagement; g a fourth and subsequent members and joining a first end of said fourth and nembers with said first structural member ing a second end of said fourth and subsequent members with said third structural ie method includes the further steps of repeating steps f) and g) until a stud frame of d length is formed. Preferably, the method includes the further step prior to of any one or more of said fourth and subsequent members, of telescopically 7 COMS ID No: SBMI-03189877 Received by IP Australia: Time 10:46 Date 2006-03-31 31/03/2006 10:51 +61-2-95522894 WALSH AND ASSOCIATES PAGE 11/29 extending ti height varial second end! engagement The preseni embodimeni Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 Figure 6 Figure 7 Figure 8 Figure 9 e length of one or more said, fourth and subsequent members to accommodate ions in a space defined by said first and third members. Preferably, said first and of said, fourth and subsequent members are positively rotated into snap fit with said first and third members.

D.MCRPUTON

invention will now be described according to preferred but non limiting 3 and with reference to the accompanying illustrations wherein; 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; shows a perspective view of respective ends of a typical stud and plate according to one embodiment of the invention prior to engagement.

shows an assembled view of the arrangement in figures I and 2.

shows an elevation view of a typical stud and plate frame according to a preferred embodiment of the invention.

shows a perspective view of an engagement between an intermediate stud and bottom plate in the frame of figure 4.

shows an end -iew of the arrangement of figure shows an isometric view of a telescopic stud member according to a preferred embodiment of'the invention.

shows an isometric view of a telescopic stud member according to an alternative embodiment; shows an abbreviated perspective section of a stud frame showing mating between telescopic studs and plate according to a preferred embodiment of the invention.

shows an isometric view of a stud member according to an alternative embodiment; shows an isometric view of a stud member including an extension member with a flared end for biased engagement with a plate.

9 Figure 10 Figure 11 COMS ID No: SBMI-03189877 Received by IP Australia: Time 10:46 Date 2006-03-31 31/03/2006 10:51 +61-2-95522894 WALSH AND ASSOCIATES PAGE 12/29 Referring tc structural in member 2 1, walls 5 and4 Wall memb inwardly dir roll fbrming use in metal as either a t( includes wd 14 and 15.X male protru formations S the art that outwardly re Referring to rotation of shown is tyj rotation of s press fit in t plate 3. Th, locations 24 On site, stur indicate to t] to ensure el allow for lo4 that frame n the claddin, figure 1 there is shown an exploded view of an assembly 1 for joining two =ibers 2 and 3 according to a preferred embodiment of the invention. Structural preferably channel shaped and includes a web 4 to which is connected opposing which terminate in respective flanges 7 and 8.

,rs 5 and 6 have formed therein respective formations 9 and 10 which each define eted recesses. Formations 9 and 10 may be introduced into member 2 by means of a step during production of member 2. Member 2 is preferably employed as a stud for frame construction and is adapted for releasable attachment to member 3 which acts p or bottom plate in a metal stud frame. Member 3 is generally channel shaped and 11 to which is connected opposing walls 12 and 13 which terminate in free ends ialls 12 and 13 include formations 16 and 17 defining respective inwardly directed ions 18 and 19 and external &-male recesses 20 and 21. Although respective 0 and 16 and P7 are inwardly directed, it will be appreciated by those skilled in the formations 'nay be reversed such that the male formations would project lative to the walls in which they are formed.

figure 2 there is shown the stud and plate an-angement of figure 1 showing the tstud 2 relative to plate 3 prior to mutual engagement thereof The arrangement iical of engagement between a stud and bottom plate. Engagement takes place by ad 2 in the general direction of arrow 22 to allow stud 2 to be urged into position by ie direction of arrow 23. Figure 3 shows the final engagement position of stud 2 and arrangement shown in figure 3 is the typical engagement which would occur at and 25 of frame 26 shown in figure 4.

frames are genemlly assembled on the floor according to engineering plans which ie assembler the positions of the stud members. The positions of the studs are critical mination, of cumulative error along the length of the frames, even spacing and to ,ations of doors and windows, Location of the stud members is also critical to ensure 'embers match the location of joins in cladding affixed to the frames to ensure that joins are rigidly supported. Where the top and bottom plates of a stud frame are 9 COMS ID No: SBMI-03189877 Received by IP Australia: Time 10:46 Date 2006-03-31 31/03/2006 10:51 +61-2-95522894 WALSH AND ASSOCIATES PAGE 13/29 prefabricate flexibility in stud. Correc slot joining pressed into plate is not a According t stud membc cladding anD doors. This i a strong con may be relo walls of the latter case, t formation. I the plates v distance in t over a short Figure 5 shc in which ini plate 3 in th, accommoda Figure 6 sh engagement opening 30 conduits. A in buildings frames. Aco to fit the dis I with formations which dictate the exact location of the studs there is no inherent the positioning of the studs to accommodate misalignment of a cladding join with a ring stud location for this misalignment is difficult if not impossible with the tab and systems and also with the existing systems employing corresponding formations the walls of the plate and stud members as relative movement between stud and vailable once the members are fitted.

the invention the joining arrangement allows for the relative movement between rs and top and bottom plate members to adjust for any misalignments between I studs and where fine adjustments may be required to accommodate windows and s achieved by means of a snap fit connection between stud and plate which provides aection yet allowing relative movement between stud and plate members so the stud cated at any position along the length of the plate members. The formation in the stud may travel the full length of the member or they may be intermittent In the he studs will be adjustable along the length of the plate over the full length of the Vith this choice for the formation, the movement flexibility of the studs relative to ill either be absolute along the full length of the plate or over a predetermined le stud location. In the latter case the formation in the walls of the plate will occur distance in the region of a predetermined stud position.

ws a perspective view of a typical intermediate joint 27 of the frame 26 of figure 4 ermediate stud 28 engages plate 3. Stud 28 is able to move longitudinally along e direction of arrow 29, thereby allowing fine adjustments to the position of stud 3 to :e stud spacing requirements, joins in cladding or positions of windows or doors.

ows an end view of the arrangement of figure 5 and the nature of the mating between stud 28 and plate 3. According to one embodiment stud 28 includes an formed therein which accommodates material such as but not limited to service :ommon problem which exists in frame installation is ceiling to height irregularities This may occur where concrete finishing is uneven creating fit problems for stud arding to present methodology this problem is addressed by cutting individual studs tance between bottom and top plates. This is time consuming during construction of COMS ID No: SBMI-03189877 Received by IP Australia: Time 10:46 Date 2006-03-31 1 31/03/2006 10:51 +61-2-95522894 WALSH AND ASSOCIATES PAGE 14/29 frames and present inve ceiling to h which incluc a first minir length up to Figure 7 sl embodimeni predetennin, element 42 1 In the event fitted, meml measuring a time and lab According ti element 41 i members ac relative to t cold forminj and 44 are ii 54 and 55 a stud elemenl which are c comprises ii plate in a m which will e Figure 9 shc and end jun telescopic st adds to labour costs. This problem is overcome according to one aspect of the ntion by providing an extendible stud which eliminates the need for cutting to suit ight irregularities. According to one embodiment there is provided a telescopic stud les an extension member which moves between a retracted state in which the stud is tum length and an extended state in which the stud is extended from the minimum a maximum length.

lows an isometric view of a structural member 40 according to a preferred including telescopic elements 41 and 42 which enable extension and retraction to a id distance. Elements 41 and 42 are channel shaped and are arranged such that its inside a channel formed by element 41.

of floor to ceiling height misalignments in a structure to which a stud frame is to be >er 40, due to its telescopic extension capability eliminates the need for on site ad cutting where studs are found to be too long or too short. This reduces on site :ur costs.

l the embodiment shown in figure 7, element 42 includes formations 43 and 44 and acludes formations 45 and 46. These mate with corresponding top and bottom plate ;ording to the anrangements previously described allowing longitudinal adjustment ie plates in addition to vertical adjustment in the direction of arrow 47. During the of element 42, flanges 48 and 49 are crushed at regions 50 and 51 as formations 43 itroduced into element 42. Likewise flanges 52 and 53 are crushed in the regions of s formations 45 and 46 are introduced into element 41. Figure 8 shows a telescopic 60 according to an alternative embodiment. Stud 60 comprises elements 61 and 62 apable of telescopic adjustment in the direction of the arrow 63. Stud 60 further I element 62, formations 64 and 65 which engage corresponding formations in a anner previously described. Likewise element 61 comprises formations 66 and 67 agage a bottom pi ate as previously described.

ws a section of the frame of figure 4 defined by line X-X and includes junction ;tion 71. Junction 71 is formed by mating of telescopic stud 72 and top plate 73. As ad 72 comprises telescopic elements 74 and 75, stud 72 may extend to increase the 11 COMS ID No: SBMI-03189877 Received by IP Australia: Time 10:46 Date 2006-03-31 31/03/2006 10:51 +61-2-95522894 WALSH AND ASSOCIATES PAGE 15/29 local height may also e) direction of comprising formations i previously d element 92 i Figure 11 s allows elem between stu which woul< One major formations additional tc require an a( such as turn methods.

It will be re may be mac spirit and sc of the frame. Likewise, intermediate stud 76 which comprises elements 77 and 78 tend in which case that portion of the frame can be extended or retracted in the arrows to accommodate height variations, Figure 10 shows an alternative stud telescopic elements 91 and 92. This is a more conventional stud profile without n the ends of elements 91 and 92 to engage with corresponding plate profiles as escribed. Element 92 includes a tab 93 which provides a bearing shoulder for urging a a direction of arrow 94 to accommodate height variations.

lows stud 90 of figure 10 including flared ends on element 92. this arrangement ,nt 92 to engage a top plate with a positive bias thereby increasing frictional fit i and plate. This arrangement can also be introduced into the end of element 91 engage a bottom plate.

idvantage of the joining arrangement using the formations described is that the n the plate members are fabricated during the rolling phase without any steps those already involved in the manufacture of the plates. The formation in the studs ditional forming Step but when the system is used in the field additional labour steps ng down tabs are eliminated rendering the invention more economic than the known cognised by persons skilled in the art that numerous variations and modifications e to the invention as broadly described herein without departing from the overall >pe of the invention.

12 COMS ID No: SBMI-03189877 Received by IP Australia: Time 10:46 Date 2006-03-31