AU2017201062A1

AU2017201062A1 - Wall and ceiling construction

Info

Publication number: AU2017201062A1
Application number: AU2017201062A
Authority: AU
Inventors: Lei Xiao
Original assignee: Studco Australia Pty Ltd
Current assignee: Studco Australia Pty Ltd
Priority date: 2016-04-11
Filing date: 2017-02-16
Publication date: 2017-10-26
Also published as: AU2022241551A1

Abstract

A fitting 1, for within a stud wall locating a stud along a track T, including an integral body of plastic dimensioned to fit over a side wall TSW of the track and defining an outer portion 3 and an inner portion 9. The outer portion is positionable 5 outside the side wall of the track. One or more fastener(s) are passable through the outer portion to secure the fitting to the track. The inner portion is positionable inside the track to block the stud from moving along the track. Fiig 2 -2 3 Fig 5

Description

WALL AND CEILING CONSTRUCTION FIELD OF THE INVENTION

This invention relates to walls and ceilings and to components therefor. BACKGROUND TO THE INVENTION

Stud walls are commonplace in modern buildings. Such walls are typically 'nonstructural' in that they are not intended to support the ceiling under which they are mounted. Rather, stud walls principally serve to partition a space into separate rooms.

The framing of such walls typically includes: • a bottom track that runs horizontally along the floor; • a header track that runs horizontally along the ceiling; • a noggin track that runs horizontally and sits between the floor and ceiling; and • vertical studs passing through suitable apertures in the noggin track and connecting the bottom track to the ceiling track.

In the context of high-rise buildings, the stud walls are typically steel framed, signifying that the tracks and studs are formed of steel. Typically these members are roll-formed channel sections each of which includes an at least approximately planar body (or 'web') and a respective side wall (or 'flange') running along each of the long sides of its body. Typically, the long edge of each of the side walls carries a short return fold and the members are zinc treated to limit corrosion.

Typically, the bottom track is mounted so that it is upwardly open (i.e. so that its side walls project upwardly from its body), and the header track is mounted so that it is downwardly open (i.e. so that its side walls project downwardly from its body). The studs are narrower than the tracks so that they may be received within the side walls of those tracks.

Typically, each stud will be secured to the bottom track with the aid of a respective self-drilling screw on each side of the bottom track. Each self-drilling screw is passed through a side wall of the track and in turn through the side wall of the stud. The studs are likewise attached to the noggin track.

The studs are not secured to the header track in the same manner. Instead, off-cuts of stud material are secured to, and spaced along, the header track to bracket each stud. These secured off-cuts limit the stud's movement along the horizontal header track and thereby locate the stud along the track. The secured off-cuts hold the stud upright but allow the header track to move up and down relative to the stud. As such the studs are sometimes referred to as floating studs. This relative movement allows for relative movement of the floor and ceiling without overloading the stud wall. Such movement is most significant in the context of modern high-rise constructions in which millimeters of movement may be detected as the building sways in the wind, even if such movement is not perceptible to an occupant of the building.

Plasterboard, or other suitable sheet material, is mounted to the bottom track and to the studs and left to overlie the header track without fastening thereto so as not to restrict this relative movement. The top edge of the plasterboard is typically hidden behind a suitable cornice.

Steel frames are also used in the construction of ceilings. A typical ceiling batten is illustrated in Figures 9 and 10. It too is formed of roll-formed steel with a suitable anticorrosion treatment. Typical batten profiles include a central channel section CS including a body B and a pair of side walls SW diverging away from the body B. A respective flange F projects outwardly away from the end of each side wall SW, is parallel to the body B and terminates with a return fold running along its long edge.

To install a ceiling using this method, first a steel frame is installed. This entails mounting perimeter channel. Perimeter channel is channel section mounted in the vicinity of the walls and oriented to open horizontally. For convenience, the lower of the two side walls typically projects further from the body of the channel than the upper of the two side walls. The battens are cut to length and mounted upside down relative to Figures 10 and 11. The mounting typically includes inserting an end of each batten into the perimeter channel and then fastening the batten to rafters or other overlying structure. In the context of high-rise construction, the rafter might be the floor joist of an overlying floor. Typically, the battens are fastened to the overlying structure with the aid of suitable fastener(s) and/or bracket(s)

Figure 21 illustrates a channel section CS ceiling batten supported by a bracket BR fastened to an overlying body of concrete. The bracket includes a vertical web W on each side of the channel section CS. Each of the webs W includes a inwardly directed toothed edge defining receiving grooves for receiving the flange F of the channel section CS.

Typically, the battens are not secured to the perimeter channel to allow for some relative movement. Plasterboard, or other suitable sheeting material, is then attached to the bodies B of the battens.

As high-rise dwellings get bigger, and sway more in the wind, noisy stud walls are becoming increasingly problematic. Sometimes an installed stud wall can produce noise and significant resources are expended to locate the noisy joint in the wall, penetrate the adjacent sheet material, operate to reduce the noise and repair the sheet material. Various builders have their own techniques for operating on a noisy joint. Sometimes, with the aid of hand tools, the adjacent portions of the stud and/or track can be locally deformed to modify the contact. Other times a suitable lubricant can be injected. Sometimes it is as simple as squirt from an aerosol can of lightweight oil.

Despite the relative simplicity of operating on a noisy joint, it can nonetheless be a very expensive operation. Sometimes the noise only manifests under specific wind conditions, making the problem very difficult to diagnose unless a technician is able to be onsite when those wind conditions are present. Moreover, often the problem is only detected well after the building is occupied, meaning that its freshly painted walls which must be penetrated and that furniture is in the way and at risk of being damaged by workmen, etc.

Various aspects of the invention aim to provide improvements in and for stud walls, and/or ceilings, and components therefor.

It is not admitted that any of the information in this patent specification is common general knowledge, or that the person skilled in the art could be reasonably expected to ascertain or understand it, regard it as relevant or combine it in any way before the priority date.

SUMMARY

One aspect of the invention provides a fitting, for locating a stud along a track, including an integral body of plastic dimensioned to fit over a side wall of the track and defining an outer portion positionable outside the side wall of the track and through which one or more fastener(s) are passable to secure the fitting to the track; and an inner portion positionable inside the track to block the stud from moving along the track.

Preferably, the body defines a bias for biasing the outer portion towards the inner portion to in use hold the side wall so that the fitting stays in place until the fastener(s) can be placed. The fitting may define a wall, transverse to the track, for bearing against the stud, in which case the fitting may include a buttress for supporting the wall. The outer portion preferably includes one or more screw holes.

Another aspect of the invention provides a method, of locating a stud along a track, including fitting, to a side wall of the track, a plastic fitting to block the stud from moving along the track.

The fitting is preferably a resilient fitting and the method preferably includes opening the fitting, against the fitting’s resilience, to receive the side wall whereby the fitting grasps the side wall. The method may include passing a fastener through an outer portion of the fitting to engage the side wall of the track and thereby secure the fitting. At least two of the fittings may be fitted along the track to bracket the stud.

Preferably, at least two of the fittings may be fitted to each of the side walls and along the track to bracket the stud.

Another aspect of the invention provides a method, of forming a frame for a ceiling, including mounting a perimeter channel; and mounting battens; wherein the mounting battens includes fitting plastic caps to ends of at least some of the battens to form capped ends; and fitting the capped ends into the perimeter channel.

Another aspect of the invention provides a method, of forming a ceiling, including forming a frame for the ceiling; and fixing sheet material to the frame.

Another aspect of the invention provides a plastic cap, for a ceiling batten, having dimensions pre-selected to fit each of an end of the batten and within a perimeter channel. Preferably, an exterior of the plastic cap includes a lead-in portion shaped to lead the plastic cap into the perimeter channel.

Another aspect of the invention provides a cap, for suppressing noise at the juncture of a ceiling batten and a perimeter channel, including an exterior shaped for receipt, and to vertically locate the cap, within the perimeter channel; and an interior shaped to receive, and vertically locate, at least two ceiling battens having mutually different heights.

The cap preferably includes at least one set of two mutually opposing projections projecting into the interior to overlie respective flanges of a ceiling batten.

Most preferably the cap includes two of the sets vertically spaced from each other.

Another aspect of the invention provides a clip for suppressing noise in a stud wall; the clip including an integral body of plastic dimensioned to fit an end of a side wall of a stud; the body defining a separating portion for overlying an exterior of the side wall of the stud to separate the side wall of the stud from a side wall of a track; an opposing portion for bearing against an interior of the side wall; and a bias for biasing the separating portion towards the opposing portion to in a free condition of the body press the separating portion against the opposing portion; and in use hold the side wall so that the clip stays in place.

The clip is preferably formed by injection moulding. The separating portion is preferably no more than 1 mm thick. Likewise, the opposing portion is preferably no more than 1 mm thick.

Another aspect of the invention provides a method of forming a clip for suppressing noise in a stud wall; the clip including an integral body of material dimensioned to fit an end of a side wall of a stud; the body defining a separating portion for overlying an exterior of the side wall of the stud to separate the side wall of the stud from a side wall of a track; and an opposing portion for bearing against an interior of the side wall; the method including injection moulding. A clip formed in accordance with the method is also provided.

Another aspect of the invention provides a method of forming a stud wall including at one end of a stud fitting a respective clip to each side wall of the stud; and inserting the end of the stud into a track.

Another aspect of the invention provides a fitting for suppressing noise in a stud wall; the fitting including an integral body of plastic dimensioned to fit about a stud and within a hole, of a noggin track, through which the stud passes; the body defining a first separating portion for overlying an exterior of the side wall of the stud to separate the side wall of the stud from a side wall of the noggin track; and a second separating portion for overlying an exterior of a web of the stud to separate the web of the stud from a web of the noggin track.

The body preferably further defines a third separating portion for separating, from the web of the noggin track, a long outer-periphery of the side wall of the stud. A support portion may project away from the third separating portion to overlie the web of the noggin track. A support portion may project away from the second separating portion to overlie the web of the noggin track.

The first separating portion is preferably a web of material.

The second separating portion may be dimensioned to project no more than half way across the web of the stud.

Another aspect of the invention provides a fitting, for suppressing noise in a stud wall, including an integral body of plastic defining a separating portion for overlying an exterior of a side wall of the stud to separate the side wall of the stud from a side wall of a track; an opposing portion to be received by the stud to locate, in one direction along the track, the stud relative to the fitting; and a locating portion configured to be beyond a long-periphery of the side wall of the stud to locate, in at least one direction along the track, the fitting relative to the track whilst the stud is free to vertically float relative to the track.

Preferably, a connecting portion connects the separating portion to the opposing portion and is positioned to overlie a top edge of the side wall of the stud.

The fitting may be configured to clip on to the side wall of the stud.

Optionally: the track includes the side wall of the track and another side wall of the track; the locating portion includes an inner portion to be received by the track; and an outer portion to be outside the track; and the inner portion is a separating portion and the outer portion is an opposing portion to enable the fitting to be mounted on the other side wall of the track.

Another aspect of the invention provides a frame for a stud wall.

Another aspect of the invention provides a stud wall including the frame.

Another aspect of the invention provides a fitting for suppressing noise at the interface between a ceiling batten and a bracket along the length of the batten and supporting the batten; the ceiling batten having side flanges with which the bracket co-operates; the clip including portions shaped to cover portions of the flanges to separate the batten from the bracket.

The fitting preferably includes a connecting portion mutually connecting the flangecovering portions and being shaped to reside within an interior of the ceiling batten. The clip may have a length and a substantially uniform cross-section along the length. The flange-covering portions are preferably no more than about 0.5 mm thick.

Another aspect of the invention provides a method of suppressing noise between a ceiling batten and a bracket along the length of the bracket and by which the batten is supported; the method including fitting a fitting to separate the bracket from the batten.

BRIEF DESCRIPTION OF DRAWINGS

Figure 1 is a side view of a guide fitting;

Figure 3 is a cross-section view corresponding to the line A-A in Figure 2;

Figure 4 is a cross-section view corresponding to the line B-B in Figure 2;

Figure 5 is an end view of a separating-clip;

Figure 6 is a perspective view of a portion of a stud-wall frame;

Figure 7 is a perspective view of an end of a stud from inside the header track of the frame of Figure 6;

Figure 8 is a perspective view of the end of the stud of Figure 7 from the other side of the stud;

Figure 9 is a perspective view of a portion of another stud-wall frame;

Figure 10 is an end view of a ceiling batten;

Figure 11 is a perspective view of the ceiling batten;

Figure 12 is a perspective view of a separating-cap;

Figure 12a is a perspective view of a ceiling batten, perimeter channel and separating clip;

Figure 12b is a perspective view of a ceiling batten and the bracket by which it is retained;

Figure 12c is a cross-section view of a noise-suppressing clip;

Figure 12d is a cross-section view of another noise-suppressing clip;

Figure 13 is a perspective view of a noggin clip;

Figure 15 is a perspective view of a stud and a noggin fitted with the two noggin clips; Figure 16 is a side view of a guide fitting;

Figure 17 is a perspective view of a guide fitting;

Figure 18 is a perspective view of another fitting;

Figure 19 illustrates one half of an injection-mould tool; and Figure 20 is a perspective view of a slider.

DESCRIPTION OF EMBODIMENTS

The following examples are intended to illustrate to enable reproduction and comparison. They are not intended to limit the scope of the disclosure in any way.

Figures 1 to 4 illustrate a guide fitting 1 which consists of a single integral body of plastic. As used herein, 'integral' and similar terms are used in their ordinary sense to refer to a single continuous phase of material. Two bodies may be integrated through processes such as welding, but not through other processes such as typical adhesives which result in separate albeit mutually fastened bodies. Plastics such as acrylonitrile butadiene styrene (ABS), polyvinyl chloride (PVC), polypropylene (PP) and polyamide (nylon or PA, e.g. nylon 66) are suitable.

The fitting 1 includes four walls 3, 5, 7, 9 extending upwardly from a horizontal base 11. The walls 3, 5, 7 are approximately parallel to each other and in use parallel to the track side wall TSW. The wall 9 is perpendicular to the walls 3, 5, 7 and in use to the track side wall TSW.

The wall 3 is approximately square in profile and is configured to sit on the outside of the side wall TSW. The walls 3, 5 are triangular in profile and constitute buttresses for supporting the wall 9. The walls 5, 7, 9 are approximately planar, whereas the wall 3 assumes a curved shape as it is pressed against the wall 5.

The fitting 1 is formed by injection moulding. The part is vertically cored. For this purpose the wall 3 may have short landings (not shown) running along its top edge and against which ejector pins may bear to eject the part from the injection mould tool. The mould tool is shaped to initially mould an upright planar wall 3' as suggested in phantom lines in Figure 2, and also to form a bias 13 by which the wall 3 is biased towards the wall 5. Achieving such a bias is well within the ordinary skill of a tool maker. Without wishing to be bound by any particular theory, it is understood to entail the blade of the tool, by which the gap G separating the walls 3, 5 is formed, being hotter than other portions of the tool so that differential cooling of the part after it has been stripped from the tool results in internal stresses within the plastic.

The bias 13 enables the fitting 1 to clip on to the side wall TSW in a manner akin to a paperclip clipping on to a sheath of papers. As a portion of the wall 3 projects beyond the inclined edge of the walls 5, 7, that portion can be placed against the outside of the track TSW whilst the remainder of the fitting 1 is manipulated to move the wall 5 away from the wall 3 and slide the fitting on to the wall TSW so that that wall is received between the walls 3, 5.

The bias of the wall 3 towards the wall 5 grasps the side wall TSW so that the fitting 1 can remain in place by itself, thus freeing the installer's hands for the next operation. The fitting 1 is permanently fastened to the wall TSW by suitable fasteners, in this case by self-drilling screws S (Figures 7 and 8), passing through the side wall 3 and engaging the side wall TSW. For this purpose the side wall 3 has screw holes 15 passing therethrough. The screw holes are positioned to locate the screws towards the centre of the wall 3 whilst still clearing the top inclined edges of the walls 5, 7.

The screw holes 15 are preferably formed by sliding side cores in the mould tool but could be formed by a drilling operation after the part has been moulded.

Variants without the screw holes 15 are possible. The screws S could simply drill through the side wall 3. Modes of fastening other than the screws S are also possible.

Figures 7 and 8 show the clip 1 mounted to a side wall TSW so that its wall 9 is presented to block horizontal movement of a stud ST along the track T. The fitting 1 is thus positioned to locate the stud ST in one horizontal direction. Typically another fitting T (Figure 9) that is essentially a mirror image of the fitting 1 would then be fitted to the side wall TSW (in the foreground of Figure 7) so as to locate the stud ST in the other horizontal direction. The stud ST remains free to vertically move relative to the track T.

Preferably, one of the fittings 1,1' includes one or more tactile features by which it is readily distinguishable from the other of those two fittings, e.g. a bump may be formed in the centre of the wall 7.

Relative to the prior art use of stud off-cuts to locate the studs, this method is quicker and easier and eliminates potentially noisy metal to metal contact.

The inventor has also recognised that the interface between the side wall of the stud ST and the track side wall TSW is another source of noise, and to address this issue a separating clip 17 has been invented. The clip 17 is another integral body of plastic material. The clip may be formed on one of the previously mentioned plastics. The exemplary clip 17 is formed by injection moulding but has a uniform cross-section and therefore might be producible by an extrusion process. The clip 17 has a planar outer leaf 19 and a planar inner leaf 21. The leaves 19, 21 are connected by a bulbous end portion 23, one side 25 of which is thicker than the other portions of the clip 17. The end portion 23 is a bias which serves to bias the leaves 19, 21 towards each other in a manner akin to the bias 13 serving to press the walls 3, 5 against each other. The thicker portion 25 enhances the strength of the bias.

The clip 17 is configured to clip on to the stud side wall SSW (Figure 7). The leaf 19 is an outer portion of the clip which sits on the outside of the side wall SSW. The leaf 21 is an inner portion of the clip which opposes the leaf 19. In use the leaf 21 sits on an inside of the wall SSW. The clip 17 is about 35 mm high. The leaf 19 is about 5 mm longer than the leaf 21, leaving an interior portion of the leaf 19 exposed to bear against an exterior of the wall SSW whilst the remainder of the clip 17 is hand-manipulated to separate the leaves 19, 21 and place the clip 17 over the side wall SSW. The leaf 19 serves to separate the walls SSW, TSW and thereby reduce the risk of squeaking resultant from relative movement between those two walls.

Figure 9 illustrates fittings 1,1' spaced along a track side wall TSW to bracket the stud S. Clips 17 fitted to the top end of the stud separate the stud side walls SSW from the track side walls TSW to avoid noise resultant from metal to metal contact.

At the bottom end of the stud S a respective clip 17 is fitted to each of the stud side walls SSW. The outer leaves 19 of these clips space the stud side walls SSW from the bottom track side walls BTSW. The end portion 23 of each of these two clips 17 spaces the stud S from the central body of the bottom track BT.

The cap 27 of Figure 12 serves to suppress noise potentially arising from relative movement between the end of a ceiling batten and the perimeter channel in which it is received. The cap 27 is another integral body of plastic formed by injection moulding. The cap may be formed on one of the previously mentioned plastics.

The cap’s key components are a top portion 29 which serves to separate the flanges F from the top flange of the perimeter channel, a bottom portion 31 which serves to separate the body B from the bottom flange of the perimeter channel, and connecting structure connecting the portions 29, 31 to enable them to be handled and placed as a single unitary body. In this case, the connecting structure includes a pair of side walls 35 and rear wall 37.

In this case, the walls 23, 31,35 define a rectangular profile about a front opening 39 and are capped by the rear wall 37. Square-profile reinforcing portions in the vicinity of 2 mm by 2 mm run along each of the top-side corners of the cap 27.

The configuration of the cap 27 is preselected to suit the ceiling batten and the perimeter channel. The reinforcing portions 41 are mutually spaced by a distance A' corresponding to the spacing A of the extremities of the flanges F. The internal height of the cap 27 B' is selected to complement the height B of the batten. The length D' of the cap 27 is selected to exceed the length of the flanges of the perimeter channel.

In this case the dimensions A', B', D' are 52 mm, 30 mm and 30 mm, although other dimensions to suit other battens and other perimeter channels are possible.

By fitting the cap 27 to the end of a batten before it is placed into the perimeter channel, metal to metal contact at this juncture is avoided with the accompanying reduction in risk of noise. Advantageously one, or more preferably both, of the top and bottom edges 43, 45 may be chamfered (or otherwise shaped) to define lead-in portions for leading the cap 27 into the perimeter channel.

Figure 12a illustrates an alternative cap 127 for suppressing noise at the juncture of a ceiling batten CS and perimeter channel PC. The cap 127 is akin to the cap 27 but further includes a first set of internal ribs 129a, 129b and a second set of ribs 131a, 131b projecting inwards from the side walls 35 of the cap 127.

The cap 127 is dimensioned to be snugly received within the perimeter channel PC so that it is vertically located.

The ribs 129a, 129b are mutually opposed to each other and positioned to overlie the flanges F of the batten CS whereby the batten CS is captured between a floor 131 and the ribs 129a, 129b and thereby vertically located.

The set of ribs 131a, 131b is substantially identical to the set of ribs 129a, 129b but positioned lower down the side walls to overlie and vertically locate a vertically shorter batten CS. As such, the cap 127 is configured to co-operate with three distinct heights of ceiling batten CS, one for each of the sets of ribs and another one in which the flanges F sit immediately under the ceiling 129 of the cap 127.

Of course overlying structures other than the ribs 129a, 129b are possible.

It has also been recognised that the juncture illustrated in Figure 12b is another potential source of noise. And accordingly the inventor has proposed a noise suppressing clip 137 to separate the metallic bracket BRfrom the batten CS. The fitting 137 takes the form of a clip to clip onto the channel section CS. It includes on each of its sides a respective wing with a suitably shaped end portion 139a to overlie and embrace the outer edge of the flange F of the batten CS. The wings 139 are mutually connected by a central portion 141 shaped to sit into the interior of the batten CS to clear fasteners such as the bolt BT or other potential obstructions.

Advantageously the wings, including their end portions 139a, are no more than about 0.5 mm thick whereas the central portion 141 is relatively thicker at about 0.2 mm thick and therefore more robust. The relatively thin end portions enable the fitting 137 to be used with conventional batten CS and brackets BR without modification to those components.

Figure 12c illustrates the profile of the fitting 137. Preferably the fitting is about 30 mm long. This shape lends itself to construction by extrusion although injection moulding is also suitable. The previously mentioned plastics are preferred.

Figure 12d is a cross-section view of a variant 137’ of the clip 137. Wings 139’, 139” of the clip 137’ are downwardly inclined at a shallow angle from the horizontal. In this case the angle is about 8°.

Furthermore the end 139”a differs from the end 139’a to aid in the fitment of the clip to the ceiling batten. In this example the end 139a’ is a gripping end whilst the end 139a” is more open (i.e. its included angle a is larger) to more easily fit over the flange in the ceiling batten. To fit the clip 137’ the gripping end 139a’ is fitted to one of the flanges whilst the clip is pushed on to fit the fitting end 139a” over the other flange. In this example the angle a is in the vicinity of 60°.

The described combination of gripping end 139a’ and fitting end 139a” shaped to fit over the flange makes for easy installation. Configurations of gripping end and fitting end other than the illustrated configuration are possible.

Figure 13 illustrates a noggin clip 47. The noggin clip 47 is another integral body of plastic. The noggin clip 47 may be formed of one of the previously mentioned plastics.

As shown in Figures 14 and 15 the noggin clip is dimensioned to fit about the stud side wall SSW of the stud S and within a stud-hole SH of a noggin track NT. The stud S passes through the stud-hole SH.

The clip 47 includes a first separating portion in the form of web 49 configured to overlie an exterior of the side wall SSW to separate the side wall from the side wall SWNT of the noggin NT. Thus in use the web 49 is sandwiched between the side walls SSW, SWNT. An exterior 51 of the web 49 is shaped to lead the web 49 into the hole SH. A second separating portion 53 takes the form of a planar web extending away from the web 49. In use the second separating portion 53 separates the web WNT of the noggin track, or more specifically the free edge FE-ι of the stud-hole SH, from the web SW of the stud. A third separating portion 55, like separating portion 53, takes the form of a vertical planar web extending perpendicularly away from the web 49. The third separating portion 55 serves to separate the long outer periphery OP of the stud side wall SSW from the web WNT of the noggin track NT or more specifically from the free edge FE2 of the stud-hole SH.

The long outer-periphery could simply be a free edge of the stud side wall SSW. Alternatively it could be a rounded edge defined by a return fold or a planar face presented by a short inward fold of the side wall of the stud. A planar flange 57 runs along the top edge of the separating portion 53. The flange 57 is a horizontal portion configured to overlie the web WNT of the noggin track NT. A flange 59, analogous to the flange 57, runs along the top edge of the separating portion 55. The flanges 57, 59 sit on top of the web WNT to support the clip 47 against falling through the hole SH. In this example the web 49 spaces the separating portions 55, 57 by a distance X corresponding to the cross-sectional height of the stud side wall SSW. In this case X is 33 mm.

In this example the separating portions 53, 55 are rectangular each being about 5 mm high and projecting about 25 mm away from the web 49.

The projection away from a web 49 is selected to be less than the cross-sectional width of the web WNT of the noggin track NT so that a respective clip 47 can be fitted to either side of the noggin NT as suggested in Figures 14 and 15. Whilst the clip 47 is dimensioned to fit about the stud side wall SSW, an alternative form of the clip may be dimensioned to fit about the web SW of the stud.

The described construction of two clips 47 per stud-noggin juncture gives the option of placing the clips after a noggin and stud have been installed so that it is no longer practical to slide an encircling clip over an end of the stud, and along the stud to the noggin. Whilst this two clip per stud-noggin juncture construction is preferred, encircling forms of the clip are also contemplated. Likewise, four clip per stud-noggin juncture construction is also contemplated, e.g. each clip may fit about a respective 'corner' of the stud.

Figures 16 and 17 illustrate a clip 1 a which is a ‘double-sided’ variant of the clips 1, T. The clip 1a includes a wall 3a' (illustrated in its ‘as moulded’ position in Figure 17) akin to the wall 3. In place of the walls 5, 7 and 9 is an inner structure which defines blocking faces 9a, 9b. As such, the clip 1a can be positioned along the track on either side of a stud so that a respective one of its blocking faces 9a, 9b serves to locate the stud.

In this example, the inner structure of the clip 1a takes the form of a 5 mm thick U-shaped body surrounding a central opening 61. It is contemplated that the solid body could be replaced by a thin-walled arrangement. The opening 61 sits in register with the screw holes 15a passing through the leaf 3a' so that fastening screws by which the clip 1a is fastened to the side wall of the track do not contact the inner structure.

Figure 18 illustrates a clip 63 for suppressing noise at the juncture between a stud and a track. The clip 23 includes a central planar wall 65 which may be conveniently thought of as two rectangular portions 65a, 65b for reasons that will become apparent. A short connecting portion 67 projects horizontally away from a top edge of the portion 65 to connect the portion 65 to another portion 69. As moulded (and as illustrated in Figure 18), the portion 69 is a planar leaf substantially parallel to the portion 65 and spaced, by the connecting portion 65, to define an opening 71 for receiving the side wall of a stud. The connecting portion 67 is arranged to fit over the top edge of the stud side wall. As in the clip 19, the leaves 65a, 69 are biased towards each other to grip the side wall of the stud to hold the fitting 63 in place during assembly of the stud wall and frame.

In use, the portion 65a is a separating portion separating the exterior of the side wall of the stud from the interior of the side wall of the track. The leaf 69 is received within the stud so that its edge 69a constitutes a stop against which the web of the stud bears to locate the fitting 63 relative to the stud in a direction parallel to the track. A connecting portion 73 projects a short distance horizontally from a bottom edge of the portion 65b to support an outer portion 75. The outer portion 75, in its as moulded position, is substantially parallel and spaced from the portion 65b to define a space for receiving the side wall of the track. The portions 65b, 73, 75 are substantially identical to the portions 65a, 67, 69.

The portions 65b, 73, 75 together constitute a locating portion projecting beyond the long vertical periphery of the side wall of the stud to provide a convenient means for locating the clip 63 horizontally along the track. For this purpose, the leaf 75 is penetrated by a pair of screw holes 77 and the portion 65b is likewise penetrated by two screw holes complementary to the screw holes 77.

To form this juncture in the stud wall frame, the clip 63 is clipped on to the top edge of the side wall of the stud. The stud is then maneuvered to insert its top end and the portions 65a, 65b, 67 and 69 into the track, whilst the leaf 75 is left on the outside of the track. As such, during this insertion the locating portions 65b, 73, 75 clip on to the side wall of the track.

The stud is then maneuvered so that the connecting portion 73 is homed against the long peripheral edge of the side wall of the track whilst some clearance is left between the top of the side wall of the stud and the connection portion 67. The screw holes 77 are then used as guides for the placement of a pair of self-drilling screws to fix the fitting 63 relative to the track. The stud is not fixed relative to the clip 63.

Rather, it is left to vertically float, to accommodate any movement of the ceiling relative to the wall and the floor, etc. The end 69a of the inner leaf 69 acts as a stop against which the web of the stud acts to locate the stud in one horizontal direction along the track.

If the stud side wall has an inwardly directed flange, that flange can co-operate with the other horizontal extremity 69b of the leaf 69 so that the stud is also horizontally located in the other direction along the track. Alternatively, a clip such as the clip 1a may be used.

It will be appreciated that the portions 63, 75 at one end of the clip 63 are substantially identical to the portions 67, 71 at the other end of the clip 63, but for being rotated through 180° about an axis parallel to the axis of the track (and putting aside the insubstantial variation of the different location of the screw holes). As such, the clip 63 can be reversed to also be used on the other side of the track.

The walls 3, 3a', 29, 31,65 and leaves 69, 75 are preferably about 0.5 mm thick. A thickness of no more than about 1 mm enables the described fittings to be used with conventional track, stud, batten and perimeter channel profiles.

Figure 19 illustrates a portion 79 of an injection mould tool for forming the clip 17. The tool 79 is a four cavity tool having four cavities 81 a to 81 d for simultaneously forming four clips 17 with each shot of the tool. The portion 79 is shaped to define the exteriors of the leaves 17 whilst the other half of the tool defines the exteriors of the leaves 21. A pair of sliders 83 are mounted to slide within the cavities 85a, 85b defined by the two halves of the tool. Each slider 83 defines a blade 83a for defining the interiors of the leaves 17, 21. In this example the blade is a flat plate being 1.32 mm thick and having zero draft angle on its major faces. Its two side edges are drafted to one degree. The tool portion 79 is fitted with water galleries 87 and defines a sprue bush 89. The sprue bush 89 is shaped to convey molten polymer from a central aperture 91 to a respective two injection points 91 a, 91 b for each of the clips.

The injection mould tool is operated cyclically whilst water is continuously circulated through the water galleries 87 (and through similar galleries of the other half of the tool).

The tool is closed when the portion 79 and the other main half of the tool are in abutment and the blades 83 are in their innermost positions. In this configuration the cavities 81 a to 81 b are filled with liquid polymer, from the barrel of the injection moulding machine, supplied via the inlet 91 and the sprue bush 89.

The sliders 83 are then hydraulically driven so that the blades 83 clear the cavities 81a to 81 d. The tool is then opened (i.e. the two main tool portions are separated) to enable the clip 17 and the sprue bush to fall away. The clips are then manually separated from the sprue bush.

Through the above process internal stresses are created to create the bias by which the leaves 19, 21 of each clip 17 are biased towards each other.

Whilst one preferred approach to injection moulding has been described in respect of one of the preceding fittings, various other injection moulding techniques are possible and similar techniques can be applied in respect of the other preceding fittings. Extending the present teachings to other injection moulding techniques is well within the skill of one of ordinary skill in this art.

Claims

1. A fitting, for locating a stud along a track, including an integral body of plastic dimensioned to fit over a side wall of the track and defining an outer portion positionable outside the side wall of the track and through which one or more fastener(s) are passable to secure the fitting to the track; and an inner portion positionable inside the track to block the stud from moving along the track.

2. The fitting of claim 1 wherein the body defines a bias for biasing the outer portion towards the inner portion to in use hold the side wall so that the fitting stays in place until the fastener(s) can be placed.

3. The fitting of claim 1 or 2 wherein the fitting defines a wall, transverse to the track, for bearing against the stud.

4. The fitting of claim 3 including a buttress for supporting the wall.

5. The fitting of any one of claims 1 to 4 wherein outer portion includes one or more screw holes.

6. A method, of locating a stud along a track, including fitting, to a side wall of the track, a plastic fitting to block the stud from moving along the track.

7. The method claim 6 wherein the fitting is a resilient fitting and the method includes opening the fitting, against the fitting’s resilience, to receive the side wall whereby the fitting grasps the side wall.

8. The method of claim 6 or 7 including passing a fastener through an outer portion of the fitting to engage the side wall of the track and thereby secure the fitting.

9. The method of claim 6, 7 or 8 including fitting at least two of the fittings along the track to bracket the stud.

10. The method of claim 6, 7 or 8 including fitting to each of the side walls of the track at least two of the fittings along the track to bracket the stud.

11. A method, of forming a frame for a ceiling, including mounting a perimeter channel; and mounting battens; wherein the mounting battens includes fitting plastic caps to ends of at least some of the battens to form capped ends; and fitting the capped ends into the perimeter channel.

12. A method, of forming a ceiling, including forming a frame in accordance with claim 11; and fixing sheet material to the frame.

13. A plastic cap, for a ceiling batten, having dimensions pre-selected to fit each of an end of the batten and within a perimeter channel.

14. A cap, for suppressing noise at the juncture of a ceiling batten and a perimeter channel, including an exterior shaped for receipt, and to vertically locate the cap, within the perimeter channel; and an interior shaped to receive, and vertically locate, at least two ceiling battens having mutually different heights.

15. The cap of claim 15 including at least one set of two projections projecting into the interior to overlie respective flanges of a ceiling batten.

16. The plastic cap of claim 15 including two of the sets vertically spaced from each other.

17. A clip for suppressing noise in a stud wall; the clip including an integral body of plastic dimensioned to fit an end of a side wall of a stud; the body defining a separating portion for overlying an exterior of the side wall of the stud to separate the side wall of the stud from a side wall of a track; an opposing portion for bearing against an interior of the side wall; and a bias for biasing the separating portion towards the opposing portion to in a free condition of the body press the separating portion against the opposing portion; and in use hold the side wall so that the clip stays in place.

18. The clip of claim 17 formed by injection moulding.

19. The clip of claim 17 or 18 wherein the separating portion is no more than 1 mm thick.

20. The clip of claim 17, 18 or 19 wherein the opposing portion is no more than 1 mm thick.

21. A method of forming a clip for suppressing noise in a stud wall; the clip including an integral body of material dimensioned to fit an end of a side wall of a stud; the body defining a separating portion for overlying an exterior of the side wall of the stud to separate the side wall of the stud from a side wall of a track; and an opposing portion for bearing against an interior of the side wall; the method including injection moulding.

22. A clip formed in accordance with claim 21.

23. A method of forming a stud wall including at one end of a stud fitting a respective clip of any one of claims 17 to 20 and 22 to each side wall of the stud; and inserting the end of the stud into a track.

24. A fitting for suppressing noise in a stud wall; the fitting including an integral body of plastic dimensioned to fit about a stud and within a hole, of a noggin track, through which the stud passes; the body defining a first separating portion for overlying an exterior of the side wall of the stud to separate the side wall of the stud from a side wall of the noggin track; a second separating portion for overlying an exterior of a web of the stud to separate the web of the stud from a web of the noggin track;

25. The fitting of claim 24 including a support portion projecting away from the second separating portion to overlie the web of the noggin track.

26. The fitting of claim 24 or 25 including a third separating portion for separating, from the web of the noggin track, a long outer-periphery of the side wall of the stud.

27. The fitting of claim 26 including a support portion projecting away from the third separating portion to overlie the web of the noggin track.

28. The fitting of any one of claims 24 to 27 wherein the first separating portion is a web of material.

29. The fitting of any one of claims 24 to 28 wherein the second separating portion is dimensioned to project no more than halfway across the web of the stud.

30. A fitting, for suppressing noise in a stud wall, including an integral body of plastic defining a separating portion for overlying an exterior of a side wall of the stud to separate the side wall of the stud from a side wall of a track; an opposing portion to be received by the stud to locate, in one direction along the track, the stud relative to the fitting; and a locating portion configured to be beyond a long-periphery of the side wall of the stud to locate, in at least one direction along the track, the fitting relative to the track whilst the stud is free to vertically float relative to the track.

31. The fitting of claim 30 including a connecting portion connecting the separating portion to the opposing portion and positioned to overlie a top edge of the side wall of the stud.

32. The fitting of claim 30 or 31 being configured to clip on to the side wall of the stud.

33. The fitting of claim 30, 31 or 32 wherein the track includes the side wall of the track and another side wall of the track; the locating portion includes an inner portion to be received by the track; and an outer portion to be outside the track; and the inner portion is a separating portion and the outer portion is an opposing portion to enable the fitting to be mounted on the other side wall of the track.

34. A frame, for a stud wall, including at least one of the fitting of any one of claims 1 to 5 and 24 to 33; and the clip of any one of claims17 to 20 and 22.

35. A stud wall including the frame of claim 34.

36. A fitting for suppressing noise at the interface between a ceiling batten and a bracket along the length of the batten and supporting the batten; the ceiling batten having side flanges with which the bracket co-operates; the clip including portions shaped to cover portions of the flanges to separate the batten from the bracket.

37. The fitting of claim 36 including a connecting portion mutually connecting the flange-covering portions and being shaped to reside within an interior of the ceiling batten.

38. The clip of claim 36 or 37 having a length and a substantially uniform crosssection along the length.

39. The clip of any one of claims 36 to 38 wherein the flange-covering portions are no more than about 0.5 mm thick.

40. A method of suppressing noise between a ceiling batten and a bracket along the length of the bracket and by which the batten is supported; the method including fitting a fitting to separate the bracket from the batten.