AU2017201257A1

AU2017201257A1 - Stud frame

Info

Publication number: AU2017201257A1
Application number: AU2017201257A
Authority: AU
Inventors: David Humphrey
Original assignee: BlueScope Steel Ltd
Current assignee: BlueScope Steel Ltd
Priority date: 2008-06-25
Filing date: 2017-02-24
Publication date: 2017-03-16
Anticipated expiration: 2029-06-25
Also published as: AU2015202726A1; AU2017201257B2

Abstract

Abstract A stud frame in which an end of a stud 10 of channel section is positioned within a plate 12 of channel section is disclosed. Stud locator deformations 20, 20', 34, 34' are 5 provided in flange(s) of the plate and flange(s) of the stud, with a given one of the plate or stud deformation(s) 20, 20' being received in use in the corresponding stud or plate deformation(s) 34, 34' to correctly locate the stud along the plate. Stud orientation formation(s) 36, 38 are also provided in the plate 12 that are spaced separately from the plate deformation(s) 20, 20', and are adapted to ensure that the stud 10 is correctly 10 orientated when the stud end has been correctly located in the plate 12. 8764295_1 (GHMatters) P77939.AU.4

Description

2017201257 24 Feb 2017 5 15 20 30 -1 -

STUD FRAME

This application is a divisional of AU2009202559 the entire contents of which are hereby incorporated by reference in their entirety.

TECHNICAL FIELD A method for constructing a stud frame and a stud frame system are disclosed. The stud frame may suitably be constructed from elongate channel sections (eg. sections of roll-formed steel) though it is by no means limited to such components or materials. The stud frame may also find particular, though not exclusive, application as a wall frame in building construction.

BACKGROUND ART US 5,394,665 and US 5,797,233 each disclose stud wall framing constructions with spacings marked in a base track to enable rapid location of a stud, and so as to accurately space it from another stud. A reference herein to a prior art document is not an admission that the document forms a part of the common general knowledge of a person of ordinary skill in the art in Australia or elsewhere.

SUMMARY OF THE DISCLOSURE

In a first aspect there is disclosed a method for constructing a stud frame in which an end of a stud of channel section is positioned within a plate of channel section. The method comprises the steps of: - providing stud locator deformations in flange(s) of the plate and flange(s) of the stud, with a given one of the plate or stud deformation(s) being received in use in the corresponding stud or plate deformation(s) to correctly locate the stud along the plate; and - providing stud orientation formation(s) in the plate that are spaced separately from the plate deformation(s), the stud orientation formation(s) being adapted to ensure 24/02/17 8764295J (GHMatters) P77939.AU.4 -2- 2017201257 24 Feb 2017 that the stud is correctly orientated when the stud end has been correctly located in the plate.

The stud locator deformations enable a rapid and correct location of the (or each) stud along the plate. However, by providing stud orientation formation(s) in the 5 plate that are spaced separately from the plate deformation(s) it also becomes self-evident to a user as to how to correctly orient the stud into the plate during such rapid location.

In this regard, the stud orientation formations can instruct a user to orient the stud “flange to the right” or “flange to the left” as the case may be. For instance, when 10 viewing a length of plate from the side, for a “flange to the right” orientation a stud orientation formation can be located to the right of a given plate deformation, and for a “flange to the left” orientation a stud orientation formation can be located to the left of a given plate deformation.

This combination of “in-built” location and orientation in the stud frame method 15 results in a “foolproof’ stud frame assembly, ensuring that an optimal frame configuration is consistently achieved.

For example, in a wall frame the orientation of the stud flanges can be required to vary moving along the plate. More particularly, where two studs are located on either side of a door or window opening the opposing studs are usually orientated such that 2 0 one stud is “flange to the right” and the other stud is “flange to the left”. Thus, a manufacturer can in-build the required stud orientations into a “kit” frame as supplied to a user, so that the user can more simply and rapidly assemble the frame.

In one form a stud orientation formation can be provided in each of opposing flanges of the plate (ie. to oppose each other across the plate) whereby each formation 2 5 indicates where a corresponding free end of the stud flange is to be positioned. In this regard, each such flange formation can protrude into the plate channel to abut a corresponding free end of the stud flange once the stud end has been correctly located in the plate. For example, each flange formation can comprise a D-shaped flap of plate flange material that is deformed to protrude into the channel from a respective wall of 3 0 the flange, and whereby a straight edge of the D-flap can abut the stud flange free end. 24/02/17 8764295_1 (GHMatters) P77939.AU.4 -3- 2017201257 24 Feb 2017

In this one form, when the stud is of C-channel section, each flange formation can abut a respective return located at the stud flange free end.

In an alternative or additional form, the stud orientation formation can be provided in a web of the plate, whereby the formation visually indicates a correct 5 orientation of the stud flanges when locating the stud end in the plate. In this regard the web formation can be provided as eg. an arrow head shape that clearly and visually indicates the correct orientation of the stud flanges when locating the stud end in the plate.

In one form, and to ensure a “square” location of the stud in the plate, opposing 10 plate deformations are provided in respective flanges of the plate to protrude into the channel to be received in use in corresponding stud deformations that are provided in respective flanges of the stud. For example, each plate deformation can be formed to have a dimple construction, whereby a dome-like shape of the plate dimple protrudes into the channel, and wherein each stud deformation is formed to have a corresponding 15 dimple recess construction to snugly receive the dome-like shape of the plate dimple therein once the stud end has been correctly located in the plate in use. This arrangement can provide feedback to a user (eg. tactile and audible feedback) to inform the user that a correct stud location has been reached.

For efficient manufacture each of the plate and stud can be roll-formed from 2 0 metal (eg. steel) sheet, whereby the stud locator deformations can be formed into the plate or stud by a respective die that forms a part of roll-forming apparatus, and whereby the stud orientation formation(s) can be punched into the plate by another die that forms a part of roll-forming apparatus for the plate.

When assembling the stud frame the method can comprise the further step of 2 5 introducing a respective fastener to pass through each plate deformation and into the stud deformation. In this regard, each plate deformation can also act as a location point for a respective fastener.

To further assist the assembly of the stud frame the method can comprise the step of providing markings on one or both of the plate and stud, and/or the step of 3 0 providing written/printed instructions. The markings/instructions can further “foolproof’ the frame construction by indicating the correct mode of making use of the 24/02/17 8764295J (GHMatters) P77939.AU.4 -4- 2017201257 24 Feb 2017 stud locater deformations and the stud orientation formations. This can further ensure that the stud end is positioned in the channel of the plate in one correct way only.

In a second aspect there is provided a stud frame system for locating an end of a stud of channel section within a plate of channel section. 5 The system comprises the plate of channel section, with the plate comprising: - stud locator deformations in flange(s) thereof, and - stud orientation formation(s) that are spaced separately from the stud locator deformation(s); and

The system further comprises the stud of channel section, with the stud also 10 comprising stud locator deformations in flange(s) thereof.

In use of the system a given one of the plate or stud deformation(s) is adapted for being received in use in the corresponding stud or plate deformation(s) to correctly locate the stud along the plate; and the stud orientation formation(s) are adapted to ensure that the stud is correctly orientated when the stud end has been correctly located 15 in the plate.

In the second aspect each of the stud and plate can be as defined in the method of the first aspect.

The system of the second aspect can further comprise one or more fasteners that are each adapted to pass through a given plate deformation and into the stud 2 0 deformation. For example, each fastener may comprise a self-tapping fastener or rivet.

The system of the second aspect can also employ markings on one or both of the plate and stud. Additionally or alternatively, the system can employ instructions that indicate a correct mode of making use of the stud locater deformations and the stud orientation formation(s), so as to ensure that the stud end is positioned in the channel of 2 5 the plate in one correct way only.

In a third aspect there is provided a plate of channel section for receiving an end of a stud of channel section therein, the plate comprising: - opposing stud locator deformations in opposing flanges thereof; and - stud orientation formation(s) that are spaced separately from the stud locator 3 0 deformations, with the stud orientation formation(s) being provided in: 24/02/17 8764295 1 (GHMallers) P77939.AU.4 -5- 2017201257 24 Feb 2017 (i) opposing flanges of the plate, whereby each formation can indicate in use where a corresponding free end of the stud flange is to be positioned; and/or (ii) in a web of the plate, whereby the formation can indicate in use a correct orientation of the stud flanges when locating the stud end in the plate. 5 The plate of the third aspect can be otherwise as defined in the first aspect. A further disclosure relates to a method for constructing a stud frame in which a stud end is positioned within a plate of channel section. The method comprises the steps of: - providing a deformation in one flange only of the plate of channel section, the 10 deformation protruding into the channel; and - providing a deformation in one side only of the stud end, whereby the stud deformation is alignable with the plate deformation when the stud end is positioned within the channel of the plate in use.

By providing the deformation in one flange only of the plate and in one side 15 only of the stud end it becomes self-evident to a user as to how to correctly insert the stud into the plate (ie. by only inserting so that the deformations align).

When, for example, the stud is also of channel section, the stud/plate deformations can function to instruct a user to place the stud “flange to the right” or “flange to the left” as the case may be. For example, in a wall frame that employs studs 2 0 of channel section, the orientation of the stud flanges can be required to vary moving along the plate. For example, where two studs are located on either side of a door or window opening the opposing studs are usually orientated such that one stud is “flange to the right” and the other stud is “flange to the left”. Thus, a manufacturer can in-build the required stud orientations into a “kit” frame as supplied to a user. 2 5 In this regard, the deformation that is provided in the one side only of the stud end can be provided in one flange only of the stud channel section. Thus, by preconfiguring one flange only of a given stud with such a deformation, the user can be informed as to the stud orientation that is to be employed at a given location on the plate. 30 24/02/17 8764295J (GHMallers) P77939.AU.4 -6- 2017201257 24 Feb 2017

BRIEF DESCRIPTION OF THE DRAWINGS

Notwithstanding any other forms which may fall within the scope of the stud frame system and method for constructing a stud frame as defined in the Summary, a specific embodiment of the system and method will now be described, by way of 5 example only, with reference to the accompanying drawings in which:

Figures 1 and 2 respectively show two alternative perspective (3D) views of a stud positioned with reference to a plate according to a first embodiment; and

Figures 3A and 3B respectively show a side view, and a plan-section taken through the stud/plate of Figure 3A (on the line B-B). 10

DETAILED DESCRIPTION OF SPECIFIC EMBODIMENTS

Referring to Figures 1 to 3 a stud framing system is depicted wherein the end of a stud 10 of C-shaped channel section has been located within a plate 12 of U-shaped channel section. 15 The plate 12 comprises a web 14 and two opposing flanges 16 and 18. A stud locator system for rapidly attaining the correct location of the stud along the plate employs, in this case, two stud locator deformations on the plate in the form of dimple constructions 20, 20’. Dimple construction 20 is formed in the flange 16 and dimple construction 20’ is formed in the flange 18. A dome-like shape 21 of each dimple 2 0 protrudes into the channel U of plate 12. The use of two opposing dimple constructions 20 and 20’, whilst not essential, is the simplest way of ensuring that the stud 12 is “squarely” located in the channel U of plate 12, as best shown in Figure 3B.

The stud 10 comprises a web 24 and two opposing flanges 26 and 28. Returns 30 and 32 are defined at the free ends of the flanges 26 and 28. Again, the stud locator 2 5 system employs, in this case, two stud locator deformations on the stud in the form of dimple recess constructions 34, 34’. The dimple recess 34 is formed in the flange 26 and dimple recess 34’ is formed in the flange 28. Each dimple recess is sized and located to snugly receive the dome shape 21 of the plate dimple 20 or 20’ therein (Figure 3B) once the stud end has been correctly located within and along the plate as 3 0 shown. 24/02/17 8764295J (GHMatters) P77939.AU.4 -7- 2017201257 24 Feb 2017

The stud locator system is also configured to provide feedback to a user that correct stud location has taken place (ie. correct location can provide both a tactile feel and an audible sound to a user).

As shown in Figures 1, 2 and 3B, the stud 10 is orientated “flange to the right”. 5 When the stud framing system is used to construct a stud wall frame, the orientation of the stud flanges (ie. to the right or to the left) can be required to vary, moving along the plate. For example, where two studs are located on either side of an opening for a door or window the opposing studs are typically orientated such that, facing the door or window, one stud (ie. the right-hand stud) is “flange to the right” and the other stud (ie. 10 the left-hand stud) is “flange to the left”.

To enable a manufacturer that supplies the stud wall frame as a kit to in-build the required stud orientations (ie. to ensure not only correct location of the stud along the plate but its correct orientation at a given location), stud locator formations can be provided. In Figures 1 to 3 two types of stud locator formations are depicted that can be 15 used separately or together. A first such stud locator formation is depicted in the form of D-shaped locator flaps 36 and 38 that are directly opposed to each other across the channel U of plate 12. The locator flaps 36 and 38 are punched by a die into a respective flange 16, 18 of the plate during the roll-forming of the plate channel section. Each locator flap is spaced 2 0 separately from and in relation to the plate dimples 20, 20’ such that, when the stud end has been correctly located along the plate, a respective external face of each stud return 30 and 32 abuts a respective locator flap 36 and 38.

Again, the use of two opposing locator flaps 36 and 38, whilst not essential, also ensures that the stud 12 is “squarely” located and correctly orientated in the channel U 2 5 of plate 12.

In the plate orientation of Figures 1 to 3 the locator flaps 36 and 38 are located to the right of the plate dimple 20. This also instructs a user that the correct stud orientation is a “flange to the right” configuration. If the particular stud location requires a “flange to the left” configuration, then the location of the D-shaped locator 3 0 flaps 36 and 38 can be reversed, as shown by the dotted outline for locator flap 36’. The 24/02/17 8764295 1 (GHMatters) P77939.AU.4 -8- 2017201257 24 Feb 2017 user can be further guided by markings and/or printed instructions that indicate that the stud returns are to abut the locator flaps. A second stud locator formation is depicted in Figure 3B in the form of arrow-shaped aperture 40 formed in the web 14 of plate 12. Again, the aperture 40 can be 5 punched by a die into the web of the plate during roll-forming. In Figure 3B the arrow shape directs the user to insert the stud 10 “flange to the right”. Also, in the particular location selected for aperture 40, the “tip” of the arrow-shape aligns with the web 24 of stud 10, which can again provide a further guide for correct stud orientation to a user.

Once the stud 10 has been correctly located and orientated in the plate 12 a self-10 tapping fastener (eg. a TEK screw) or a rivet can be driven through each plate dimples 20 and 20’ and into and through the respective dimple recesses 34 and 34’ to fasten the plate and stud together.

As mentioned above, the system can employ additional markings on one or both of the plate and stud to indicate a correct mode of using, locating and orientating each 15 stud 10 on the plate 12. The markings can also be used to delineate particular components (eg. a base plate or top plate, a right or left window stud, a right or left door frame stud, etc). This can also allow like components to be manufactured and prepackaged together into a kit for later easy on-site sorting and assembly.

These additional markings can be symbols and/or words that are engraved, 2 0 punched or printed (eg. by inkjet or using stickers) on either or both of each plate 12 and each stud 10. Such markings can further reinforce how the correct location and orientation of each stud is to be obtained.

As mentioned above, the system can alternatively or additionally supply written and drawn (eg. printed) instructions to indicate a correct mode of locating and 2 5 orientating the stud at the plate, to make best and correct use of the plate dimples, stud dimple recesses and D-shaped locator flaps. The markings and instructions can further ensure that a given stud end is positioned at a given location and orientation in the channel of plate 12, in one correct way only, to thereby foolproof the assembly. 30 24/02/17 8764295J (GHMatters) P77939.AU.4 -9- 2017201257 24 Feb 2017

Example - Method of Constructing a Stud Frame Stud

Each stud of C-section was roll-formed from steel sheet. The dimple recess constructions 34, 34’ were formed into the sheet at a location corresponding to each 5 stud end, by a respective die that formed a part of the stud roll-forming apparatus.

Plate

Each plate of U-section channel was also roll-formed from steel sheet. The plate dimples 20, 20’ were formed into the sheet at a position corresponding to a required stud location, again by a respective die that formed a part of the plate roll-forming 10 apparatus. The D-shaped stud locator flaps 36 and 38 and aperture 40 were punched into the plate by a die that also formed a part of the plate roll-forming apparatus.

In the manufacture of the stud and plate, the simplest way of producing a resultant “flange to the right” or “flange to the left” configuration in the resultant frame was to vary the location of punching of the D-shaped stud locator flaps 36 and 38 in the 15 plate (eg. see flap 36’ in Figure 3A).

In an optional manufacturing step, markings (such as further arrows, notches and letters) were rolled into one or both of the plate and stud by the respective dies. These indicated a correct mode of inserting the stud into the plate to make sure that the dimple recesses aligned with and received the plate dimples, and to ensure that the stud 2 0 would be orientated in the plate in one way only. They also helped to delineate one stud type from another and one plate type from another.

Frame

The now-roll formed studs and plates were assembled. Written/drawn printed instructions supplied with the studs and plates instructed the user as to the correct mode 2 5 of locating the stud at the plate, making use of the plate dimples, the stud dimple recesses, the D-shaped stud locator flaps and the web aperture 40. In this regard, the stud end was urged (eg. tapped by a hammer/mallet) along and into the channel U of the plate until the dimple recesses 34, 34’ aligned with and received the respective plate dimples 20, 20’ therein. At the same time, the stud returns 30 and 32 were brought into 3 0 abutment with respective D-shaped locator flaps 36 and 38. 24/02/17 8764295_1 (GHMatters) P77939.AU.4 -10- 2017201257 24 Feb 2017

Then, one or more fasteners (eg. TEK screws or rivets) were inserted through each plate dimple 20, 20’ and into respective dimple recesses 34, 34’ to fasten each stud to the plate.

This process was repeated along the plate (eg. along lower and upper plates of 5 the frame) to complete the stud frame construction.

Whilst a number of specific system and method embodiments have been described, it should be appreciated that the system and method may be embodied in many other forms. 10 For example, whilst a stud of C-section has been described, the stud could be of U-section, or of closed hollow section, or even of a solid member for insertion into the plate channel. The stud deformations would then be provided in the requisite external faces of the stud.

In the claims which follow and in the preceding description, except 15 where the context requires otherwise due to express language or necessary implication, the word “comprise” or variations such as “comprises” or “comprising” is used in an inclusive sense, i.e. to specify the presence of the stated features but not to preclude the presence or addition of further features in various embodiments of the method and system. 20 24/02/17 8764295_1 (GHMatters) P77939.AU.4

Claims

Claims

1. A method for constructing a stud frame in which an end of a stud of channel section is positioned within a plate of channel section, the method comprising the steps of: - providing stud locator deformations in flange(s) of the plate and flange(s) of the stud, with a given one of the plate or stud deformation(s) being received in use in the corresponding stud or plate deformation(s) to correctly locate the stud along the plate; and - providing stud orientation formation(s) in the plate that are spaced separately from the plate deformation(s), the stud orientation formation(s) being adapted to ensure that the stud is correctly orientated when the stud end has been correctly located in the plate.
2. A method as claimed in claim 1 wherein the stud orientation formation(s) are provided in: (i) opposing flanges of the plate, whereby each formation indicates where a corresponding free end of the stud flange is to be positioned; and/or (ii) in a web of the plate, whereby the formation visually indicates a correct orientation of the stud flanges when locating the stud end in the plate.
3. A method as claimed in claim 1 wherein in: (i) each flange formation protrudes into the plate channel to abut a corresponding free end of the stud flange once the stud end has been correctly located in the plate; and/or (ii) the web formation has an arrow head shape that indicates the correct orientation to be assumed by the stud flanges when locating the stud end in the plate.
4. A method as claimed in claim 5 wherein in (i) each flange formation comprises a D-shaped flap of plate flange material that is deformed to protrude into the channel from a respective wall of the flange, and whereby a straight edge of the D-flap abuts the stud flange free end.
5. A method as claimed in claim 3 or 4 wherein the stud is of C-channel section, whereby each flange formation abuts a respective return located at the stud flange free end.
6. A method as claimed in any one of the preceding claims wherein opposing plate deformations are provided in respective flanges of the plate to protrude into the channel to be received in use in corresponding stud deformations that are provided in respective flanges of the stud.
7. A method as claimed in claim 6 wherein each plate deformation is formed to have a dimple construction, whereby a dome-like shape of the plate dimple protrudes into the channel, and wherein each stud deformation is formed to have a corresponding dimple recess construction to snugly receive the dome-like shape of the plate dimple therein once the stud end has been correctly located in the plate in use.
8. A method as claimed in any one of the preceding claims wherein each of the plate and stud is roll-formed from metal sheet, whereby the stud locator deformations are formed into the plate or stud by a respective die that forms a part of roll-forming apparatus, and whereby the stud orientation formation(s) are punched into the plate by a die that forms a part of roll-forming apparatus for the plate.
9. A method as claimed in any one of the preceding claims comprising the further step of introducing a respective fastener to pass through each plate deformation and into the stud deformation.
10. A method as claimed in any one of the preceding claims comprising the further step of providing markings on one or both of the plate and stud, and/or providing instructions, that indicate a correct mode of making use of the stud locater deformations and the stud orientation formation(s), so as to ensure that the stud end is positioned in the channel of the plate in one correct way only.
11. A method for constructing a stud frame substantially as herein described with reference to the accompanying drawings.
12. A stud frame system for locating an end of a stud of channel section within a plate of channel section, the system comprising: - the plate of channel section, the plate comprising: - stud locator deformations in flange(s) thereof, and - stud orientation formation(s) that are spaced separately from the stud locator deformation(s); and - the stud of channel section, with the stud also comprising stud locator deformations in flange(s) thereof; wherein a given one of the plate or stud deformation(s) is adapted for being received in use in the corresponding stud or plate deformation(s) to correctly locate the stud along the plate; and wherein the stud orientation formation(s) are adapted to ensure that the stud is correctly orientated when the stud end has been correctly located in the plate.
13. A system as claimed in claim 12 wherein each of the stud and plate are as defined in any one of claims 2 to 8.
14. A system as claimed in claim 12 or 13 that further comprises one or more fasteners that are each adapted to pass through a given plate deformation and into the stud deformation.
15. A system as claimed in any one of claims 12 to 14 that further comprises markings on one or both of the plate and stud, and/or instructions, that indicate a correct mode of making use of the stud locater deformations and the stud orientation formation(s), so as to ensure that the stud end is positioned in the channel of the plate in one correct way only.
16. A stud frame system substantially as herein described with reference to the accompanying drawings.
17. A plate of channel section for receiving an end of a stud of channel section therein, the plate comprising: - opposing stud locator deformations in opposing flanges thereof; and - stud orientation formation(s) that are spaced separately from the stud locator deformations, with the stud orientation formation(s) being provided in: (i) opposing flanges of the plate, whereby each formation can indicate in use where a corresponding free end of the stud flange is to be positioned; and/or (ii) in a web of the plate, whereby the formation can indicate in use a correct orientation of the stud flanges when locating the stud end in the plate.
18. A plate as claimed in claim 17 that is as further defined in any one of claims 3 to 8.