AU2021104508A4

AU2021104508A4 - A Building Frame and A Bracing Channel

Info

Publication number: AU2021104508A4
Application number: AU2021104508A
Authority: AU
Inventors: Clinton Wells
Original assignee: Worldwide Truss And Frames Pty Ltd
Current assignee: Worldwide Truss And Frames Pty Ltd
Priority date: 2020-09-04
Filing date: 2021-07-23
Publication date: 2021-09-16
Anticipated expiration: 2029-07-23

Abstract

The present invention provides a bracing channel adapted to be secured to a plurality of spaced apart studs of a building frame. The bracing channel comprises an elongate element having a web with at least one spanning section. Each of the at least one spanning sections has a flange extending from each side of the web at an angle thereto, and a plurality of fastening sections, wherein each fastening section is thinner than the spanning section and is adapted to be attached to the studs. 10 4 Lt 22a~ 24d 26~ 22e 2,5tG27 27e

Description

4 Lt

22a~

24d

26~ 22e

2,5tG27 27e

A Building Frame and A Bracing Channel.

TECHNICAL FIELD

[0001] The present invention relates to building frames including wall frames used for erecting buildings.

[0002] The invention has been devised particularly, although not necessarily solely, in relation to bracing the studs of building frames, using a bracing channel.

BACKGROUND ART

[0003] The following discussion of the background art is intended to facilitate an understanding of the present invention only. The discussion is not an acknowledgement or admission that any of the material referred to is or was part of the common general knowledge as at the priority date of the application.

[0004] Building frames typically include an outer periphery defined by upper and lower plates and outer studs with a plurality of inner studs. The inner studs are surrounded by the periphery and extend between the outer studs in a spaced apart relationship with respect to each other. In order to add strength and rigidity to the studs, horizontal bracing pieces (noggins) are attached between the studs.

[0005] The noggins may be timber pieces which are positioned between neighboring studs. During assembly of the building frame the noggins have to be cut to length and attached, one at a time, between the studs. This process is typically cumbersome and time consuming, in particular, if the building frame is relatively large.

[0006] Solutions have been developed to try to overcome the above disadvantage. One such solution consists of a metal strip with a uniform C-shaped cross section along its entire length. In use, the metal strip is attached to each of the studs in place of timber noggins, with the webbing of the strip secured against the surface of a rebate. The disadvantage of this type of noggin is that the studs have to incorporate a rebate sufficient in depth for receiving respective portions of the metal strip. The inclusion of the rebate of a relatively large depth reduces the strength of studs, compromising the robustness of the frame. To compensate for the reduction in strength one or more additional metal strips are connected to the studs in order to provide sufficient strength to the building frame. This increases costs.

[0007] A further disadvantage of the above-mentioned metal strip is that, when the metal strip is received in the rebate and attached to the studs, the exposed surface of the stud is irregular, with the metal strip presenting an indent. This defines an uneven surface making it cumbersome and time consuming to attach cladding and wall panels to the building frames.

[0008] It is against this background that the present invention has been developed.

SUMMARY OF INVENTION

[0009] According to a first aspect of the invention there is provided a bracing channel adapted to be secured to a plurality of spaced apart studs of a building frame, the bracing channel comprising an elongate element having a web with at least one spanning section, each of the at least one spanning sections having a flange extend from either side of the web at an angle thereto, and a plurality of fastening sections, each fastening section being thinner than the spanning section and being adapted to be attached to the studs.

[0010] According to a second aspect of the invention there is provided a bracing channel adapted to be secured to a plurality of spaced apart studs of a building frame, the bracing channel comprising an elongate element having a web with a flange extending from each end of the web, the elongate element incorporates a plurality of spanning sections, wherein the flanges of each spanning section extend outwardly from the ends of the web at an angle thereto, the elongate element further incorporates fastening sections located between each spanning section and at each end of the bracing channel, wherein the flanges at each of the fastening sections is adjacent the web such that the fastening section is thinner than the spanning section, the fastening sections being adapted to be fastened to the studs.

[0011] According to a third aspect of the invention there is provided a bracing channel adapted to be secured to a plurality of spaced apart studs of a building frame, the bracing channel comprising a web and is generally elongate in form, the bracing channel being formed from at least one spanning section which spans between two fastening sections, the spanning section having a flange extending from each end of the web, wherein the flanges of each spanning section extend outwardly from the ends of the web at an angle thereto, the fastening sections having a flange extending from each end of the web wherein the flange is adjacent to the web such that the fastening section is thinner than the spanning section, the fastening sections being adapted to be fastened to the studs.

[0012] Preferably the bracing channel incorporates a plurality of spanning sections.

[0013] Each flange may comprise two sections folded over each other such that the thickness of each flange is twice that of the web.

[0014] Preferably, each spanning section is located between a pair of fastening sections.

[0015] Preferably, the fastening sections are relatively thin permitting attachment of the fastening sections to studs with relatively shallow or no rebates formed in the studs.

[0016] The thickness of the thickest portion of the fastening section may be 3 mm or less.

[0017] Preferably, each fastening section to be attached to a stud comprises a portion of the web having reinforced sides.

[0018] Preferably, the reinforced sides comprises flanges located adjacent the inner surface of the web.

[0019] Preferably, the bracing channel is made out of metal material.

[0020] Preferably, the bracing channel is roll-formed out of coiled steel.

[0021] Preferably, the flanges are oriented with respect to the web at an angle 90 degrees or less.

[0022] Preferably, the angle is 75 degrees.

[0023] Preferably, each flange of each spanning section comprise a free end having a rolled down lip.

[0024] Preferably, each flange has a length of 10 mm.

[0025] According to a fourth aspect of the invention there is provided a building frame having upper and lower plates and outer studs joined together defining an outer periphery surrounding a plurality of inner studs arranged in a spaced apart relationship with respect to each other and attached to the upper and lower plates, the building frame comprising at least one bracing channel as herein described attached to the inner and outer studs.

[0026] Preferably, the studs comprise relatively shallow rebates.

[0027] Preferably, the rebates have a maximum depth of 5 mm.

[0028] In an alternative arrangement, the studs are devoid of rebates.

[0029] According to a fifth aspect of the invention there is provided a method for manufacturing a building frame, the method comprising the steps of:

joining together the outer studs and lower and upper plates and attaching the inner studs by fastening the ends of the inner studs to the lower and upper plates; and

attaching at least one bracing channel as herein described to the inner and outer studs.

[0030] Preferably, the method further comprises the step of roll-forming the bracing channel out of coiled steel.

[0031] Preferably, the method further comprises the step of roll-forming the bracing channel out of coiled steel and forming the fastening sections at the required position.

[0032] Preferably, the method further comprises the step of roll-forming the bracing channel out of coiled steel, forming the fastening sections at the required position and fastening the bracing channel to the studs.

[0033] According to a sixth aspect of the invention there is provided a forming machine to form a bracing member according to a method of manufacturing a building frame as herein described.

[0034] According to a seventh aspect of the invention there is provided a forming machine to carry out a method of manufacturing a building frame as herein described.

[0035] According to an eighth aspect of the invention there is provided a forming machine to form a bracing member as herein described.

BRIEF DESCRIPTION OF THE DRAWINGS

[0036] Further features of the present invention are more fully described in the following description of several non-limiting embodiments thereof. This description is included solely for the purposes of exemplifying the present invention. It should not be understood as a restriction on the broad summary, disclosure or description of the invention as set out above. The description will be made with reference to the accompanying drawings in which:

Figure 1 is a front view of a particular arrangement of building frame in accordance with the present embodiment of the invention;

Figure 2 is a cross-sectional view along the line C-C of the building frame shown in figure 1;

Figure 3 is a cross-sectional view along the line B-B through a fastening section of a bracing channel of the building frame shown in figure 1; and

Figure 4 is a cross-sectional view along the line A-A through a vertical stud of the building frame shown in figure 1.

DESCRIPTION OF EMBODIMENT(S)

[0037] Figure 1 shows a particular arrangement of a building frame 10 in accordance with the present embodiment of the invention.

[0038] The building frame 10 comprises upper plate 12a and lower plate 12b and outer studs 14a, 14b. The lower and upper plates 12a, 12b and outer studs 14a, 14b are joined together in such a manner that an outer periphery 16 of the building frame 10 is defined. The outer periphery 16 surrounds a plurality of inner studs 18 (18a, 18b, 18c, 18d).

[0039] The plurality of inner studs 18 are arranged in a spaced apart relationship with respect to each other and are located between outer and inner studs 14a, 14b. The inner studs 18 extend between the upper and lower plates 12a, 12b with ends of the studs 18 being attached to the lower and upper plates 12a, 12b defining the building frame 10 as shown in figure 1.

[0040] In the particular arrangement shown in figure 1, the building frame 10 further comprises a bracing channel 20 attached to the outer studs 14a, 14b and inner studs 18. The bracing channel 20 provides rigidity to the building frame 10 as the bracing channel 20 braces the studs 14a, 14b and 18a to 18d minimising movement of the studs 14a, 14b, 18a to 18d relative to the plates 12a, 12b when, for example, load is applied to the building frame 10.

[0041] Referring now to figure 2. Figure 2 is a cross-sectional view of the building frame 10 along the C-C line shown in figure 1.

[0042] The bracing channel 20 comprises an elongate element having a web 26 and a plurality of flanges 27 extending from sides of the web 26.

[0043] The bracing channel 20 comprises ends 22 adapted to be attached to the outer studs 14a, 14b and fastening sections 24 adapted to be attached to inner studs 18. The fastening sections 24 are arranged in a spaced apart relationship with respect to each other whereby when secured to the studs, each fastening section 24 may be fastened to a respective inner stud 18, as shown in figure 2.

[0044] Further, the bracing channel 20 according to the present embodiment is divided into five spanning sections 28a to 28e with neighboring spanning sections being linked by one of the fastening sections 24. Each spanning section 28 is defined by a portion of the web 26 from which a pair of flanges 27c and 27c' extend, as is shown best in figure 3.

[0045] Figure 3 is a side cross-sectional view of the building frame 10 along the line B-B shown in figure 1 showing the cross section of the spanning section 28c.

[0046] As shown in figure 3, the spanning section 28c comprises a portion 30c of the web 26 with flanges 27c and 27c' extending from the sides of the portion 30c of the web 26. In the particular arrangement shown in the figure 3, each flange 27 is oriented at an angle of 750 with respect to the surface of the web 26 and have a length of 10 mm. A person skilled in the art would readily understand that this angle and dimension can vary depending on the required application, with such variations being considered to fall in the scope of this invention.

[0047] The remaining spanning sections 28a, 28b, 28d and 28e are substantially identical to the spanning section 28c depicted in figure 3.

[0048] Each flange 27 comprises an end 32 (the free end) which is thicker than the remaining part of the flange 27. In the particular arrangement shown in figure 3, the ends 32 of the flanges 27 are defined by a rolled down lip 34 rolled down in such a manner that the lip 34 is adjacent the inner surface of remaining part of the flange 27. The rolled down lip 34 provides a blunt end (a safe edge) to each of the flanges 27 to avoid injury during handling of the bracing channel 20. The rolled down lip 34 reinforces the flanges 27 and the bracing channel 20 as a whole in conjunction with the flanges 27.

[0049] Further, as mentioned before, the ends 22 and fastening sections 24 are adapted to be attached to the outer studs 14a, 14b and inner studs 18. For this, the ends 22 and fastening sections 24 are configured in a particular manner for attaching the ends 22 and fastening section 24 to the outer studs 14a, 14b and inner studs 18. As will be described later, the manner in which the ends 22 and fastening sections 24 are configured facilitates attachment of the bracing channel 20 to the outer studs 14a, 14b and inner studs 18 reducing the time that is currently required for assembly of conventional building frames 20.

[0050] The ends 22 are configured in substantially the same manner as the fastening sections 24. Thus, the description below related to how the fastening sections 24 are configured for attachment to the inner studs 18 also apply to the ends 22.

[0051] Figure 4 depicts a side cross-sectional view of the building frame 10 along line A-A shown in figure 1. Figure 4 shows the fastening section 24d attached to the inner stud 18d. The remaining fastening sections 24a to 24c are substantially identical to the fastening section 24d depicted in figure 3.

[0052] As shown in figure 4, each fastening section 24 (as well as ends 22) comprise a second portion of the web 26 having reinforced sides 33a and 33b providing maximum lateral strength to the bracing channel 20 at each side of the studs 18. Also, each fastening section 24 (as well as ends 22) are relatively thin when compared to other noggins made from metal strips. In an arrangement, the thickness of each section 24 may be 1.65 mm. A person skilled in the art would readily understand that the thickness can vary depending on the required application/arrangement, with such variations being considered to fall in the scope of this invention.

[0053] The fact that each fastening section 24 is relatively thin is particularly advantageous because it avoids the need for deep rebates 38 to accommodate the thickness of the fastening section 24. Instead, in accordance with the present embodiment of the invention, a minimal checkout of the studs 14a, 14b and 18 (for defining the rebates 38) is required, such as, for example, a maximum depth of 5 mm. In alternative arrangements, the rebates 38 of the studs 14a, 14b and 18 may be omitted facilitating assembly of the building frame 10 by further reducing time and costs.

[0054] Due to the minimal checkout of the studs 14a, 14b and 18, there is minimal reduction in the strength of the studs, resulting in the need for the same number of bracing channels 20 as would be found in a frame having timber noggins. For example, a single bracing channel 20 for wall frames up to 2.7 m high is sufficient in order to provide the required strength to the building frame 10. This is in sharp contrast with other metal strip noggins where two or more rows of noggins are required to compensate for the reduction in strength of the studs caused by forming rebates 38 having a depth of at least 10 mm to accommodate the thickness of the metal strip nogging.

[0055] Further, in the particular arrangement shown in figure 4, each section 24 is defined by rolling over the ends 32 of the flanges 27 in such a manner that ends of the flanges 27 (once rolled over) are located adjacent the inner surface 36 of the web 26. Rolling over the flanges 27 is done with the objective of forming the reinforced sides 33 and reducing the thickness of the fastening section 24.

[0056] Furthermore, as shown in figure 4, the fastening section 24 (as well as ends 22) are attached to the studs 14a, 14b and 18 with the reinforced sides 32 abutting the surface 40 of the inner stud 18 (or outer stud 14a, 14b). As the outer surface 42 of the web 26 is substantially in line with the outer surface of the stud, external cladding and sheet products can be easily attached to the building frame 10.

[0057] The bracing channel 20 may be made of metal materials such as galvanised steel. In particular, the bracing channel 20 may be roll-formed out of coiled steel.

[0058] In a particular arrangement in accordance with the present embodiment of the invention, the bracing channel 20 is manufactured using a metal strip which is continuously bent to obtain the particular configuration of the bracing channel 20 described above and depicted in the figures.

[0059] In particular, the metal strip may be passed through a set of rollers spaced apart with respect to each other, wherein the rollers, for example, are configured and oriented in a particular manner and spaced apart specific distances in order to define the particular cross sections along the length of the bracing channel 20. These particular cross sections of the bracing channel 20 define (1) the plurality of flanged section 28 with flanges 27 oriented at a particular angle with respect to the surface 42 of the web 26 and (2) the ends 22 and the plurality of fastening sections 24 with the flanges 27 rolled over for defining the reinforced sides 33. In other embodiments the flanges 27 may be pressed down or crushed to form the fastening sections.

[0060] Furthermore, the method for assembling the building frame 10 in accordance with the present embodiment of the invention comprises the steps of joining together the outer studs 14a, 14b and lower and upper plates 12a, 12b to define the periphery 16 and attaching the inner studs 18 within the perimeter 16 by fastening the ends of the inner studs 18 to the lower and upper plates 12a, 12b.

[0061] Subsequently, the bracing channel 20 may be attached to the inner and outer studs via, for example, screws. In one arrangement, the rebates 38 may be formed in the inner and outer studs 18 and 14a, 14b for receiving the ends 22 and fastening sections 24 of the bracing channel 20.

[0062] Alternatively, the ends 22 and fastening sections 24 may be fastened directly to the surfaces of the inner and outer studs 14a, 14b and 18 without having the need to form the rebates 38 in the studs 14a, 14b and 18.

[0063] In one arrangement, the bracing channel 20 may be a pre-fabricated bracing channel 20 with its length and spacing between the fastening sections 24 configured in such a manner that the ends 22 and fastening sections 24 may be attached to the outer and inner studs 14a, 14b and 18 of a particular building frame 10.

[0064] Alternatively, the bracing channel 20 may be manufactured using equipment incorporating a roll-forming machine (not shown) having an uncoiler for uncoiling the coiled steel and the roller sets arranged and configured for defining the particular cross sections of the bracing channel 20 required for attachment to the inner and outer studs 14a, 14b and 18 of the particular building frame 10 that is being assembled. Manufacturing the bracing channel 20 in situ is particularly advantageous as it allows the bracing channel 20 to be tailored to the required dimensions in accordance with the design of the building frame 10. Thus, there is no need to adjust the length of the bracing channel 20 by, for example, cutting metal noggins to fit the building frames 10. The roll forming machine may also form the fastening sections 24 by compressing the bracing channel 20 in the area a fastening section 24 is required, causing the flanges 27 to deflect inwardly to lie adjacent the underside of the web 26. Alternatively the flanges 27 may be otherwise deform such that the fastening section 24 presents a thin section.

[0065] Modifications and variations as would be apparent to a skilled addressee are deemed to be within the scope of the present invention. For example, the previously described bracing channel 20 is configured for a building frame 10 as shown in figure 1. However, in accordance with other arrangements, the bracing channel 20 of the invention may be used in connection with building frames having any suitable shape as well as for attachment to floor joists to avoid twisting or rotating under load.

[0066] Further, it should be appreciated that the scope of the invention is not limited to the scope of the embodiments disclosed. These embodiments are intended for the purpose of exemplification only. Functionally equivalent products, formulations and methods are clearly within the scope of the invention as described herein.

[0067] Reference to positional descriptions, such as lower and upper, or inner and outer, are to be taken in context of the embodiments depicted in the figures, and are not to be taken as limiting the invention to the literal interpretation of the term but rather as would be understood by the skilled addressee.

[0068] The terminology used herein is for the purpose of describing particular example embodiments only and is not intended to be limiting. As used herein, the singular forms "a", "an" and "the" may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms "comprise", "comprises," "comprising," "including," and "having," or variations thereof are inclusive and therefore specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.

[0069] Although terms such as first, second, third, etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as "first," "second," and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example embodiments.

[0070]Spatially relative terms, such as "inner," "outer," "beneath", "below", "lower", "above", "upper" and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. Spatially relative terms may be intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as "below" or "beneath" other elements or features would then be oriented "above" the other elements or features. Thus, the example term "below" can encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.

Claims

Claims 1. A bracing channel adapted to be secured to a plurality of spaced apart studs of a building frame, the bracing channel comprising an elongate element having a web with at least one spanning section, each of the at least one spanning sections having a flange extend from either side of the web at an angle thereto, and a plurality of fastening sections, each fastening section being thinner than the spanning section and being adapted to be attached to the studs.
2. A bracing channel adapted to be secured to a plurality of spaced apart studs of a building frame, the bracing channel comprising an elongate element having a web with a flange extending from each end of the web, the elongate element incorporates a plurality of spanning sections, wherein the flanges of each spanning section extend outwardly from the ends of the web at an angle thereto, the elongate element further incorporates fastening sections located between each spanning section and at each end of the bracing channel, wherein the flanges at each of the fastening sections is adjacent the web such that the fastening section is thinner than the spanning section, the fastening sections being adapted to be fastened to the studs.
3. A bracing channel adapted to be secured to a plurality of spaced apart studs of a building frame, the bracing channel comprising a web and is generally elongate in form, the bracing channel being formed from at least one spanning section which spans between two fastening sections, the spanning section having a flange extending from each end of the web, wherein the flanges of each spanning section extend outwardly from the ends of the web at an angle thereto, the fastening sections having a flange extending from each end of the web wherein the flange is adjacent to the web such that the fastening section is thinner than the spanning section, the fastening sections being adapted to be fastened to the studs.
4. The bracing channel according to claim 3 wherein the bracing channel incorporates a plurality of spanning sections.
5. The bracing channel according to any one of the preceding claims wherein each flange comprises two sections folded over each other such that the thickness of each flange is twice that of the web.
6. The bracing channel according to any one of the preceding claims wherein each spanning section is located between a pair of fastening sections.
7. The bracing channel according to any one of the preceding claims wherein the thickness of the thickest portion of the fastening section may be 3 mm orless.
8. The bracing channel according to any one of claims 1 to 4 wherein each fastening section to be attached to a stud comprises a portion of the web having reinforced sides.
9. The bracing channel according to claim 8 wherein the reinforced sides comprises flanges located adjacent the inner surface of the web.
10. The bracing channel according to any one of the preceding claims wherein the bracing channel is made out of metal material.
11. The bracing channel according to any one of the preceding claims wherein the bracing channel is roll-formed out of coiled steel.
12. The bracing channel according to any one of the preceding claims wherein the flanges of the spanning sections are oriented with respect to the web at an angle 90 degrees or less.
13. The bracing channel according to claim 12 wherein the angle is 75 degrees.
14. The bracing channel according to any one of claims 1 to 4 wherein, each flange of each spanning section comprise a free end having a rolled down lip.
15. The bracing channel according to any one of the preceding claims wherein each flange has a length of 10 mm.
16. A building frame having upper and lower plates and outer studs joined together defining an outer periphery surrounding a plurality of inner studs arranged in a spaced apart relationship with respect to each other and attached to the upper and lower plates, the building frame comprising at least one bracing channel as herein described attached to the inner and outer studs.
17. The building frame according to claim 16 wherein the studs comprise relatively shallow rebates.
18. The building frame according to claim 17 wherein the rebates have a maximum depth of 5 mm.
19. The building frame according to claim 16 wherein the studs are void of rebates for the bracing channel.
20. A method for manufacturing a building frame, the method comprising the steps of:

joining together the outer studs and lower and upper plates and attaching the inner studs by fastening the ends of the inner studs to the lower and upper plates; and

attaching at least one bracing channel as herein described to the inner and outer studs.
21. The method according to claim 20 further comprising the step of roll-forming the bracing channel out of coiled steel.
22. The method according to claim 20 further comprising the step of roll-forming the bracing channel out of coiled steel and forming the fastening sections at the required position.
23. The method according to claim 20 further comprising the step of roll-forming the bracing channel out of coiled steel, forming the fastening sections at the required position and fastening the bracing channel to the studs.
24. A forming machine to form a bracing member according to a method of manufacturing a building frame according to any one of claims 20 to 23.
25. A forming machine to carry out a method of manufacturing a building frame according to any one of claims 16 to 19.
26. A forming machine to form a bracing member according to any one of claims 1 to 18.