AU679265B2 - Steel frame structural members - Google Patents

Description

Regulation 3.2(2)

AUSTRALIA

Patents Act 1990

ORIGINAL

COMPLETE SPECIFICATION STANDARD PATENT Application Number: Lodged: 0 9* 0

S.

SO

5000 400* Invention Title: STEEL FRAME STRUCTURAL MEMBERS The following statement Is a full description of this Invention, Including the best mothod of performing It known to me STEEL FRAME STRUCTURAL MEMBERS The present invention relates to steel frame members for use in the construction of steel frame housing. More particularly the application relates to a method of production, and apparatus for the production of steel framework components, and joining of said members.

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

1 0 Generally the shapes produced by conventional rolling methods include U, C and Z shapes, which are generally bolted or welded together to produce structural members. Prior art rolling apparatus have only been able zo produce "Open" sections, that is where the longitudinal sides of the metal bands do not meet.

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

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

The C sections used to produce the stud members are such that the sides permit plasterboard sheeting to be secured thereto. To properly drill hex screws tr..,ough the plasterboard and the C section is difficult because the screw can wander acrooss the face of the C section, until the drill tip on the screw bites in.

This results in damage to the plaster board as the screw moves through the plaster board until the screw bites Into the metal.

Conventionally formed stud members are sometimes required to be joined back to back or mouth to mouth in order to provide a double stud which is generally used at either side of a door or window opening. If placed back to I 2 back, the backs can be bolted, screwed or welded together, However, a back to back orientation can be useless in door and window openings, as a fiat face is generally required. When a front to front combination is used, tack welding is generally all that is used. However, whilst twice the stren,,th is provided, twice the size also results.

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

Statement of Invention According to a first aspect of the present invention there is disclosed a method of forming a closed structural member, said member being formed on a rolling machine from a sheet material, said method comprising: a) Forming at least 3 sides being a base portion and first and second sides portions; b) Forming first and second extension members each depending from one of said portions; then c) Forming the first extension member through an angle greater than ninety degrees such that the first extension member is folded around the second extension member thereby forming said closed member.

According to a second aspect of the present invention there is disclosed a rolling apparatus to form a closed structural member, said apparatus having a series of rollers to form at least 3 sides being a base portion and first and second side portions, said apparatus also forming first and second extension members each depending from one of said portions, said apparatus being characterised by the provision of rolling members which fold at least the said first extension member about the second extension through an angle exceeding ninety degrees thereby forming a closed structural member whereby said folding forms a closed structural member, According to a third aspect of the present invention there Is disclosed a closed structural frame member for use iii ,construction of a building comprising a base portion and first and second side portions and first and second extenslon members each depending from one of said portions wherein said first extension members is folded around said second side extension thereby forming said 3 closed structural member and whereby said folding forms a closed structural member.

The apparatus can also have rollers which are axled on vertical axes In order to produce the movement of side extension(s) through 1800. The vertical axes rollers can be idler rollers, The first and second aspects of the Invention provide a not previously achievable result from conventional rolling machines. That is, the provision of a closed structural member which is sealed at the previously free ends, by a single forming process. When such a closed structural member is used with fine 1 0 threaded Hex or Tek screws, it has been discovered that roof trusses built with these components are generally silent when compared with bolted constructions, during the expansion and contraction of the truss during heating and cooling.

According to a fourth aspect of the present invention there is disclosed a method of joining first and second substantially channel shaped structural members of a frame of a dwelling structure such as a house, garage, shed or other such complex said method comprising: 1. Forming on at least one side of at least said first member at least one tab member, 2. forming on at least one side of at least said second member at least one recess 3. locating the tabs of said first member within said recess of said second member, 4. turning down each said tab member located within said recess so as to complete said joint, According to a fifth aspect of the present invention there is disclosed a joining system to join first and second channel shaped structural members of a frame of a dwelling structure such as a house, garage, shed or other such complex, at least said first member having at least one tab member on, at least said second member having at least one cooperating recess adapted to receive said tab member said tab member being further adapted to being turned down to complete said join,

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4 The fourth and fifth aspects provide a joining system which locates studs onto top and/or bottom plates and prevents relative motion thereby. It provides a very speedy connection that does note require power tools or hardware to be used with the join.

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

According to a seventh aspect of the present nvention there Is disclosed a channel member for use as a structural beam of a building frame said member having a central portion and two side portions depending substantially perpendicularly there from and at least one deformation located on said central member In a region that extends inwards between one tenth of the width of the central member Inwards of the edge and one third of the central member inwards of the edge The sixth and seventh features result In a much stronger beam than that previously produced by a roll method. The deformations help to strengthen the oentral portion against buckling.

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

The eighth aspect allows a plasterboard fixer to find a line which extends vertically upwards, across the width of the stud such that should drill bit of the screw not bite immediately, it will move only a short distance before the bite is enhanced, According to a ninth aspect of the presen. !nvention the e is disclosed an

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I I Il elongate member with a substantially constant cross sectional arrangement includes at least a first set of two substantially perpendicular portions whereby in use said first set of substantially perpendicular portions are adapted to Interlock with a first set of two substantially perpendicular portions of a second elongate frame member of substantially constant cross section whereby said interlocking provides a structurally sound frame member with at least a partially hollow cross section for use in construction of a building frame.

According to a tenth aspect of the present Invention there Is disclosed a hollow sectional frame member for use in construction of a building frame said 1 0 beam comprising at least two interlocked elongate members of substantially constant cross section each said member having at least a first set of two substantially perpendicular portions adapted to interlock with said first set of substantially perpendicular portions of said alternate member whereby said interlocking pro,ides a structurally sound beam.

1 5 By providing the C shaped member with different length sides such that the fdiort side is nestable in the long side, an Rectangular Hollow Section (RHS) or Square Hollow Section (SHS) can be formed without the need of welding, riveting, bolting or securing.

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

Detailed description of the preferred embodiment Illustrated in Fig. 1 is a roll forming machine 30 which has a series of rolling stages marked with the numerals 1 to 20, as is well understood by the skilled addressee, each stage produces a modified shape in a metal sheet passing through the machine 30. At stage 1 the flat metal sheet of any suitable thickness Is passed through in the flat condition through the first roller, Depending upon the shape of the rollers A the structural member which Issues from stage 20 will be capable of bearing stresses applied to It after it has been constructed into a framework or other article.

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

Each of the rollers 1 to 11, 15, 19 and 20 revolve around a substantially horizontal axi. Rollers 12 to 14 and 16 to 18 revolve around a non-horizontal axis and in the preferred embodiment herein described the axis more approximates the vertical. However, the angle of orientation will depend upon the process required, As the Idling rollers are not powered, the power to pass the material to be deformed is supplied by the roller stages 1 to 11 which push the metal sheet through the idling rollers, and by stages 15, 19 and 20 which pull the material being deformed through the Idling rollers, The Idling rollers revolving around a vertical axis are able to achieve a greater level of pressure applied to the metal being deformed than rollers revolving around a horizontal axis I i 7 A closed structural member 70 of figure 2 may be formed by the rollers of figure 1. The closed member is formed by folding member 71 through 180 degrees. The movement through 180 degrees is done in stages as the material passes through preferably six vertically axled rollers. Figure 3a through figure 3c Illustrate the stages that the extended member 71 may pass thorough.

To form the chord member 70 of Fig. 2 roller stages 12 to 15 bend overhanging member 71, which enters roller 12 In the vertical orientation, through approximately 90°. By the time the chord 70 exits roller 18 the member 71 has Leen folded through 1800 from Its original starting point. Member 71 is pressed against metal sheet section 72 by high pressure exerted by the roller of figure 3c at least. These rollers hold the members 71 and 72 in firm location relative to each other, No securing between members 71 and 72 need take place other than the pressure applied to member 71 because during use of the chord member 1 5 bolts or screws or other fixing means which are used to fix the member into place pass through the flange section 73, The invention is not limited to a chord member and other closed structural members may be formed according to the disclosed method of forming a member through 180 so as to secure the opposing edges of metal sheet material.

The roller of figure 3a is the roller of stage sixteen of figure 1 and it rotates about a vertical axis, The operating face of this roller is angled at seventy five degrees to the vertical axis. This roller operates on member 71 when it exits stage 15 to form it through a further fifteeen degrees to the horizontal, The roller of figure 3b is the roller of stage seventeen of figure 1 and it rotates about a vertical axis, The operating face of the roller is angled at thirty degrees to the vertical axis, It operates on the member 71 as it exits roller sixteen to form it through to an angle of P«ixty degrees to the horizontal.

The roller of figure 3c is the roller of stage eighteen of figure 1 and it rotates about a vertical axis. The operating lace of the roller is parallel to the vertical axis, It operates on the member 71 as it exits stage seventeen and forms It through the final thirty degrees so that member 71 has been formed through A: P I 8 180 degrees, In another preferred embodiment six rollers are used, Each roller forms the member 71 through a fifteen degree Increment. A similar set of vertically axled rollers may be used to form member 71 through the first ninety degrees to stage By utllising the chord member 70 and fine threaded screws to secure the truss braces, a stronger and quieter truss results, By varying the rollers the output product of the forming machine 30 can be varied according to the need required. The one machine can be utilised to manufacture all the different 1 0 sections required In wall frame and roof truss construction.

Illustrated in Figs. 4, 8, 9A and 9B are details of the stud 80 and bottom or top wall plate 90 arrangements, In Fig. 8 Is the construction of the stud member whilst Figs. 9A and 9B illustrate the top and bottom wall plate 90 construction, These are both Illustrated in Fig. 4 showing the method of joining, Illustrated In 1 5 Fig, 4 is a bottom wall plate 90 to which Is being perpendicularly attached, stud member 80. The stud member 80 has formed in it, on side walls 81 and 82, recesses or slits 83 which allow the entry of tab members 91 and 92 on bottom wall plate 90 to pass therethrough. The tab members 91 and 92 are respectively on side walls 93 and 94 of bottom wall plate 90. The tabs may alternatively be located on the stud member 80 and the recess may be located on the wall plate A combination of tabs and recesses may be located on each of the wall plate 90 and the stud member By bending tab members 91 and 92 downward (or upward In respect of the top plate stud loint) the stud 80 is secured to the stud 90 and is prevented from translation. Such a joint provides all the necessary strength without riveting, gluing, welding, bolting or screws, The tabs are located at intermittent lengths along the wall plate 90 so the stud member may have a plurality of locations along the wall plate or so that a plurality of studs may be located to the one wall plate.

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

Illustrated in Fig, 5 is the stud member 80 which has a U shaped noggin I~ I 9 member 85 which passes through it, By crimping the sides of the nogging on both sides of the wall stud the wall stud 80 Is satisfactorily braced to help it to resist buckling under vertical loading, Illustrated in Fig. 6A and 6B is the method of joining, or splicing bottom wall plates 90A and 90B, and top wall plates 90D and 900, respectively, As a piece of stud section has an outside length equivalent to the '.,idth of wall plate members 90A,B,C and D the stud or splicing membe a Ba snugly fits therebetween. By then Tek screwing into the sides of the watll plates, or from the top in the case of the top wall plate the splicing or joint can be 1 0 completed, Illustrated In Fig. 9A and 9B the top and bottom wall pate, are shown as having the half round tab members 91 and 92 being In a substantially parallel orientation relative to the central portion 95 of the top and bottom wall plate. Alternatively the tab members 91 and 92 can be in the vertical orientation and only bent over when it is desired to connect a stud member 80 thereto or 1 5 other member, The shape of the tab members 91 and 92 can be any appropriate shape such as rectangular or square, If the tabs 91 and 92 are maintained in the vertical orientation, a larger recess 83 needs to be formed in the sides of the stud Illustrated in Fig. 12 is of a detail three-way join of a wall junction whereby a stud section 117 is utilised to assist in the joining of the three-wall sections A, B and C.

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

The beam is preferably of a substantially C shape construction havilg side walls 111 and 112 and on the central portion 113 there are located tw6 longitudinally shaped, or deformed recesses 114 and 115. Such recesses may be applied to other members of a building frame to achieve increases In the members strength.

These recesses are preferably located in a region of some 16 to away from the sides 111 and 112 in the direction of arrows A and B respectively.

Outside of these regions the strength benefit which is derived from the location of the deformations 114 and 115 Is decreased. To locate the deformations 114 and 115 towards the centre in the region of 50mm or greater away from side walls 111 and 112 will in fact weaken the beam and not give any benefit to the strength.

The recesses 114 and 115 can be suitably deformed into the central portion 113 by the rolling machine 30 durirg production of this substantially C shaped member. Conventional 150mm beams which don't have deformations 114 and 115 are normally allowed to span only a maximum length of 3,6m carrying a maximum weight of 600kg. By the present method and construction the beam 110 can span a length of 4.6m and carry some 800kg.

Use of such spaced deformations to obtain Increased strength advantages is not limited to C shaped frame members and it may eb applied to 1 5 any building frame member.

Illustrated in Fig. 8, as previously described, is a stud member 80 which has reinforcing deformations 84 which are produced in a similar manner to that of the product of Fig. 11. The side walls 81 and 82 each have 6 longitudinally extending deformations which allow Tek screws to be located as they drill through the metal of sides 81 and 82. Recesses of other shapes and orientations on the surface of the stud may also be used, provided they encourage the tok screw to engage the surface of the member rather than wandering across Its surface. Such recesses may also be applied to the surface of other frame members that are required to receive Tek screws.

Frame members whose cross jectional shape is at least partially hollow may be produced by two or more interlocking members who's cross sectional shape is substantially constant along their length. These members Interlock due to the provision of perpendicular sections on each member. These perpendicular sections of each member overlap when the members are arranged to form a said further member whose cross sectional shape is at least partially hollow. By the overlapping portions, the members lock into place and form a structurally sound memberWhich does not require fixing screws, welds or the like to hold the member, which is at least partially hollow in cross section, together The me;bers used to form the hollow members may be of any suitable shape, however it is preferred that a C shaped channel member of figure 10 be used to form Rectangular Hollow Sections or Square Hollow Sections, The side walls 81 and 82 of figure 9 and figure 10 are of a dimension which is different from each other. The side wall member 81 is some shorter than that of side 82. Preferably the side 81 Is some 35,5mm whilst the side 82 Is 37.5mm.

1 0 By such a construction, the stud members 80 are nestable within each other as is illustrated In FIg. 10, In Fig. 10 there are three stud members and 800. Members 80A and 80B are back to back whilst member 800 Is nested within member or stud section 80. 80B and 800 are nested such that the opening between the side walls face each other and a substantially 1 5 rectangular hollow section is produced, Because of the Inwardly pointing flanges being Inwardly angled to the horizontal, in the direction of the central portion, and the sizes and dimensions of the sides, the members 80B and 800 can be joined without need of fixing screws or the like.

However, as it Is common that the plaster board or other Internal wall sheetlnging is attached by Tek screwing or hex screws the members 80B and 800 will generally have a Tek screw also helping them not to separate.

Claims (16)

1. A method of forming a closed structural member, said member being formed on a rolling machine from a sheet material, sad method comprising: a) Forming at least 3 sides being a base portion and first and second sides portions; b) Forming first and second extension members each depending from one of said portions; then c) Forming the first extension member through an angle greater than ninety degrees such that the first extension member is folded around the second extension member thereby forming said closed member,

2. A method of forming a closed structural member as claimed in claim 1 wherein step a) further comprises said first and second side portions depending from opposing sides of said base portion and step b) further comprises said first and second extension members extending from said side portions,

3. A method as claimed in claim I or 2 wherein said the first extension portion is longer than the second extension portion.

4. Method as claimed in any one of claims I through claim 3 wherein step c) further comprises forming said first and second extension members into a substantially parallel arrangement, Method as claimed in any one of claims 1 through claim 4 wherein said substantially parallel extension members are formed into an arrangement whereby they touch substantially along their parallel lengths, 6, Method as claimed in any preceding claim wherein step b) further comprises forming at least one extension member with a first angle Intermediate the portion it depends from and the end of the extension member distal said portion. 3, 13

7. Method as claimed In claim 6 wherein step b) further comprises forming said at least one extension member with an angle adjacent the portion it depends from. 8, Method as claimed in any preceding claim wherein step c) in folding the first extension member over the second extension member further comprises forming said first extension member through a plurality of intermediate angles,

9. Method as claimed in claim 8 wherein said number of Intermediate angles is less than or equal to six. A rolling apparatus adapted to form a closed structural member, said apparatus having a series of rollers to form at least 3 sides being a base portion and first and second side portions, said apparatus also forming first and second extension members each depending from one of said portions, said apparatus being characterlsed by the provision of rolling members which fold at least the said first extension member about the second extension through an angle exceeding ninety degrees thereby forming a closed structural member whereby said folding forms a closed structural member, 11, A rolling apparatus as claimed in claim 10 wherein said series nf rollers form the closed structural member with the side portions depending from opposing edges of said base portion and wherein said extension members each depends from one of said side portlos. 12, A rolling apparatus as claimed in claim 10 or claim 11 wherein said first extension member 1. longer than the second extension member.

13. The apparatus as claimed in claim 10 wherein the axis of at least one roller of said series is positioned at an angle to the axis of at least one other roller of said series so that said apparatus may bend said extension members through an angle exceeding ninety degrees. 14

14. The apparatus of claim 11 wherein the axis of at least one roller is substantially at right angles to the axes of at least one other roller. The apparatus of claim 11 through 14 wherein the operating face of any one of the said rollers is displaced at an angle to the axis of that roller.

16. The apparatus of any one of claims 12 through 15 wherein a first roller forms said firct extension member at substantially an angle of ninety degrees to the first side portion and wherein a plurality of said rollers located sequentially within said apparatus each operate to Incrementally form said first extension member through the remaining angle above ninety degrees,

17. The apparatus of claim 16 wherein the plurality of rollers are positioned with their axis at ninety degrees to the axis of said first roller.

18. The apparatus of claim 15 wherein the successive increment In the angle of the operating face of the sequential rollers is 15 degrees to the axis of the final roller so that the angle of the first roller of the sequence is 75 degrees to the axis of the final roller.

19. The apparatus of claim 16 wherein the operating face of the final roller is positioned so that It is parallel with its axis, The apparatus as claimed in any one of claims 14 through 17 wherein said vertical axes rollers are Idler rollers,

21. A closed structural frame member for use In construction of a building comprising a base portion and first and second side portions and first and second extension members each depending from one of said portions wherein said first extension members is folded around said second side extension thereby forming said closed structural member and whereby said folding forms a closed structural member. I

22. A closed structural member as defined in claim 21 wherein said first and second side portions depend from opposing sides of said base portion and wherein said side extensions depend from the end of said side portions distal the base portion.

23. A closed structural member as claimed in claim 21 or claim 22 wherein said first extension member is longer than said second extension member. 24 A closed structural member as claimed in claim 21 through 23 wherein said extension members are formed in a substantially parallel arrangement. A closed structural member as claimed In any preceding claim wherein at least one extension member is formed with a first angle intermediate the portion it depends from and the end of the extension member distal said portion.

26. A closed structural members as claimed in claim 25 wherein said at least one extension member is formed with an angle adjacent the portion It depends from. DATED this 26th day of February, 1997. PAUL SEMRANI 0a0 WATERMARK PATENT TRADEMARK ATTORNEYS 290 BURWOOD ROAD HAWTHORN VICTORIA 3122 AUSTRALIA PNF:RJD:JZ (DOC.41) AUOOOPM2302 S.0 Sr .i. \\a -L VV s ABSTRACT The present invention relates to building frames constructed from metal. It discloses a method and the apparatus for roll forming sheet metal through an angle greater than ninety degrees so as to form a frame member for a building that has at least a partially hollow cross section, It discloses building frame membef with plurality of deformations located on Its surface for the purpose of engaging a drill bit or a tek screw. It discloses a building frame member with a plurality of deformations located so as to strengthen the member. A method of joining two structural frame members with a series of tabs and co-operating recesses on the joined members which receive the tabs, The tabs are folded down to complete the join, A plurality of elongate building frame members the interlock to form a structurally sound partially hollow sectional member Is disclosed. At least two substantially perpendicular portions located on each building frame member interlock form said partially hollow sectional member which does not require further joining such as welding or screws or bolts.