AU680886B2 - Wall frame - Google Patents

Description

Our Ref: 507717 P/00/011 Regulation 3:2

AUSTRALIA

Patents Act 1990

ORIGINAL

COMPLETE SPECIFICATION STANDARD PATENT Applicant(s): Address for Service: Invention Title: Masterton Homes Pty Ltd 76 Heathcote Road MOOREBANK NSW 2170

AUSTRALIA

DAVIES CILLISON CAVE Patent Trade Mark Attorneys Level 10, 10 Barrack Street SYDNEY NSW 2000 Wall frame The following statement is a full description of this invention, including the best method of performing it known to me:- 5020 I I WALL FRAME Background of the Invention The present invention relates to a wall frame, and in particular, to a wall frame which is comprised of a combination of timber and metal. In particular, the present invention relates to a wall frame having its upright members constructed of metal in a certain unique configuration, such that a strong and easy connection to horizon'al timber members is facilitated.

Description of the Prior Art Traditionally, wall frames, either structural or non-structural, were constructed of timber. That is, they were comprised of horizontal timber beams, vertical timber struts .connected therebetween, and horizontal timber noggings. Primarily due to the expense of timber and the deterioration or decay of timber after a period of time, recent trends, particularly for mass produced "project homes" have tended towards the use of metal, 20 particularly steel, for the construction of wall frames. Steel frames obviously have certain advantages in that they are not prone to insect or pest infestation, and they are not as likely to rot, so long as they are provided with appropriate anti-rust treatments. Metal, and particularly steel is also, in recent times, less expensive than timber. However metal frames do have disadvantages, in that, to effect good connection between the horizontal e: 25 and vertical members of the frame, conventional carpentry techniques of nailing, screwing or like, cannot be used. This makes, not only the construction of the wall frames more difficult in having to connect steel top and bottom plates to concrete floors, etc., but also, makes the connection of the wall finishing surfaces, such as plaster board to the wall 0 frame, more difficult. That is, plaster board cannot be simply nailed or screwed by conventional techniques to a metal frame.

p \wpdocs\amd\spcci\507717,spc 1 I I ~I Summary of the Invention The present invention seeks to overcome the disadvantages of prior art timber or metal wall frames by providing a unique wall frame which is constructed of a corm ination of timber and metal.

The present also seeks to provide a wall frame which uses substantially conventional timber horizontal members and which utilises prefabricated metal upright members the end(s) of which preferably have a novel configuration to facilitate simple and strong interconnection to the timber top and bottom plates and to also allow for simple interconnection of timber noggings thereto.

I In one broad form, the present invention provides a stud of a wall frame which is adapted to cooperate with timber beam(s) and/or nogging(s), characterised in that said stud is formed substantially of metal and is substantially U-shaped in section, comprising two substantially parallel spaced apart face portions connected by an intermediate portion and having at least one longitudinal strengthening rib therealong, wherein at least one end of only one of the face portions is provided with a tab which extends beyond a respective end of said intermediate portion.

Said stud is preferably connected to said respective timber member by nails, screw, adhesive, or the like.

:\wlpdocs\and'pcci\ 57 17. Spe II -E, Most preferably, at least one service hole is provided within said intermediate portion of said U-shaped member.

Most preferably, an end plate is provided at least at one end of and substantially perpendicular to said intermediate portion of said U-shaped member.

A most preferred form of the invention is wherein said end plate is formed integral with said intermediate portion by providing a cut at the intersection of said intermediate portion and at leasi one of said face portions, and by then bending said end plate relative to said intermediate portion.

Brief Description of the Drawings The present invention will become more fully understood from the following detailed 20 with the present invention; desription of a preferred butan elevationg embod of the vertical metal mesribed in connection withrame th e accompanying dr1; ings, wherein: Figure 3 details a sectional view of the vertical metal member; o S oS Figure 1 shows a perspective view of a typical assembled wall frame in accordance 20 with the present invention;

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Figure 2 details an elevational view of the vertical metal members of the wall frame shown in Figure 1; Figure 3 details a sectional view of the vertical metal member; Figure 4 illustrates a perspective view of the end detail of the metal member; and Figure 5 shows an alternatively preferred end detail to that shown in Figure 4.

p:Awpdocs\wd\speci\507717,pe -1 I ii Detailed Description of Preferred Embodiment(s) As shown in Figure 1, the wall frame, in accordance with the present invention and illustrated by the numeral i, comprises a bottom plate or beam 2, a top plate or beam 3, and three vertical extending metal U-shaped supports 4, 5 and 6 interconnected by timber noggings 7 and 8.

As shown in Figure 2, each metal support 4, 5 or 6 is provided with at least one service hole 9 such that, in use, electrical cabling, water pipes, etc., can be supplied therethrough. The end portions 10 and 11 of the metal members 4, 5 or 6 are shown to have a 'ab 12 and 13 extending from one side thereof, the purpose of which will be described hereinafter with reference to Figure 4.

As shown in Figure 3, the metal supports 4, 5 or 6 are preferably of U-shaped section, but could, of course, be any other shape, having face portions 14 and 15, and intermediate portion 16 provided with strengthening ribs 17 and 18. The provision of strengthening ribs 17 and 18 enable a reduced thickness whilst adding strength to the *q metal uprights.

20 A preferred end detail of the metal uprights 4, 5 and 6 is shown in Figure 4. As shown, the metal upright has a tab 13 extending from one end of the base portion 14 beyond the end of the ntermediate portion 16. Figure 4 also shows the provision of an end plate 19 which is substantially perpendicular to the portions 14, 15 and 16, and which extends therebetween. The end portion 19 may be formed separately or may be formed 25 by providing a cut at the intersection of portions 14 and 16 and 15 and 16 and then bending the end of the intermediate portion 16 to the position as shown in Figure 4.

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It will be appreciated that a further tab 20 similar to tab 13 could optionally be stoplied, as shown in Figure 5, extending from the base portion 15, sucn n! 1 t upon connection over the bottom plate 2, screws, nails or the like could be supplied through those tabs to the timber beam 2.

In like manner, the end detail of the top of the uprights 4, 5 or 6, are preferably p:\wpd.cs\aimdl\spcci\5077 17.spc similar to the end detail at the bottom of the uprights 4, 5 or 6.

It will be appreciated that, in use, such a wall frame, constructed in accordance with the invention and described hereinbefore, will have a number of distinct advantages over prior art timber or prior art steel frames. It will be appreciated that, the timber top and bottom plates or beams will be simply and easily connected to the floor and roof constructions of a building, by conventional techniques. Since ceilings are of reasonably standard heights, the upright members or support can be prefabricated in reasonably standard lengths. They can be simply placed into position at the required locations, and securely fastened via the tabs provided at their end portions to the timber top and bottom beams, without the necessity for any complicated connecting pieces, or without having to provide cutouts in the timber beams. Then, noggings can be simply ins -ted and secured to the metal uprights.

Thereafter, during the provision of facing materials, such as plaster board to the wall frames, screws, nails and the like may be used to attach the plaster board to the wooden portions of the frame, unlike the situation with an all steel wall frame.

The use of a combination of timber and metal also leads to a more cost effective 20 wall frame, reducing the amount of relatively expensive timber which is required to be used. Other advantages inherent in the use of the unique combination of materials used in the present invention, include taking advantage of the more stable characteristics of steel, whilst still allowing for expansion and movement to avoid cracking (by the use of the timber portion) and eliminating noise from the expansion of metal.

Most preferably, the metal uprights are constructed of high tensile steel, and are S. formed in standard lengths with spacings between the face portions 14 and corresponding to conventional size timber dimensions. It will therefore be appreciated that, one of the main advantages of the present invention is the reduction in time to construct a wall frame.

p: \wpdocs\amid\spicci\5077 I7.spc I I -6- It will be understood that there are numerous other advantages inherent in the wall frame construction in accordance with the present invention. It will also be appreciated that there are numerous variations and modifications to the wall frame and particular the detail of the metal uprights which are used, which will become obvious to persons skilled in the art. All such variations and modifications should however be considered to fall within the spirit and the scope of the invention as broadly described he-cinbefore.

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Claims (7)

1. A stud of a wall frame which is adapted to cooperate with ti beam(s) and/or nogging(s), characterised in that said stud is formed substantially of n and is substantially U-shaped in section, comprising two substantially parallel spaced apart face portions connected by an intermediate portion and having at least one longitudinal strengthening rib therealong, wherein at least one end of only one of the face portions is provided with a tab which extends beyond a respective end of said intermediate portion.

2. A stud of a wall frame as claimed in claim 1, wherein, in use, said stud is attached to said timber beam and/or nogging(s) by nails, screws, adhesive, or the like.

S3. A stud as claimed in claim 1 or 2, wherein at least one service hole is provided within o said intermediate portion thereof.

4. A stud as claimed in any one of claims 1 to 3, wherein an end plate is provided at least at one end of and substantially perpendicular to said intermediate portion.

5. A stud as claimed in claim 4, wherein said end plate is formed integral with said intermediate portion by providing a cut at the intersection of said intermediate portion and S* at least one of said face portions, and by then bending said end plate relative to said intermediate portion.

6. A stud, substantially as herein described with reference to the accompanying drawings.

7. A wall frame and/or a method of forming a wall frame substantially as herein described in relation to the accompanying drawings. DATED this 2nd day of June, 1997. MASTERTON HOMES PTY LIMITED By Their Patent Attorneys DAVIES COLLISON CAVE p:\wvj(doc\alntl\ slcci\50771 I, I ABSTRACT A wall frame and method of construction, provides first members extending vertically, and constructed of metal, and, second members extending horizontally and constructed of timber. The combination of these materials provides significant advantages including cost savings, high strength, and easy application of finishing surfaces thereto such as plasterboard. (Fig. 1) e* 0 Wpdocs~nd\spc5O77 17.spe L