AU716988B3 - Connector for attaching structural members to a building panel - Google Patents

Description

Regulation 3.2

AUSTRALIA

PATENTS ACT 1990 COMPLETE SPECIFICATION FOR A PETTY PATENT

(ORIGINAL)

NAME OF APPLICANT(S): ACTUAL INVENTOR(S): ADDRESS FOR SERVICE: INVENTION TITLE: COMPOSITE BUILDING SYSTEMS, INC.

PAUL M. CLARK, Jr.

GEORGE R.TOOTH DAVIES COLLISON CAVE, Patent Attorneys 1 Little Collins Street, Melbourne, 3000 "Connector for attaching structural members to a building panel" The following statement is a full description of this invention, including the best method of performing it known to us: S IP AUSTRALIA I RECEIVED Q\oPER\RSH\CoMNe.200 19n7/99 CONNECTOR OR ATTACHING STRUCTURAL MEMBERS TO A BUILDING PANEL Background of the Invention The present invention generally relates to connectors for attaching structural members to building lianels and, more particularly, to a connector for attaching a structural member to a building panel of the type used to construct walls, floors, roofs and the like.

Over the years, various methods and devices have been developed to manufacture low cost housing and other buildings that are relatively quick and simple to construct, without sacrificing the structural integrity of the finished structure. One such method employs pre-fabrioated building panels, usually constructed from concrete, to form the walls, floors and roofs of the building. Such building panels can be constructed on-site or off-site and then moved into a specific position to form the walls, floors and roofs of the building. These pre-fabricated panels are generally joined to each other by metal studs and joists structurally attached to the panels.

A typical pre-fabricated building panel has numerous parallel metal studs and joists structurally attached to a substantially planar concrete panel. The concrete panel is usually 1.5 to 2 inches thick, although the thickness can vary depending on the particular application and the strength requirements needed. The metal studs, which are usually common C-shaped channel members, are placed substantially parallel to each other, with one of their flange edges in contact with the newly poured concrete panel.

When the concrete hardens, it is necessary to have the metal studs securely attached to the panel. With the metal studs securely attached, the whole panel is then transferred into a position to form part of the wall, floor or roof of the building.

It is well known that the overall strength of a pre-fabricated building panel is, in large part, dependent upon the integrity of the connection that is created between the metal stud and the concrete panel, after the concrete has hardened. For example, simple surface to surface contact between the stud and the surface of the concrete panel results in a relatively weak connection and, therefore, a relatively weak panel. Accordingly, it is desirable to provide some means to positively connect the stud to the panel.

P:\OPER\RSH\40175-99.017 -17/1100 -2- While various methods and techniques have been employed to anchor the studs to the building panels, these methods and techniques are not without their drawbacks. Accordingly, a definite need has existed for an improved manner for positively and securely attaching studs to building panels in a rapid, convenient and economical manner. The present invention satisfies these and other needs and provides further related advantages.

According to the present invention, there is provided a combination comprising: a structural member; a connecting member for attachment to the structural member, wherein the connecting member comprises an elongated wall and a plurality of projections; a fastener that attaches the wall of the connecting member to the structural member, such that the projections on the connecting member extend outwardly from the structural member; and a building panel comprised of a material capable of hardening from a liquid or semi-liquid state to a solid state, and wherein the projections are adapted to be embedded within and connected to the building panel when the material comprising the building panel has reached a solid state.

Preferred embodiments of the present invention provide a connector for attaching structural members to a building panel, such as a pre-fabricated building panel used to construct walls, floors and roofs of a building. A connecting member is attached to the structural member prior to connection to the building panel. The connecting member is fastened to the structural member such that a plurality of projections on the connecting member extend outwardly from the structural member where they are embedded within the building panel. This structural arrangement is relatively inexpensive to manufacture and simple to assemble, on-site and off-site, yet provides an extremely strong bond and shear transfer between the building panel and the structural member.

The connecting member is especially adapted for use with structural members that are attached to building panels from composite or cementious materials, such as concrete.

However, it will be appreciated that the building panel may be constructed from any other suitable building material. Accordingly, the material of the building panel may comprise any suitable material capable of hardening from a liquid or semi-liquid state to a solid state, which will surround and adhere to the projections of the connecting member.

P:\OPER\RSH\40175-99.017 17/1/00 -2A- In a first embodiment of the invention, the connecting member comprises a substantially planar wall with a plurality of projections extending along an upper edge thereof.

Each projection has a base section connected to the upper edge of the wall, and an anchoring section extending at an angle from the base section. The projections preferably are spaced apart from each other, with adjacent projections extending at alternating different angles from the connecting member's upper edge. The planar wall of the connecting member is adapted to be fastened to the web of a structural member by appropriate fastening means, such as screws. The structural member can be a standard C-shaped stud or joist, or it may be any other appropriate structural member designed for connection to a building panel, such as a track, a structural steel I-beam joist or the like.

In a second embodiment of the invention, the connecting member also comprises a substantially planar wall with a plurality of projections extending from one edge of the wall. These projections also are preferably spaced apart from each other and alternately extend at different angles relative to the edge of the connecting member. The planar wall of the connecting member is adapted to be fastened to one of the flanges of the structural member that is ordinarily in contact with the surface of the building panel.

This attachment can be accomplished by appropriate fastening means, such as screws.

The projections generally extend toward the building panel when the connecting member is attached to the structural member, .The foregoing structural arrangement of the first and second embodiments of the invention provides several important advantages. One important advantage is that the connecting member can be fastened to a standard C-shaped stud, joist, track, or other conventional structural member, Thus, for example, the studs arid joists do riot need to be specially modified or specially manufactured, thereby keeping the cost of labor and materials of the finished building panel as low as possible. In addition, since a common, off-the-shelf C-shaped stud may be used, modifications and adjustments as between the stud and the connecting member can be accommodated in the field in expeditious and economical manner. Moreover, the connecting member provides some reinforcement component to the stud.

In addition, since the projections which engage the building panel are not made out of material removed from the edge flange of the stud itself, the stud is not weakened in that area. Furthermore, the projections are not limited in size, shape or number, because they are fonmed directly on the connecting member, thereby providing a more secure connection to the building panel. If desired, the connecting member need not be connected along the entire length of the stud. Accordingly, a plurality of connecting members may be connected to aL single stud in a spaced-apart relation in a manner that still provides a secure connection between the stud and the building panel.

Other features and advantages of the Present invention will become apparent from the following description of the preferred embodiments, taken in conjunction wvith the accompanying drawings, which illustrate, by way of example, the principles of the invention.

Brifjjscinton f te rawings The~~9 folwn r~ gs illustrate the invention, In such drawings: FIG. I is a cross-sectional view of a building panel showing a structural member attached to the building panel by a connecting member in accordance with a fitst embodiment of the invention; FIG. 2 is an exploded perspective view of the structural member and the connecting mermber according to the first embodiment of the invention; FIXG. 3 is an enlarged perspective view of the connecting member according to the first embodiment of the invention; FIG. 4 is an enlarged perspective view of a connecting member in accordance with a second embodiment of the invention; and FIG. 5 is a cross-sectional view bf a building panel showing a structural member attached to the building panel by the connecting member according to the second embodiment of the invention.

Detailed Desritio of the Preferred imbodiments As shown in the exemplary drawings, the present invention is embodied in a connector 10 for attaching a structural member 12 to a building panel 14 or other appropriate structure. In accordance with the invention, the structural member 12 is attached to the building panel 14 by a connecting member 10 having a plurality of projections 16 which are embedded within the material of the building panel. These projections 16 are specially designed to~provide an extremely secure connection and improved shear transfer between the building panel 14 and the structural member 12, thereby providing a building panel with the highest possible structural integrity, FIG. I is a cross-sectional view showing the structural member 12 attached to the building panel 14 by the connecting member 10 in accordance with a first embodiment of the invention. A building panel 14 typically has a plurality of structural members 12 arranged in a substantially spaced, parallel relationship. The connecting member 10 has a plurality of the projections 16 embedded within the building panel 14.

In this regard, it is noted that the connecting member 10 of the present invention is especially adapted for use with building panels 14 constructed fr~om composite or cementious materials, such as concrete. However, it will be understood that the connecting member 10 is designed for use with any suitable building material capable of hardening from a liquid or semi-liquid state to a solid state. Therefore, the invention is not intended to be limited in any way by the type of material comprising the building panel 14, or other shaped building structure, to wvhich the connecting member 10 is attached. Further details illustrated in FIG. I will be described below.

FIG. 2 is an exploded perspective view of the structural member 12 and the connecting member 10. It is intended that the connecting member 10 shall be adapted for connection to any suitable type of structural member 12, such as a standard

C-

shaped stud or joist. However, the structural member 12 may comprise any other is suitable structural member adapted for connection to a building panel 14. By wvay of example, the structural member 12 shown in FIG. 2 comprises a standard C-shaped stud having a planar central web 18 with upper and lower edge flanges 20 and 22, respectively, extending in a perpendicular direction with respect to the web. Again, this structural member 12 may be a standard stud or joist constructed, for example, from steel. Accordingly, for purposes of convenience and reference, the structural member 12 in all forms shall be simply referred to herein as a "stud." The connecting member 10, as best shown in FIG. 3, comprises a substantially planar wvall 24 and a plurality of projections 16 extending from an upper edge 28 of the connecting memnber. The planar wall 24 of the connecting member 10 is designed to fit in an overlapping relationship with respect to the central web 18 of the stud 12, It will be appreciated, however, that the shape of the connecting member 10 can be configured as desired to conform to the shape of the stud 12, which need not be planar.- Referring again to FIG. 1, it can be seen that the upper edge 28 of the connecting member 10 Is generally aligned with the upper edge flange 20 of the stud 12, with-the planar wall 24 of the connecting member in overlapping relationship with the- central web 18 of the stud. Suitable fastening means are employed to connect the connecting member 10 to the stud 12. By way of example, as shown in FIG. 1, a screw 30, such as a tapping screw, can be used to fasten the connecting member 10 to the stud 12. Other types of mechanical fastening means may be employed, such as bolts, rivets or punching tools, In addition, fastening techniques such as welding, brazing, adhesives or other suitable bonding techniques may be used as another alternative.

More particularly, with respect to the Connecting member 10, shown best in FIG.

3, each projection 16 has a generally planar base section 32 with a lower edge integrally connected to the upper edge 28 of the connecting member. Each projection 16 also has a generally planar anchoring section 34 extending from the end of the base section 32 opposite the connecting member 10. Thus, each projection 16 substantially resembles an inverted Each successive projection 16 faces in a opposite direction from the projection adjacent to it. In addition, the projections 16 are spaced-apart from each other by a section 36 of the upper edge 28 of the connecting member The shape of these projections 16 advantageously maximizes the overall surface is area of the connecting member 10 that is connected to the building panel 14, thereby increasing the strength of the bond between them. In addition, the spacing between the projections 16 facilitates shipping and stacking of the connecting members 10 prior to use, substantially without tangling the members together. The spacing 36 between projections 16 also results in the use of less material to form the connecting member thereby reducing the weight of the building panel 14, yet without sacrificing the integrity of the connection. This arrangement also reduces the overall materials costs.

It will be noted that each of the projections 16 provides a relatively. large surface area for connection to the building panel 14. Since the projections 16 are formed on the connecting member 10 as a piece separate from the stud 12, the surface area of these 2S projections is not limited by the material available from the stud, such as the surface area of the upper edge flange 20. In addition, the angled shape of the projections 16 provides a very secure connection to the building panel 14. Thus, the large surface area and angled shape of the projections 16 results in a superior bond between the stud 12 and the building panel 14. In addition, the stud 12 itself is reinforced to some degree by the connecting mlember 10 attached to It. The connecting member 10 also provides excellent shear transfer betw~een the stud 12 and buildin ae 4 If desired, optional ties 38 may be provided to connect a reinforcing-type mesh to the projections 16, as shown in FIG. 1. Alternatively, the building panel 14 may be poured in a form or the like, with plastic chairs (not shown) being positioned to support the mesh 40. Thereafter, the stud 12 and its attached connecting miember may be placed in position over the building panel 14 and then lowered into the unhardened material of the building panel. Once the material hag hardened, the projections 16 and thus the stud 12 will be securely attached to the building panel 14, A particular advantage of the connecting member 10 is that no laborious bending or forming of projections from the edge flanges 20 or 22 of the stud 12 is required.

Further, the stud 12 has no cut-Outs in its upper edge flange 20 and thus retains all of its original structural integrity. Another advantage is the relatively large size and number of alternating projections 16 on the connecting member 10. The size and number of the alternating projections 16 are not limited by the area of the stud upper edge flange mnaterial. Thus, when a greater number of large projections 16 are used, the strength of the bond between the stud 12 and the building panel 14 is enhanced, resulting in a, stronger and more desirable building panel, FIGS. 4-5 show a second embodiment of the invention, In this second embodiment, like the first embodiment discussed above, the connecting member comprises a substantially planar wall 42 and plurality of projections 44 extending from one edge 46 of the wall. In this second embodiment, however, the planar wall 42 of the connecting member 10 is designed to fit in an overlapping relationship with respect to the edge flange 20 of the stud 12 ordinarily in contact with the building panel 14, A suitable fastener, such as a screw 48, and most preferably a tapping screw, may be used to fasten the connecting member 10 to the stud 12. Other fastening means of the type discussed above also may be used.

Like the first embodiment described above, each projection 44 in the second embodiment has a generally planar base section 50 and generally planar anchoring section 52 connected at an angle to the base section. However, the base section 50 is joined to the edge 46 of the wall 42 at alternating acute and obtuse angles. The projections 44 also are spaced apart from each other by a section 54 on the edge 46 of the wall 42. Because the connecting member 10 is connected to the edge flange 20 of the stud 12, the projections 44 extend from the edge 46 in a direction substantially perpendicular to the planar wall 42 of the connecting member and the edge flange 20 of the stud. In this way, when the connecting member 10 is connected to the stud 12 and positioned with respect to the building panel 14, the projections 44 will extend into the building panel.

The numerous advantages associated with the first embodiment of the connecting member 10 are equally applicable to the second embodiment of the connecting member. In addition, the connecting member 10 of the second etbodiment offers the option to the builder to attach the connecting member to a different portion of the stud 12, From the foregoing, it will be appreciated that the present invention provides convenient alternatives for attaching a structural member 12 to a building panel 14 in a rapid, reliable and secure manner. While a particular form the invention has been illustrated and described, it will be apparent that various modifications can be made without departing from the spirit and scope of the invention. Accordingly, it is not intended that the invention be limited, except as by the appended claims.

Throughout this specification and claims which follow, unless the context requires otherwise, the word "comprise", and variations such as "comprises" or "comprising", will be understood to imply the inclusion of a stated integer or group of integers or steps but not the exclusion of any other integer or group of integers.

Claims (3)

1. A combination comprising: a structural member; a connecting member for attachment to the structural member, wherein the connecting member comprises an elongated wall and a plurality of projections; a fastener that attaches the wall of the connecting member to the structural member, such that the projections on the connecting member extend outwardly from the structural member; and a building panel comprised of a material capable of hardening from a liquid or semi-liquid state to a solid state, and wherein the projections are adapted to be embedded within and connected to the building panel when the material comprising the building panel has reached a solid state.

2. The combination according to Claim 1, wherein the projections are spaced apart from each other and extend in opposite directions along one edge of the wall, and wherein the wall of the connecting member is attached to an elongated web of the structural member.

3. The combination according to Claim 1, wherein the projections are spaced apart from each other and extend in opposite directions along one edge of the wall, and wherein the wall of the connecting member is attached to an elongated flange extending from a web of the structural member. DATED this 17th day of January, 2000. COMPOSITE BUILDING SYSTEMS, INC. By its Patent Attorneys: DAVIES COLLISON CAVE