AU718964B2

AU718964B2 - A stud wall frame

Info

Publication number: AU718964B2
Application number: AU39967/97A
Authority: AU
Inventors: Andrew William Close; William Gilbert Poynter
Original assignee: Boral Australian Gypsum Ltd; Australian Gypsum Ltd
Current assignee: Knauf Gypsum Pty Ltd
Priority date: 1996-10-08
Filing date: 1997-10-08
Publication date: 2000-05-04
Anticipated expiration: 2017-10-08
Also published as: AU3996797A

Description

-1- Regulation 3.2

AUSTRALIA

PATENTS ACT 1990 COMPLETE SPECIFICATION FOR A STANDARD PATENT

(ORIGINAL)

S

S.

Name of Applicant: Actual Inventors: Address for Service: Boral Australian Gypsum Limited POYNTER, William Gilbert CLOSE, Andrew William DAVIES COLLISON CAVE, Patent Attorneys, 1 Little Collins Street, Melbourne, 3000.

A stud wall frame Invention Title: Details of Associated Provisional Application(s) No(s): P02837/96 The following statement is a full description of this invention, including the best method of performing it known to us: Q:\OPER\PHH\CAPBORAL.276 6/10/97 P:\OPER\PHH\BORALPRO.271 3/10/97 -2- A STUD WALL FRAME The present invention relates to stud walls, and is particularly concerned with a stud wall frame comprising a plurality of channel-section studs capped by a top track comprising a web and opposed depending flanges along each side of the web.

The top track is a loose fit on top of the studs, that is it is not fixed to the studs, so as to freely allow for expansion under, for example, fire conditions or deflection of the beam, soffit or other building structure to which it is attached. This can present problems during erection of the wall frame, particularly when the top track is oversized.

S:Oversized top tracks are commonly used in staggered stud walls, that is where two parallel but laterally spaced overlapping arrays of studs are provided for the affixing of respective opposed wall linings on opposite sides of the wall. With an oversized top track, the wall 15 lining-engaging flanges of one array of channel-section studs will abut one of the opposed .ote depending flanges of the top track, while the wall lining-engaging flanges of the other array of channel-section studs will abut the opposite depending flange of the top track. A problem exists with this arrangement in that during erection the studs are free to move laterally S•between the opposed flanges of the top track.

S This problem has been alleviated in the past by, for example, providing a slide bracket having an opening therethrough whose shape corresponds generally to the cross-section of the stud.

The stud is passed through the opening, but typically the slide bracket is secured to the top of the stud, for example by a threaded fastener or rivet, to stop it sliding down the stud and thereby ensure that it remains within the top track. The slide bracket has an overall crosssection corresponding to the inner width of the top track. In an alternative arrangement, an angle bracket of cross-section suited to take up the excess width of the top track is secured externally to the appropriate wall portion of the stud at the upper end thereof by means of a fastener. In both of these solutions, it will be appreciated that the need to secure the bracket to the stud by means of a fastener is inconvenient and time consuming.

P:\OPER\PHH\BORALPRO.271 3/10/197 -3- It is an object of the present invention to alleviate the aforementioned problems, and there is accordingly provided a stud wall frame comprising two parallel arrays of channel-section studs capped by a common oversized top track comprising a web and opposed depending flanges along each side of the web, each of the arrays of studs being disposed adjacent a respective one of the flanges of the top track, and wherein the excess width of the top track is taken up by a respective bracket at the upper end of at least one of the studs in each array, each said bracket comprising a clip portion which is slidingly engaged with a wall portion of the respective stud and frictionally retained thereon and an abutment portion which projects outwardly from the clip portion to abut the flange of the top track that is spaced from the stud.

Also according to the present invention there is provided a stud wall comprising a frame as described in the immediately preceding paragraph and wall lining material on at least one of Ec "the arrays of studs.

By the present invention, the bracket may be readily engaged with the stud and retained thereon without any need to be secured by a separate fastener.

Preferably, each of the channel-section studs in the stud wall frame has a respective one of the brackets at the upper end thereof. In one embodiment, the stud wall frame is a staggered stud wall frame and alternating studs have respective brackets slidingly engaged therewith which abut opposite respective flanges of the top track.

Advantageously, the two parallel arrays of channel-section studs are received in a common oversized bottom track comprising a web and opposed upstanding flanges along each side of the web, each of the arrays of studs being disposed adjacent a respective one of the flanges of the bottom track, and the excess width of the bottom track may be taken up by another respective one of the brackets at the lower end of at least one of the studs in each array, preferably at the lower end of each of the studs in the wall frame.

P:\OPER\PHH\BORALPRO.271 3/10/97 -4- The or each bracket may take any of a variety of forms. Preferably, the clip portion has two laterally spaced stud-engaging elements which are connected so as to have a degree of resilience. The two elements may be folded relative to each other or moulded, or, for example, one element may be cut from the other to define a tongue, such as by stamping.

The abutment portion is shaped to take up the slack between the stud and the spaced flange of the track, and advantageously has a degree of resilience. That is, the abutment portion is preferably resiliently deformable. Preferably, the abutment portion comprises an arm having a free end portion. The free end portion may abut the flange of the track, but advantageously the arm is shaped so that the free end portion lies adjacent the plane of the clip portion and :°eo e an intermediate portion abuts the flange of the track. Thus, in use, the free end portion of the arm may abut the clip portion or the stud to help absorb any forces tending to move the stud towards the opposite flange.

The bracket may be moulded or cast in any suitable material, including plastics and metallic materials, but preferably the bracket is folded from sheet metal material such as spring steel or mild steel, particularly galvanised mild steel of the type used for forming channel-section studs.

Two embodiments of a bracket for use in a stud wall frame in accordance with the invention will now be described by way of example only with reference to the accompanying drawings in which: Figure 1 is a perspective view of part of a staggered stud wall, partly broken away for clarity; Figure 2 is a perspective view of a first embodiment of bracket for attachment to a stud of the wall of Figure 1; and Figure 3 is a perspective view of a second embodiment of the bracket.

Referring to Figure 1, a staggered stud wall 10 is shown with only three studs. Two studs 12 of a first array of the studs are shown supporting a first wall lining 14 comprising a single P:\OPER\PHH\BORALPRO.271 3/10/97 sheet of plasterboard, while a single stud 16 of a second array, disposed between the two studs 12 of the first array, is shown supporting an opposed second wall lining 18 comprising a single sheet of plasterboard. It will be appreciated that at least two studs 16 will be required in the second array supporting the wall lining 18, and that more than two studs 12 may be provided to support the wall lining 14. Only the three studs have been shown for convenience. Furthermore, it will be appreciated that each wall lining 14 and 18 may comprise two or more sheets of plasterboard abutted edge to edge and/or overlying each other. As shown, the studs 12 of the first array will alternate with the studs 16 of the second array, and the studs of each array will be spaced from the wall lining supported by the other 10 array of studs to improve the acoustic properties of the wall. The two arrays of studs extend parallel to each other. Sound insulation, shown schematically, may be provided at a:.between adjacent studs of the two arrays and at 22 between each stud and the opposed wall lining. The insulation is preferably in the form of fibre batts. As the wall linings 14 and 18 are not connected to each other, they may be spaced as far as apart as desired to provide the required properties of the wall.

a.

As illustrated, each stud 12 or 16 has a known top hat channel section as used for ceiling and roof battens. The top hat section comprises a base 24, two spaced and diverging webs 26 extending from opposed edges of the base 24, an outwardly projecting distal flange 28 on each web and a reinforcing lip 30 along the distal edge of each flange 28. Such an arrangement is described and claimed in our co-pending International Patent Application entitled "a stud wall" and filed concurrently herewith. However, the present invention is equally applicable to studs of other channel-section such as the known C-shaped studs.

The distal flanges 28 of the studs 12 extend in a first common plane and the distal flanges 28 of the studs 16 extend in a second common plane parallel to the first plane.

The wall linings 14 and 18 are connected by means of screw threaded fasteners 32 at, for example, 300mm centres to each flange 28 of the respective studs 12 and 16 to define a box section with each stud by which vertical shear stresses applied to the wall may be shared by P:\OPER\PHH\BORALPRO.271 3/10/97 -6the studs and wall lining, and which resists distortion of the studs by twisting about the longitudinal axes or opening up of the webs 26 under load or in fire conditions. Torsional rigidity of the studs in use is increased by having the distal flanges 28 project outwardly away from each other and secured to the wall lining.

The studs in each array may be spaced at the usual 600 mm centres, so that the alternating studs are spaced at 300mm centres, but advantageously they may be spaced by considerably more than this, for example up to 1200-1400 mm, because of the increased strength of the box section. Ultimately, the acceptable maximum spacing of the studs is a function of the 10 stiffness of the wall lining, due, for example, to the thickness of the or each layer and the number of layers, and the ability of the studs to carry the necessary wall lining.

Each stud 12 and 16 is seated in a common bottom track 34, and a common top track 36 bridges the upper ends of the studs. Also shown in Figure 1 is an optional sealant 37 at the top of each wall lining 14 and 18 adjacent the top track 36. The bottom track 34 comprises a base 38 with opposed upstanding side flanges 40 and 42, and the base 38 is secured to a floor (not shown). The top track 36 is identical to the bottom track 34 but is inverted so that opposed side flanges 44 and 46 depend from a base 48. The top track 36 is secured to a ceiling or soffit (not shown).

Each of the tracks 34 and 36 is oversized compared to the depth of each stud in order to accommodate both arrays of studs 12 and 16. The distal flanges 28 of the studs 12 abut the flanges 40 and 44 of the top and bottom tracks, respectively, while the bases 24 of the studs 12 are spaced from the flanges 42 and 46 of the top and bottom tracks respectively.

Likewise, the distal flanges 28 of the studs 16 in the second array abut the flanges 42 and 46 of the top and bottom tracks, respectively, while the base 24 of each stud 16 is spaced from the flanges 40 and 44 of the top and bottom tracks, respectively.

With top and bottom tracks having a width of the same depth as the studs, the flanges of the tracks, particularly the top track, may be used to support the studs temporarily during P:\OPER\PHH\BORALPRO.271 3/10/97 -7construction. However, this facility is not available when the tracks are oversize, and brackets 50 (one only shown; see also Figure 2) are attached to the upper ends of the stud bases 24 to take up the space between the respective base and the opposed depending flange of the top track 36. A second bracket 50 may be provided on each stud at the bottom end to take up the space from the opposed upstanding flange of the bottom track 34, but this is not usually necessary.

Each bracket 50 is folded from an elongate strip of thin galvanised mild steel of the type used for forming channel-section studs, although thinner gauge material may be used.

9.

Referring to Figures 1 and 2, the bracket 50 comprises a clip portion 52 and an abutment portion 54 which projects laterally from the top of the clip portion. The clip portion 52 has first and second clip elements 56 and 58 between which the base 24 of, for example, the stud 12 is slidingly received to frictionally retain the bracket on the stud. Each clip element 56 and 58 has a respective ridge portion 60 and 62 to enhance the frictional engagement of the clip portion with the stud. Only one ridge portion need be provided, preferably on the clip element 58. The clip element 58 extends from the abutment portion 54 and is stamped from the clip element 56 to form a tongue, leaving an opening 63 in the clip element 56. The S"frictional engagement of the clip portion with the stud is provided by the inherent resilience of the material of the bracket, with the clip elements 56 and 58 being biased apart by the stud base 24 which is slidingly received therebetween.

The abutment portion 54 comprises an arm 64 which is folded to define a curved free end portion 66 which lies substantially in the plane of the clip portion 52 and therefore, in use, in the plane of the stud base 24. An elbow 68 between the clip portion 52 and the free end portion 66 of the arm 64 is adapted to abut the opposed flange 46 of the top track 36 in which the stud is received to help hold the stud in place during erection. Thus, the elbow 68 is spaced from the clip portion 52 by substantially the spacing of the stud from the flange.

Because of the inherent resilience of the material of the bracket 50, and particularly because P:\OPER\PHH\BORALPRO.271 3110/97 -8of the free end portion 66 of the abutment portion 54, the same bracket may be used to take up different spacings between the stud and the spaced flange. For example, a bracket having a spacing of about 30mm between the clip portion and the abutment portion elbow 68 which engages the flange may be adjustable by bending the bracket to take up a spacing between the stud and the spaced flange of from about 25 to about Referring now to Figure 3, the bracket 70 comprises a clip portion 72 and an abutment portion 74. The clip portion 72 comprises a first major clip element 76 which is adapted to lie alongside one face of the wall portion of the stud and a second minor clip element 78 which is folded from the top of the clip element 76 to extend parallel to the clip element 76 in a slightly spaced manner therefrom. The spacing of the first and second clip elements 76 ':.and 78 is slightly less than the wall thickness of the stud wall portion so as to frictionally .9 retain the clip portion 72 on the respective end portion of the stud. The second clip element 78 is flared slightly at its lower end 80 to facilitate the engagement of the clip portion 72 with the stud. The clip portion 72 is retained on the stud by the inherent resiliency of the folded material 82.

The abutment portion 74 is folded from the lower end 84 of the first clip element 76. The *9o*99 abutment portion 74 comprises an arm 86 which projects upwardly and outwardly from the lower end 84 of the clip element 76 to an elbow 88 which is adapted to abut the spaced flange of the track. From the elbow 88, the arm 86 is inclined upwardly and inwardly to a fold from which a free end portion 92 projects downwardly and inwardly to terminate adjacent the clip portion 72, that is substantially in the plane of the clip element 76.

The bracket 70 may also be folded from an elongate strip of thin galvanized mild steel and, as with the bracket 50, because of the inherent resilience of the material of the bracket and particularly because of the free end portion 92 of the abutment portion 74, the same bracket may be used to take up different spacings between the stud and the spaced flange.

Those skilled in the art will appreciate that the invention described herein is susceptible to P:\OPER\PHH\BORALPRO.271 3/10/97 -9variations and modifications other than those specifically described. It is to be understood that the invention includes all such variations and modifications which fall within its spirit and scope. The invention also includes all of the steps and features referred to or indicated in this specification, individually or collectively, and any and all combinations of any two or more of said steps or features. In particular, it will be appreciated that the bracket may be slidingly engaged with the spaced flange of the top track or bottom track to abut an opposed wall portion of the stud. However, any movement of the stud along the track during the erection may then cause the stud to be misaligned with the bracket, thereby obviating the advantage of the bracket. Furthermore, it will be readily appreciated that different shapes of bracket to those described may be adopted.

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

ad d *00 e ei oooo *ooo

Claims

1. A stud wall frame comprising two parallel arrays of channel-section studs capped by a common oversized top track comprising a web and opposed depending flanges along each side of the web, each of the arrays of studs being disposed adjacent a respective one of the flanges of the top track, and wherein the excess width of the top track is taken up by a respective bracket at the upper end of at least one of the studs in each array, each said bracket comprising a clip portion which is slidingly engaged with a wall portion of the respective stud and frictionally retained thereon and an abutment portion which projects outwardly from the O10 clip portion to abut the flange of the top track that is spaced from the stud. *0

2. A stud wall frame according to claim 1 wherein each of the channel-section studs has a respective one of the brackets at the upper end thereof. q'

3. A stud wall frame according to claim 1 or claim 2 which is a staggered stud wall frame.

4. A stud wall frame according to any one of claims 1 to 3 wherein the parallel arrays of studs are received in a common oversized bottom track comprising a web and opposed 20 upstanding flanges along each side of the web, each of the arrays of studs being disposed adjacent a respective one of the flanges of the bottom track.

A stud wall frame according to claim 4 wherein the excess width of the bottom track is taken up by another respective one of the brackets at the lower end of at least one of the studs in each array.

6. A stud wall frame according to claim 5 wherein each of the studs has a respective one of the brackets at the lower end thereof. P:\OPER\PHH\BORALPRO.271 3/10/91 -11-

7. A stud wall frame according to any one of the preceding claims wherein the abutment portion of each bracket is deformable.

8. A stud wall frame according to claim 7 wherein the abutment portion of each bracket is resiliently deformable.

9. A stud wall frame according to any one of the preceding claims wherein the abutment portion of each bracket comprises an arm having a free end portion.

10. A stud wall frame according to claim 9 wherein the abutment portion has an elbow between the free end portion and the connection thereof with the clip portion which abuts the spaced flange of the track.

11. A stud wall frame according to claim 10 wherein the free end portion of the arm abuts the clip portion or respective stud.

12. A stud wall frame according to any one of the preceding claims wherein the clip portion of each bracket has two spaced stud-engaging elements which are connected so as to have a degree of resilience. 20

13. A stud wall frame according to claim 12 wherein at least one of the stud-engaging elements has a ridge portion to enhance frictional engagement with the stud.

14. A stud wall frame according to any one of the preceding claims wherein each bracket is folded from sheet metal. A stud wall frame according to claim 14 when dependent from claim 12 or 13 wherein one of the clip elements is formed by cutting and folding from the material of the other clip element.

P:\OPER\PHH\BORALPRO.271 6/10/97 -12-

16. A stud wall frame including a bracket on at least one of the studs substantially as herein described with reference to Figures 1 and 2 or Figure 3 of the accompanying drawings.

17. A stud wall comprising a stud wall frame according to any one of the preceding claims and wall lining material supported by at least one of the arrays of studs. DATED this 8th day of October, 1997. S.. 0* BORAL AUSTRALIAN GYPSUM LIMITED By its Patent Attorneys DAVIES COLLISON CAVE