EP2395168B1

EP2395168B1 - Method for manufacturing a frame, assembly and upright

Info

Publication number: EP2395168B1
Application number: EP20110168996
Authority: EP
Inventors: Mr. Leendert Weernink
Original assignee: Individual
Current assignee: Individual
Priority date: 2010-06-08
Filing date: 2011-06-07
Publication date: 2015-05-06
Anticipated expiration: 2031-06-07
Also published as: EP2395168A1; NL2004848C2

Description

The present invention relates to a method for manufacturing a frame, such as a wall or ceiling frame, and an assembly and upright for use in the method. Uprights are here understood to mean construction elements, such as metal profiles, which as a rule are placed substantially vertically, and beams are understood to mean construction elements which as a rule are placed substantially horizontally.
In order to construct a wall, for instance a plasterboard inner wall, it is usual to place a frame, which can be manufactured from wood but also from metal uprights and beams. In the latter case the uprights are usually provided with openings at various heights, through which the beams are inserted and then anchored to the uprights using screws. In order to fixedly screw the uprights and beams it is known here to make use of accessories, such as metal L-profiles, which are arranged in one or more corners formed by the intersections of the uprights and the beams.
It is also known, for instance from American patent US 5 943 838 , to provide the uprights with tabs which are folded in the direction in which the beams extend, and to screw the beams fixedly to these tabs.
Although it is desirable to connect the uprights and beams to each other and the screws fulfil this requirement, erecting a wall from uprights and beams in this manner is a time-consuming procedure, which moreover requires a relatively large amount of materials and tools.
WO 96 23945 describes a metal frame for a building structure. It therefor describes the use of studs with tabs, which can be folded around slots in a track. Although this construction allows studs to be placed on multiple locations on a track, the location of the track is always on the top and on the bottom of the stud, which reduces flexibility.
JPH10292535 describes a frame for a wall of a building, with a metal beam and a rectangular metal stud, provided with a window through which the beam is inserted. The window is provided with a stopper that can be folded away, to allow movement of the beam in vertical direction. Such arrangement however is not suitable to lock a beam and a stud in place.
US 4 693 047 describes a wall framework consisting of vertical studs and horizontal channels extending through openings in the webs of the studs. They are locked firmly in the bottom portion of each opening by bendable sheet metal tabs formed at the sides of each opening and, when bent, engage and hold the channel firmly. Also this arrangement only secures the channel in vertical direction, and still allowing the channel to move in horizontal direction.
US 2003 0106280 describes a stud spaced for connection and extending between studs within a stud wall structure. It thereto provides an elongated member with curved notches to receive a portion of a stud. Such arrangement only prevents movement in horizontal direction, but does not prevent movement in vertical direction.
WO 2006 084367 describes a bracket and bridging member for a metal stud wall. It thereto provides a bracket with a downward extending tab. The tab fits an opening in a cross member. The bracket is than secured to both the stud and the cross member to lock all pieces in place. Such arrangement involves an additional bracket, which is unfavourable, and requires to secure the bracket in place by screwing it to the stud and cross member, which reduces structural integrity.
None of the present solution provided for an arrangement to manufacture a frame, which is secured and stable in horizontal and vertical direction, which can be raised without the use of specialized equipment. It is therefore an object of the present invention to provide a method for manufacturing a frame which obviates the above stated drawbacks or provides a practicable alternative. It is also an object of the present invention to provide uprights for use in such a method.
The invention proposes for this purpose a method for manufacturing a frame, such as a wall or ceiling frame, comprising of providing an upright comprising an elongate metal profile with an opening therein for allowing a beam to rest in the opening, and a tab extending in the opening in a plane of the profile, subsequently placing a beam with a trapezium-shaped section in the opening so that the beam extends substantially perpendicularly of the upright, and wherein the tab is placed through a slot in the beam during placing of the beam, and at least folding the tab in the direction in which the beam extends.
The method according to the invention provides the advantage that construction of for instance the wall can take place much more quickly and easily. This advantage is achieved not only in that the actual anchoring by means of bending the tab is easier than fixing the uprights and beams to each other with or without individual brackets or profiles, but also in that the tab of the upright already holds the slot of the beam after "loose" assembly of the upright and beam. The construction of uprights and beams is hereby already so stable, even when unanchored, that it can stand independently, which allows simple construction of for instance the wall frame by a single person. The material-saving due to no extra brackets and screws being necessary is also an evident advantage.
It is also possible according to the present invention to place a second beam in the opening and on the first beam before bending the tab, so that the second beam extends substantially perpendicularly of the upright, and wherein the tab is likewise placed through a slot in the second beam.
Beams can thus be connected to each other to make for instance wall frames which are wider than the length of the beam, or use can be made of relatively short and therefore manageable beams. Beams are available in fixed length dimensions, for instance 132 cm long. When a wider wall has to be constructed, two beams can in this way be arranged mutually in line. Described below are beams with a profile which is particularly suitable for this method.
Beams can be connected here to more than two uprights placed at a mutual distance and be supported by an upright for instance in the middle of their length or at fixed distances, for instance every 60 cm.
Placing the beam can for instance take place by placing the beam in the opening and then laying the beam on a support surface of the upright intended for the beam while rotating the beam substantially a quarter-turn. The opening of the upright must be dimensioned here such that the beam can be placed unobstructed. The construction of a suitable upright will be further discussed below.
In order to increase the stability of the (wall) frames constructed according to the present method slots extending substantially at a right angle to the longitudinal direction of the beam can be provided in the beam for receiving a part of the upright adjacent to the opening.
In order to perform the above described method an upright with an opening arranged therein can be applied for the purpose of allowing the beam to rest in the opening; and a tab arranged in the opening to be received in a slot of the beam, wherein the opening and the tab are shaped such that the beam can be placed in the opening without the tab having to be bent for this purpose, in addition to a beam provided with a slot for placing therethrough the tab of the upright.
A part of the opening intended to support the beam is preferably at least partially form-fitting with a side of the beam to be turned toward the upright in order to provide a support surface for the beam. The opening for receiving the beam usually takes a U-shaped form on the side intended as upper side during use.
The invention also relates to an upright, evidently intended for use in an above described method or forming part of an above described assembly, and comprising an elongate metal profile such as a C-, U- or Z-profile, in which an opening for receiving a beam therein is provided, and a tab extending in a plane of the profile in which the opening is arranged, wherein the opening and the tab are dimensioned such that a beam, which has a width substantially corresponding with an edge segment of the opening which is intended to support the beam and from which the tab extends, can be placed in the opening without having to bend the tab.
The upright has a side of the opening (generally the underside) intended for supporting the beam with a trapezium form, wherein the tab extends from a side of the trapezium form which is the upper side during use. The dimensioning of this form is further elucidated in the following figure description.
The drawback of the prior art uprights, that the beams can only be placed after the tab has been bent, is hereby obviated, whereby additional measures have to be taken for the mutual anchoring of the uprights and beams. The upright according to the invention comprises a opening sufficiently large to place a suitable beam, a part of which usually corresponds in size with a surface of the beam which is the lower surface during use, in the opening and place the slot thereof over the tab.
In an embodiment the tab is provided on a side thereof connected to the upright with a local weakening for the purpose of simplifying bending of the tab, this local weakening having a length such that the tab can be bent round one or more beams. The weakening extends for this purpose over a distance of the tab from the attachment, the length of which corresponds to the combined thickness of the two beams to be fixed. When the tab is bent it will, depending on the actually available thickness of the beams, lie in each case precisely thereagainst.
The beams that could be used in the present invention preferably comprise an elongate metal profile with a trapezium-shaped section, and a slot arranged in the profile and extending substantially transversely of the longitudinal direction of the profile for passage therethrough of a tab of an upright.
For further stabilization it also comprises one or more slots extending substantially perpendicularly of the longitudinal direction of the beam for receiving a part of the upright adjacent to a supporting part of the opening.
The invention will now be elucidated with reference to the following figures. Herein:

Figure 1 is a perspective view of an upright according to the present invention;
Figure 2 is a perspective view of a beam according to the present invention;
Figure 3 is a perspective view of an upright, coupled to two beams, according to the present invention; and
Figure 4 is a side view of an upright coupled to beam according to the present invention.

Figure 1 shows an upright 1 according to the present invention formed from a C-profile. Provided in upright 1 are recesses 2 and 3 for placing a beam therethrough (shown in figure 2). The recesses have on the upper side an arcuate form and on the underside a trapezium shape 6, 7 from which tabs 4 and 5 extend, which are each provided with local weakenings 8, 9 which make it possible to bend the tab in one of the directions A or B without tools, and for instance using the thumb, once a beam has been placed. It is noted that the invention is not limited to the embodiments shown in these non-limitative examples
Figure 2 shows a beam 10 for use with the upright of figure 1. Beam 10 has a trapezium-shaped section in that a steel from which the beam is formed is bent along fold lines 11 and 12. The distance C between fold lines 11 and 12 corresponds to the distance C of the support surface of upright 1 for the beam in figure 1, so that the upright forms an optimal support surface for the beam. In a practical embodiment the distance C is for instance between 2 and 6, and more particularly around 4 centimetres. The overall width of opening 2 is for instance between 4 and 8, and particularly around 6 cm.
A central portion of beam 10 comprises a recess 13 through which tab 4 of upright 1 can be placed, as well as notches 14 and 15 in the bent parts outside fold lines 11 and 12 in which a part of upright 1 adjacent to recess 2 can be received. Situated at a distance D from slot 17 is a subsequent slot 17, with a corresponding notches 16 and 18, for coaction with a subsequent upright. The distance D can be any random distance between uprights, for instance 30 or 60 cm.
Figure 3 shows upright 1 of figure 1 coupled to beam 10 of figure 2 and a second similar beam 19. Tab 4 is bent round in order to anchor beams 10 and 19 to upright 1.
Figure 4 is a side view of upright 1 with beam 10. Shown is how upright 1 is partially received in openings 14 and 15 of beam 10. Tab 4 is bent round so that beam 10 is secured to upright 1. Also shown by way of illustration is how a beam 19 can be carried through opening 2 without bending the tab 4.
In addition to the shown embodiment many variations can be envisaged which all lie within the scope of protection of the present invention, as defined in the following claims. It should however also be particularly noted here that the tab can also have forms other than rectangular, that the opening can have multiple forms and sizes, as can the chosen profiles. It is also possible to make use of (fibre-reinforced) plastics as well as metal, particularly for the beams. If desired, a plurality of tabs can be applied, which are for instance bent in opposite directions A, B in order to guarantee a still better securing. Instead of a recess for the purpose of bringing about weakening, a local thinning of the material can also be provided.

Claims

Method for manufacturing a frame, such as a wall or ceiling frame for the purpose of constructing for instance a plasterboard wall or ceiling, comprising of:
- providing an upright (1) comprising an elongate metal profile_with an opening (2, 3) therein for allowing a beam (10) to rest in the opening (2, 3), and a tab (4, 5) extending in the opening (2, 3) in a plane of the profile; characterized by:

- placing a beam (10) with a trapezium-shaped section in the opening (2, 3) so that the beam (10) extends substantially perpendicularly of the upright (1), and wherein the tab (4, 5) is placed through a slot (13, 17) in the beam (10);

- at least folding the tab (4, 5) in the direction in which the beam (10) extends.
Method as claimed in claim 1, comprising of placing a second beam (19) in the opening and on the first beam (10) before bending the tab (4, 5), so that the second beam (19) extends substantially perpendicularly of the upright (1), and wherein the tab (4, 5) is likewise placed through a slot (13, 17) in the second beam (19).
Method as claimed in any of the foregoing claims, comprising of connecting a beam (10, 19) to more than two uprights (1) placed at a mutual distance.
Method as claimed in any of the claims 1-3, comprising of placing the beam (10, 19) in the opening (2, 3) and then laying the beam (10, 19) on a support surface of the upright (1) intended for the beam (10, 19) while rotating the beam (10, 19) substantially a quarter-turn.
Method as claimed in any of the claims 1-4, comprising of providing slots (14, 16) extending substantially at a right angle to the longitudinal direction of the beam (10, 19) for receiving a part of the upright (1) adjacent to the opening (2, 3).
Assembly of at least one upright (1) and at least one beam (10, 19) with a trapezium-shaped section for manufacturing a frame, comprising:
- an upright (1) comprising an elongate metal profile
- with an opening (2, 3) arranged therein for the purpose of allowing the beam (10, 19) to rest in the opening (2, 3); and characterized by

- a tab (4, 5) arranged in the opening (2, 3) in a plane of the profile to be received in a slot (13, 17) of the beam (10, 19);
wherein
- the opening (2, 3) and the tab (4, 5) are shaped such that the beam (10, 19) can be placed in the opening (2, 3) without the tab (4, 5) having to be bent for this purpose;

- the beam (10, 19) having a trapezium-shaped section being provided with a slot (13, 17) for placing therethrough the tab (4, 5) of the upright (1).
Assembly as claimed in claim 6, wherein a part of the opening (2, 3) intended to support the beam (10, 19) is at least partially form-fitting with a side of the beam (10, 19) to face toward the upright (1) in order to provide a support surface for the beam (10, 19).
Upright (1), evidently intended for use in a method as claimed in claims 1-5 or to form part of an assembly according to claim 6 or 7, comprising:
- an elongate metal profile such as a C-, U- or Z-profile,

- an opening (2, 3) for receiving a beam (10, 19) with a trapezium-shaped section therein,

- a tab (4, 5) extending in a plane of the profile in which the opening (2, 3) is arranged, wherein
the opening (2, 3) and the tab (4, 5) are dimensioned such that a beam (10, 19), which has a width substantially corresponding with an edge segment of the opening (2, 3) which is intended to support the beam (10, 19) and from which the tab (4, 5) extends, can be placed in the opening (2, 3) without having to bend the tab (4, 5)
characterized in that the edge segment of the opening (2, 3) intended for supporting the beam (10, 19) is trapezium-shaped (6, 7), wherein the tab (4, 5) extends from a side of the trapezium form.
Upright (1) as claimed in claim 8, wherein the tab (4, 5) is provided on a side thereof connected to the upright (1) with a local weakening (8, 9) for the purpose of simplifying bending of the tab (4, 5), this local weakening having a length such that the tab (4, 5) can be bent round one or more beams (10, 19).