EP4644632A1

EP4644632A1 - Stud system

Info

Publication number: EP4644632A1
Application number: EP24173046.4A
Authority: EP
Inventors: Jurgen KEGELS; Francois AERTS
Original assignee: Saint Gobain Placo SAS
Current assignee: Saint Gobain Placo SAS
Priority date: 2024-04-29
Filing date: 2024-04-29
Publication date: 2025-11-05
Also published as: WO2025228723A1

Abstract

A stud system is provided having a first stud and a second stud, wherein the second stud is received and slidable within a channel of the first stud. The second stud includes a biasing element which is arranged to engage with at least one of the two flanges of the first stud or at least one of the two flanges of the second stud such that the force exerted by the biasing element on said flange or flanges holds the second stud in place within the first stud under gravity.

Description

Technical Field

The present disclosure relates to a stud system for securing a board and a board system comprising the stud system.

Background to the Invention

In order to assemble a board system, it is known that a stud frame must be first erected before a board is attached to provide a wall surface. Stud frames may be made of timber or metal studs arranged horizontally and vertically.
In most known systems, the studs (metal or timber) are cut to the bespoke size needed prior to installation. As such, the systems often cannot be recycled or reused, reducing the diversity of applications and increasing material wastage.
The present invention aims to address these problems by providing a simplified stud that can be used to construct a board system, wherein the configurability of the stud allows the stud to be adjusted for different environments and thus reused and recycled.

Summary of the Invention

In a first aspect of the present invention, an stud system for securing board is provided, the stud system comprising: a first stud and a second stud, each comprising a web and two flanges; wherein the first stud defines a channel inside which the second stud is received; and wherein the second stud is slidable within the channel of the first stud; and a biasing element affixed to the second stud; wherein the biasing element is configured to engage with at least one of the two flanges of the first stud or at least one of the two flanges of the second stud such that the force exerted by the biasing element on said flange or flanges holds the second stud in place within the first stud under gravity.
The present invention thus provides a stud system formed by inserting a second stud within the channel provided by the first stud such that the second stud can slide within the first stud. In some embodiments, the second stud can slide within the first stud to adjust the height of the stud system. In other embodiments, the second stud can be positioned perpendicular to the first stud, with the second stud slideable along the length of the first stud to adjust their relative positions. In some embodiments, the stud system is such that both the height of the stud system and the position of the second stud relative to the first stud can be adjusted independently of one another.
In the described stud systems, the second stud is held in place by the biasing element such that the second stud does not move within the channel under gravity. However, if further adjustment is required, the application of force (i.e. pushing or pulling on the second stud) can overcome the bias of the biasing element such that the second stud is moved relative to the first stud. As such, a board system assembled using the stud system of the first aspect can be taken down and reused in another environment without requiring new studs or parts to be assembled. The present invention thus provides a simple mechanism by which a stud system can be extended and/or adjusted to suit different environments, which in turn allows the stud system to be reused to reduce the carbon footprint of constructing board systems.
The following optional features of the first aspect are provided and may be combined in any suitable and/or desirable combination to provide an embodiment falling within the scope of the present invention as defined by the appended claims.
It will be appreciated that the first stud and the second stud must be suitably dimensioned such that the second stud can slide within the channel of the first stud. As such, a clearance or tolerance fit between the first stud and the second stud may be preferred to allow easy sliding and thus assembly.
Optionally, the board comprises or consists of one or more of the following plasterboard, drywall, wood fibre board, wood particle board, wood board, fibre cement board, open mesh cement board and/or gypsum fibre board.
Optionally, the first stud and the second stud are made from metal, for example, steel. Metal studs exhibit improved strength and stability and provide the advantage that they are non-combustible.
Optionally, the first stud is a C-shaped (e.g. metal) stud. C-shaped studs are known in the art and include a lip at the top of each flange which can ensure that the second stud received within the channel does not move perpendicularly with respect to the web. Optionally, the first stud is a U-shaped (e.g. metal) stud. U-shaped studs are also known in the art, and, in contrast to C-shaped studs, do not include a lip at the top of the flanges. Optionally, the second stud is either a C-shaped or a U-shaped stud.
Optionally, the first stud is a U-shaped stud and the second stud is a U-shaped stud. Optionally, the first stud is a U-shaped stud and the second stud is a C-shaped stud. Optionally, the first stud is a C-shaped stud and the second stud is a U-shaped stud. Optionally, the first stud is a C-shaped stud and the second stud is a C-shaped stud. Where the first stud is a C-shaped stud, this may be advantageous in retaining the second stud within the channel of the first stud.
Optionally, the second stud is received within the channel of the first stud such that the webs of both the first stud and the second stud are substantially parallel to each other. For example, the second stud may be inserted within the channel of the first stud such that the web of the first stud engages with the web of the second stud. In other words, the channels of the first and second studs face the same direction such that the stud system has an open backside (e.g. wherein the frontside would be the solid side provided by the web of the first stud). Alternatively, the second stud may be inserted within the channel of the first stud such that the (e.g. tops of the) flanges of the second stud engage with the web of the first stud. In other words, the second stud may be inserted such that the web of the second stud provides the backside of at least part of the stud system and the web of the first stud provides the frontside of at least part of the stud system (i.e. the second stud closes off the channel of the first stud). This arrangement may be preferable when the stud is being used as a wall stud and thus extends vertically between the floor and the ceiling, wherein movement of the second stud within the channel of the first stud extends or contracts the length of the stud.
Optionally, the second stud is received within the channel of the first stud such that the web of the first stud is substantially perpendicular to the web of the second stud. For example, the second stud may be positioned within the first stud such that the flanges of the second stud engage with the flanges of the first stud and the web of the second stud is perpendicular to the web of the first stud. Such an arrangement may be used to engage a wall stud (e.g. a stud extending between the floor and the ceiling) with a ceiling or floor stud (e.g. a stud extending horizontally along the floor or ceiling of a room where a wall is intended to be erected). Thus, in this example, the first stud acts as a track along which the second stud may be slid to adjust its position along the wall.
Optionally, the stud system comprises two first studs (e.g. a horizontal first stud and a vertical first stud, e.g. a primary first stud and a secondary first stud) and one second stud, wherein the second stud is received within the channels of both first studs. For example, one of the first studs (e.g. the primary stud, e.g. the horizontal stud) may run along the floor or the ceiling of a room and be configured to receive the second stud within its channel such that the second stud extends perpendicularly from the web of said (e.g. primary, e.g. horizontal) first stud. The other first stud may then extend perpendicularly (e.g. vertically) between the floor and the ceiling of the room in which the intended board wall is to be erected. The same second stud may then be received within the other (e.g. second, e.g. vertical) first stud such that the webs of the second stud and the other first stud are parallel and the second stud can slide within the channel of the other first stud to extend the length of the (e.g. wall) stud system.
Optionally, a stud within the stud system may act as a first stud (e.g. receive a second stud within its channel) with respect to one stud within the system, but itself act as a second stud (e.g. itself be received within a channel of another stud) with respect to another stud. For example, the stud system may comprise a first stud, a second stud and a third stud, wherein the third stud is received within the channel defined by the flanges and web of the second stud and is slidable within the channel of the second stud. The third stud optionally also comprises a biasing element affixed thereto, wherein the biasing element is configured to engage with the two flanges of the second stud or the two flanges of the third stud such that the force exerted by the biasing element on said flanges holds the third stud in place within the second stud under gravity. The third stud may therefore be considered to be equivalent to a second second stud such that the second stud acts as a second stud with respect to the first stud, but a first stud with respect to the third stud. The third stud may therefore comprise any of the features described herein with respect to the second stud.
Optionally, the stud system comprises: a floor stud extending along a floor of a room (e.g. a room in which a board wall is to be erected) and a ceiling stud extending along a ceiling of said room; and one or more (e.g. a plurality of) vertical studs, wherein each vertical stud comprises: a first stud and a second stud (e.g. as defined by the first aspect) with the webs of both the first and second studs being parallel to each other; and wherein the first stud is received within the channel of the floor stud (e.g. and extends perpendicularly from the web of the floor stud) and the second stud is received within the channel of the ceiling stud (and extends perpendicularly from the web of the ceiling stud).
Thus, in the above embodiment, the (e.g. plurality of) vertical stud(s) extend between the floor stud and the ceiling stud to provide vertical support for board being attached thereto. The floor stud may thus be considered to be a first stud with respect to the first stud of the vertical stud, and the ceiling stud may be considered to be a first stud with respect to the second stud of the vertical stud. The floor stud and the ceiling stud may therefore comprise any features described herein in relation to the first stud.
The stud system may further comprise a board panel affixed thereto, wherein the fixing of the board panel further secures the position of the second stud with respect to the first stud. Optionally, the board panel is nailed, screwed, crimped or glued to the stud system. Alternatively, the board could be secured to the stud system by a detachable fastening means. The detachable fastening means may comprise a first fastening component attached to or within the board and a second fastening component attached to or within the stud system. Alternatively, one or more elements of the stud system may comprise the second fastening component. The detachable fastening means could comprise magnetic components, or hook-and-loop fasteners. For example, a magnetic component may be attached to or embedded within the board, whereby the board can attach magnetically to the metal stud.
Optionally, the biasing element is configured to engage directly with (i.e. is in contact with) at least one of the two flanges of the first stud. Optionally, the biasing element is configured to engage directly with (i.e. is in contact with) the two flanges of the first stud. Optionally, the biasing element is configured to engage directly with (i.e. is in contact with) at least one of the two flanges of the second stud. Optionally, the biasing element is configured to engage directly with (i.e. is in contact with) the two flanges of the second stud.
Optionally, the biasing element is configured to engage with the flanges of the first stud indirectly. For example, the biasing element may engage directly with the flanges of the second stud such that the flanges of the second stud are forced (e.g. pushed) into engagement with the flanges of the second stud. As such, the biasing element may be considered to be in indirect engagement with the flanges of the first stud via the flanges of the second stud.
Optionally, the biasing element is affixed to the web of the second stud at a position such that the biasing element is located within the channel of the first stud. Optionally, said position is within both the channel of the first stud and the channel of the second stud.
Optionally, said position is within the channel of the first stud but not within the channel of the second stud.
Optionally, the second stud comprises a baseplate extending perpendicularly from the web between two flanges. Optionally the baseplate is at the end of the second stud. The baseplate may be provided via any suitable and/or desirable means. For example, the baseplate may be provided by affixing (e.g. welding) a plate to part of (e.g. the end of) the second stud. For example, the baseplate may be provided by bending the end of the second stud to a substantially 90-degree angle.
Optionally, the biasing element is affixed to the baseplate located at the end of the second stud. It will be appreciated that the topside of the baseplate is the part of the baseplate that faces towards the channel of the second stud (e.g. defined by the web, two flanges and the baseplate) and the underside faces away therefrom. Optionally, the biasing element is affixed to the underside of the baseplate. As such, it will be appreciated that the biasing element is optionally not located within the channel of the second stud. As such, the biasing element may engage with, and exert a force against, at least one of the two flanges of the first stud to hold the second stud in place within the first stud under gravity.
Optionally, the biasing element is located within a channel defined by the web and two flanges of the second stud. For example, the biasing element may be affixed to the interior surface (i.e. the surface forming part of the channel) of the web of the second stud. In such embodiments, the second stud engages with, and exerts a force against, at least one of the two flanges of the second stud which is/are, in turn, pushed against the flange or flanges of the first stud such that the second stud is held in place under gravity.
Optionally, the biasing element is affixed to the underside of the web (e.g. the reverse side to the interior surface, e.g. the surface facing away from the channel) of the second stud such that the biasing element is not located within a channel defined by the web and two flanges of the second stud. In such embodiments, the biasing element engages with, and exerts a force against, at least one of the two flanges of the first stud to hold the second stud in place within the first stud under gravity.
Optionally, the biasing element is affixed to the second stud proximate (e.g. within 10 cm of, e.g. within 5 cm of) to an end of the second stud. Optionally, the second stud comprises two or more (e.g. a plurality of) biasing elements arranged along its length. Optionally, at least one of the biasing elements is proximate to an end of the second stud. Optionally, each end of the second stud comprises a biasing element. Optionally, the second stud comprises a biasing element proximate to (e.g. within 10 cm of, e.g. within 5 cm of) each end.
Optionally, the surface of the two flanges of the first stud or two flanges of the second stud with which the biasing element engages are substantially smooth such that the second stud is held in place within the first stud by friction.
Optionally, the surface of the two flanges of the first stud or two flanges of the second stud with which the biasing element engages each comprise raised surface features such that the second stud is held in place by a combination of friction and physical contact between the biasing element and the surface features. Said raised surface features may be any suitable and/or desirable design or pattern. For example, the raised surface features may be notches, bumps, grooves, ridges or lines. Said raised features may be a textured surface (e.g. a rough surface) with no discernible pattern. Said raised surface features may be formed in any suitable and/or desirable way, e.g. by adding or depositing material, e.g. by stamping or indenting the surfaces, e.g. by texturizing (e.g. sanding) the surface. Optionally, the raised surface features comprise or consist of stamped features. Optionally, the raised surface features comprise or consist of cold rolled features.
Optionally, the biasing element is made from the same material as the first and second stud. Optionally, the biasing element is made from metal, for example, steel.
The biasing element may be any suitable and/or desirable means by which a sufficient biasing force is applied to the flanges of the first and/or second stud to hold the second stud in place. For example, the biasing element may be any suitable and/or desirable spring element such as a coil spring, a spiral spring, a leaf spring, a flat spring or a torsion spring.
Optionally, the biasing element is a (e.g. metal) spring. For example, the biasing element may comprise a central base portion and two leg portions, wherein the two leg portions extend outwardly from the central base portion, e.g. the two leg portions extend away from each other in opposing directions. Optionally, the leg portions extend away from central base portion at an obtuse angle (i.e. the plane of the central base portion intersects the planes of the leg portions at an obtuse angle). It will thus be appreciated that each leg of the biasing element will have an equilibrium angle, and deviation away from that angle (e.g. by contact with the flanges of either the first or second stud) will result in the leg exerting a biasing force on the flanges. Optionally, the central base portion is flat. Optionally, each of the leg portions comprises a curved portion or is curved. Optionally, each of the leg portions is flat or comprises a flat portion.
Optionally, the biasing element is affixed to the second stud by at least one of: one or more rivets, screws, an adhesive or a weld join.
Optionally, the stud system is extendable in a direction parallel to the longitudinal axis of the first stud. In this way, the second stud may be moved within the first stud to alter the overall length of the stud system as desired.
In a second aspect, the present invention provides a second stud for use in the stud system as hereinbefore described in the first aspect.
In a third aspect, the present invention provides a board system comprising the stud system of the first aspect and one or more boards attached thereto.
Optionally, the board comprises or consists of one or more of the following plasterboard, drywall, wood fibre board, wood particle board, wood board, fibre cement board and/or gypsum fibre board.

Brief Description of Drawings

The disclosure will be further described with reference to examples depicted in the accompanying figures in which:

Figure 1 schematically represents a second stud in accordance with an embodiment;
Figure 2 schematically represents a second stud in accordance with an embodiment;
Figure 3 schematically represents a stud system in accordance with an embodiment; and
Figure 4 schematically represents a stud system in accordance with an embodiment.

Detailed Description

The following description presents particular examples and, together with the drawings, serves to explain principles of the disclosure. However, the scope of the invention is not intended to be limited to the precise details of the examples, since variations will be apparent to a skilled person and areas deemed to be covered by the description. Terms for components used herein should be given a broad interpretation that also encompasses equivalent functions and features. In some cases, alternative terms for structural features may be provided but such terms are not intended to be exhaustive.
Descriptive terms should also be given the broadest possible interpretation, e.g. the term "comprising" as used in this specification means "consisting at least in part of' such that interpreting each statement in this specification that includes the term "comprising", features other than that or those prefaced by the term may also be present. Related terms such as "comprise" and "comprises" are to be interpreted in the same manner.
The description herein refers to examples with particular combinations of features, however, it is envisaged that further combinations and cross-combinations of compatible features between embodiments will be possible. Indeed, isolated features may function independently as an invention from other features and not necessarily require implementation as a complete combination.
Figure 1 schematically represents a second stud 100. As shown, in this embodiment the second stud 100 is a C-shaped stud having a channel 150 defined by a web 105 and two flanges 110a, 110b, wherein each flange 110a, 110b has a lip 115a, 115b. Although this embodiment is shown as a C-shape it can be appreciated that a U-shaped stud may alternatively be used without affecting any of the other features of the embodiment.
The end of the second stud 100 comprises a biasing element 120 affixed to the web 105 by two screws 135. The biasing element 120 shown is in the form of a flat metal spring having a central base portion 125 and two leg portions 130a, 130b which extend away from each other, and each engage one of the two flanges 110a, 110b. As can be seen, the biasing element 120 spans the web 105 and is designed such that, when the biasing element 120 is in position, a force is exerted on the flanges (due to the bias of the spring) to push the flanges outwardly.
Figure 2 schematically represents a second stud 200, also in the form of a C-shaped stud (although a U-shaped stud may alternatively be used without altering any of the other features) having a channel 250 defined by a web 205 and two flanges 210a, 210b, wherein each flange 110a, 110b has a lip 215. However, unlike the embodiment shown in Figure 1, the second stud 200 shown in Figure 2 comprises a baseplate 240 at the end of the stud 200. In the embodiment shown, the baseplate 240 is formed by cutting away a portion of the flanges 210a, 210b and bending the end of the web 205 up to approximately 90 degrees. The baseplate 240 is thus continuous with the web 205 in this embodiment, however, it will be appreciated that the baseplate may be formed in any suitable and/or desirable way. For example, the baseplate could be formed by cutting away the web and turning in the flanges, or by affixing (e.g. gluing or welding) a separate plate to the end of the stud 200.
In this embodiment, the biasing element 220 is affixed to the underside of the baseplate 240 with two screws 235 such that the biasing element 220 is not located within the channel 250 of the second stud 200. Again, the biasing element 220 shown is in the form of a flat metal spring having a central base portion 225 and two leg portions 230a, 230b which extend away from each other and are designed such that they will engage with one of the two flanges of a first stud once the second stud is inserted therein.
As can be seen, the biasing element 120 spans the web 105 and is designed such that, when the biasing element 120 is in position, the tip to top distance between the end of the two leg portions 230a, 230b is greater than the width of the channel 250.
Figure 3 shows a stud system 500 comprising a first stud 300 and a second stud 400. In this embodiment, both the first stud 300 and the second stud 400 are U-shaped studs having a web 305, 405, and two flanges 310a, 310b, 410. The second stud 400 includes a biasing element 420 affixed proximate to its end such that, when the second stud 400 is inserted into the channel 350 of the first stud 300 at a perpendicular angle (e.g. such that the webs 305, 405 of the two studs 300, 400 are perpendicular) the biasing element 420 is located within both the channel 350 of the first stud 300 and the channel 450 of the second stud 400.
As such, when the second stud 400 is located within the channel 350 of the first stud 300, the legs 430a, 430b engage with, and exert a force on, the flanges 410 of the second stud 400, which then, in turn, pushes against the flanges 310a, 310b of the first stud 300 to hold the second stud 400 in place within the first stud 300. To further improve the strength of the hold, the internal walls of the flanges 410 of the second strut 400 (e.g. the surfaces which engage with the biasing element 420) further comprise texturizing or raised features, which are shown as stamped bumps in the embodiment shown but may be any suitable and/or desirable feature.
The embodiment shown in Figure 3 may be particularly useful in systems wherein the first stud 300 is a ceiling or floor stud (e.g. running along a ceiling or wall) and the second stud 400 forms part of a vertical wall stud (e.g. extending between the wall and the ceiling). For example, the vertical wall stud could be an extendable vertical wall stud similar or identical to that shown in the embodiment of Figure 4.
Figure 4 shows a stud system 800 comprising a first stud 600 and a second stud 700. In this embodiment, the first stud 600 is a C-shaped stud having a web 605 and two flanges 610a with lips 615a, 615b whereas the second stud 700 is a U-shaped stud having a web 705, two flanges 710a and a baseplate 740.
In this embodiment, the biasing element 720 is affixed to the underside of the baseplate 240 at the central portion 725 such that the biasing element 720 is located within the channel of the first stud 650 but not the channel 750 of the second stud 700. As such, when the second stud 700 is inserted into the channel 650 of the first stud 600 such that the two studs 600, 700 extend in parallel (e.g. such that the webs 605, 705 of the two studs 600, 700 are parallel, and, in this embodiment, engaging) the biasing element 720 engages with the flanges 610a of the first stud 600 but not with the flanges 710a of the second stud 700. The biasing element 720 thus exerts a force on the flanges 610a of the first stud 600 to hold the second stud 700 in place within the channel 650 of the first stud 600.
As with the embodiment of Figure 3, to further improve the strength of the hold, the internal walls of the flanges 610 of the first strut 600 (e.g. the surfaces which engage with the biasing element 720) further comprise texturizing or raised features, which are shown as stamped bumps in the embodiment shown but may be any suitable and/or desirable feature.
As such, the biasing element 720 will prevent movement of the second stud 700 within the first stud 600 under gravity shown by arrow 810 due to both the biasing force and engagement with (e.g. catching on) the raised features of the internal surface of the flanges 610a. However, movement in the opposing direction (e.g. by pulling) will overcome the bias and allow the second stud 700 to be extended out from the channel of the first stud 600.

Claims

A stud system for securing board, the stud system comprising:
a first stud and a second stud each comprising a web and two flanges; and
wherein the first stud defines a channel inside which the second stud is received, wherein the second stud slidable within the channel of the first stud; and

a biasing element affixed to the second stud;
wherein the biasing element is configured to engage with at least one of the two flanges of the first stud or at least one of the two flanges of the second stud such that the force exerted by the biasing element on said flange or flanges holds the second stud in place within the first stud under gravity.
The stud system of claim 1, wherein the first stud is either a C-shaped stud or a U-shaped stud; and the second stud is either a C-shaped or U-shaped stud.
The stud system of claim 1 or claim 2, wherein the biasing element comprises a central base portion and two leg portions extending outwardly therefrom at an obtuse angle with respect to the central base portion.
The stud system of claim 3, wherein the biasing element is a metal spring.
The stud system of claim 3 or claim 4, wherein each leg portion comprises a flat portion and/or a curved portion.
The stud system of any one of any one preceding claim, wherein the second stud is received within the channel of the first stud such that the webs of both the first stud and the second stud are substantially parallel to each other.
The stud system of claim 6, wherein the biasing element is located within a channel defined by the web and two flanges of the second stud; and
wherein the second stud engages with, and exerts a force against, the two flanges of the second stud which are, in turn, pushed against the flanges of the first stud such that the second stud is held in place under gravity.
The stud system of claim 6 or claim 7, wherein an end of the second stud comprises a baseplate extending perpendicularly from the web and between the two flanges.
The stud system of claim 8, wherein the biasing element is affixed to the baseplate such that the biasing element engages with, and exerts a force against, the two flanges of the first stud to hold the second stud in place within the first stud under gravity.
The stud system of any one of claims 1 to 5, wherein the second stud is received within the channel of the first stud such that the web of the first stud is substantially perpendicular to the web of the second stud.
The stud system of claim 10, wherein the biasing element is affixed to the web of the second stud at a position such that the biasing element is located within the channel of the first stud.
The stud system of any one preceding claim, wherein the surface of the two flanges of the first stud or the two flanges of the second stud with which the biasing element engages are substantially smooth such that the second stud is held in place within the first stud by friction.
The stud system of any one preceding claim, wherein the surface of the two flanges of the first stud or the two flanges of the second stud with which the biasing element engages each comprise raised surface features such that the second stud is held in place by a combination of friction and physical contact between the biasing element and the surface features.
The stud system of claim 13, wherein the surface features are notches, bumps grooves, ridges or lines.
A second stud for use in the stud system of any one preceding claim.