GB2546573A

GB2546573A - Device for connecting components of a wall frame assembly and method of using said device

Info

Publication number: GB2546573A
Application number: GB1614991.6A
Authority: GB
Inventors: Baccarini Tony
Original assignee: Unique Construction Solutions Ltd
Current assignee: Unique Construction Solutions Ltd
Priority date: 2016-01-20
Filing date: 2016-09-05
Publication date: 2017-07-26
Anticipated expiration: 2036-09-05
Also published as: GB2546561A; GB201601017D0; GB201614991D0; GB2546508A; GB2546573B; GB201604147D0; WO2017125757A1

Abstract

The device 200 comprises a body 202 attachable to a first frame component 300 and a magnetic portion 204 for connection to a second frame component 804. The device may press fit into the first frame component. The body may be tapered, and comprise relatively movable first and second portions 202a, 202b. The first portion may attach to the first frame component and the second portion may comprise the magnetic portion. The device may have a second magnetic portion for connection to the first frame component. The magnetic portions may be on protrusions which engage recesses in the second frame component. Also claimed is a frame assembly comprising a frame component and the device. Also claimed is a method of constructing a frame, comprising attaching a device comprising a body and a magnetic portion to a frame component, and attaching the device to a magnetic surface. The frame components may be studs, transoms or lintels.

Description

DEVICE FOR CONNECTING COMPONENTS OF A WALL FRAME ASSEMBLY AND METHOD OF USING SAID DEVICE

Field of the Invention

The present invention relates to a device for connecting components of a wall frame and, more particularly, to a device for magnetically connecting two wall frame components and a method of constructing a wall frame using one or more of said devices.

Background to the Invention

Conventional dry wall frames, such as the GypWall™ manufactured and sold by British Gypsum™, are usually constructed of vertical studs, such as the steel GypFrame™ studs used in the GypWall™ which have a c-shaped cross section. The studs are cut to length and placed between and secured to floor and ceiling channels or tracks, which are respectively secured to the floor and the ceiling between which the wall is being built.

Conventionally, the vertical studs are secured to the floor and ceiling tracks by screwing or by crimping/riveting the vertical studs to the tracks.

The heads and sills of any openings in the wall are constructed by fixing horizontal wall frame members between the vertical studs. The horizontal wall frame members are secured to the vertical studs by screwing or by crimping/riveting the horizontal wall frame members to the vertical studs.

Such wall frames are commonly built in place, one piece at a time and, where the wall frame is made of steel, the various components of the wall frame are commonly fastened together using sheet-metal screws. This requires the use of power tools in the construction of a wall.

In metal wall frames, wall frame members are often cut and folded at one or both ends such that the folded portion of the wall frame member provides a surface which can be fastened to another wall frame member.

This is particularly common where a door frame or other opening is to be built into a wall frame. It is common practice for the transom or other such horizontal wall frame member to be constructed of a steel framing member that is cut and folded at both ends to create surfaces that can be fastened to vertical studs which define either side of the door frame using sheet-metal fastening screws or rivets.

The construction of conventional dry wall frames is both time consuming and requires a high level of skill as the measuring and laying out of the wall frame can be complicated and precision is required in cutting the sheet-metal of the horizontal frame members so that they can be folded and subsequently fastened to the vertical studs.

Additionally, once a wall frame has been constructed and all of the various wall frame components have been fixed together, it is difficult and time consuming to make any alterations to the wall frame. For example, if a transom needs to be repositioned, each of the fixing screws need to be removed from each end of the transom and the transom needs to be fixed again into its new position by rescrewing the transom to the vertical studs at either side.

The cost of labour is a significant part of any construction project. As such, the time taken to construct and/or alter wall frames can have a considerable associated cost.

Accordingly, there is a need to improve the construction of dry wall frames. Summary of the Invention

According to a first aspect of the invention, there is provided a device for providing a magnetic connection between first and second frame components, the device comprising: a body that is attachable to a first frame component; and a magnetic portion for forming a magnetic connection with a magnetic surface of a second frame component.

Advantageously, wall frame components can be attached together by the device of the present invention without the need for screws or rivets. Accordingly, the complexity of the construction of wall frames is greatly reduced and the alteration of constructed wall frames is simplified. As such, construction and alteration time is reduced, as is the required skill level of the constructor.

Preferably, the device is configured to be inserted into an end of the first frame component.

Preferably, the device is configured to be press fitted into an end of the first frame component.

Preferably, an outer surface of the device comprises grooves to facilitate attachment of the device to the first frame component via a press fit.

Preferably, the body further comprises a lip portion configured to abut an end of the first frame component when the device is inserted into an end of the first frame component so as to restrict the depth of insertion of the device.

Preferably, the magnetic portion further comprises a magnet and the body further comprising a recess for receiving the magnet.

Preferably, the body further comprises a first portion configured to be attached to the first frame component, and a second portion moveable relative to the first portion, wherein the second portion comprises the magnetic portion.

Preferably, the movement of the second portion relative to the first portion allows a magnetic connection between the first and second frame components to be maintained during relative movement between the first and second frame components.

Preferably, the device further comprising a biasing member to bias the second portion toward a fully protruded position.

Preferably, the device further comprises one or more abutment protrusions arranged to engage with the first frame component to enable a press fitting engagement between the first frame component and the device.

Preferably, the device further comprises a clip for clipping the device to the end of the first frame component.

Preferably, the magnetic portion is configured to form a removable magnetic connection with a magnetic surface of the second frame component such that the device can be repositioned on a magnetic surface of the second frame component.

Preferably, the body is tapered.

Preferably, the device further comprises a second magnetic portion for forming a magnetic connection with the first frame component.

Preferably, the device further comprises a damping element.

Preferably, the device further comprises at least a single protrusion for engaging a recess in the second frame component.

Preferably, the protrusion is in the form of ridge arranged to engage with a channel in the second frame component.

Preferably, the protrusion is arranged to engage with the cavity defined by the c-shaped cross section of a stud.

Preferably, the magnetic portion is disposed on the protrusion.

Preferably, the device comprises two or more protrusions for engaging recesses in the second frame component.

Preferably, the protrusions are in the form of ridges arranged to engage with channels in the second frame component.

Preferably, the magnetic portion is disposed on the protrusions.

Preferably, the first frame component is a first wall frame component and/or wherein the second frame component is a second wall frame component.

According to a second aspect of the invention, there is provided a frame assembly comprising a frame component, and the device according to the first aspect of the invention, wherein the device is attached to the frame component.

Preferably, the frame assembly further comprises a second device that is a device according to the first aspect of the invention, wherein the device is attached to a first end of the frame component and the second device is attached to a second end of the frame component opposite first end, such that both ends of the frame component are attachable to a magnetic surface.

Preferably, the frame assembly further comprises a first track and a second track, wherein the frame component is magnetically attached to the first track via the device and, wherein the frame component is magnetically attached to the second track via the second device.

Preferably, the frame assembly further comprises a plurality of frame components, wherein each frame component is magnetically attached to the first track via a device according to the first aspect of the invention and, wherein each frame component is magnetically attached to the second track via a second device according to the first aspect of the invention.

Preferably, the frame assembly further comprises a transverse frame component, wherein the transverse frame component is magnetically attached between two of the plurality of frame components via a device according to the first aspect of the invention attached to a first end of the transverse frame component and a second device a the first aspect of the invention attached to a second end of the transverse frame component opposite the first end.

Preferably, the frame component is a wall frame component and, preferably, the wall frame component is one or more of a stud, transom or lintel.

Preferably, the frame assembly is a wall frame assembly.

Preferably, the frame component, or frame components, comprises a recess or recesses arranged to receive a protrusion of the device.

Preferably, the frame component, or frame components, comprises channels arranged to receive a ridge or ridges of the device.

According to a third aspect of the invention, there is provided a method of constructing a frame, the method comprising the steps of: attaching a device comprising a body and a magnetic portion to a frame component; and attaching the device to a magnetic surface, such that the frame component is held in place relative to the magnetic surface.

Preferably, the device is a device according to the first aspect of the invention.

Preferably, the step of attaching the device to a magnetic surface comprises attaching the device to a magnetic surface of a second frame component, such that the frame component is held in place relative to the second frame component.

Preferably, the step of attaching a device comprising a body and a magnetic portion to a frame component comprises attaching the device to a first end of the frame component, the method further comprising the steps of: attaching a second device comprising a body and a magnetic portion to a second end of the frame component opposite the first end; and attaching the second device to a second magnetic surface, such that the frame component is held in place relative to the second magnetic surface.

Preferably, the second device is a device according to the first aspect of the invention.

Preferably, the step of attaching the second device to the second magnetic surface comprises attaching the second device to a magnetic surface of a third frame component, such that the frame component is held in place relative to the third frame component.

Preferably, the magnetic portion of the second device is configured to form a removable magnetic connection with the second magnetic surface, such that the device can be repositioned on the second magnetic surface.

Preferably, the magnetic portion of the device is configured to form a removable magnetic connection with the magnetic surface, such that the device can be repositioned on the magnetic surface.

Preferably, the frame component(s) is a wall frame component.

According to a fourth aspect of the invention, there is provided a device for providing a magnetic connection between first and second frame components substantially as described herein with reference to the accompanying figures.

According to a fifth aspect of the invention, there is provided frame assembly substantially as described herein with reference to the accompanying figures.

According to a sixth aspect of the invention, there is provided a method of constructing a frame substantially as described herein with reference to the accompanying figures.

According to a seventh aspect of the invention, there is provided a frame component for use in a frame assembly, the frame component comprising a recess arranged to receive the protrusion of the device of the first aspect.

Preferably, the recess is in the form of two channels.

Brief Description of Drawings

Embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which:

Figure 1 depicts a device according to an embodiment of the present invention;

Figure 2 depicts an alternative device according to an embodiment of the present invention;

Figure 3a depicts a cross section of a stud with devices according to embodiments attached;

Figure 3b depicts a perspective view of the stud of Figure 3a;

Figure 4 depicts an alternative device according to an embodiment configured to be inserted into the end of a horizontal wall frame member, such as a cross rail or a transom;

Figure 5 depicts a further alternative device according to an embodiment configured to be inserted into the end of a horizontal wall frame member, such as a cross rail or a transom;

Figure 6 depicts a cross rail or transom with a device according to an embodiment inserted into an end of the transom or cross rail;

Figure 7 depicts the cross rail or transom shown in Figure 6 with a device according to an embodiment inserted into an end of the cross rail or transom;

Figure 8 depicts an exploded diagram of an example wall frame assembly according to an embodiment;

Figure 9 depicts an alternative device according to an embodiment the present invention;

Figure 10 depicts a flowchart depicts a flowchart of the steps involved in constructing a wall frame;

Figure 11 depicts an alternative device according to an embodiment of the present invention;

Figure 12 depicts a further alternative device according to an embodiment of the present invention;

Figure 13 depicts a further alternative device according to an embodiment of the present invention

Figure 14 depicts a diagram of an example wall frame assembly according to an embodiment;

Figure 15 depicts an exploded diagram of an example wall frame assembly according to the embodiment shown in Figure 14;

Figure 16 depicts a cross-section of a frame component according to an embodiment;

Figure 17 depicts an exploded diagram of an example wall frame assembly according to an embodiment;

Figure 18 depicts a side on wireframe diagram of an example wall frame assembly according to the embodiment shown in Figure 17; and

Figure 19 depicts a top down wireframe diagram of an example wall frame assembly according to the embodiment shown in Figures 17 and 18;

Figure 20 depicts three views of a further alternative device according to an embodiment the present invention;

Figure 21 depicts a further alternative device according to an embodiment the present invention.

Figure 22 depicts an exploded diagram depicted in Figure 21.

Figure 23 depicts three views of the device depicted in Figure 21 inserted into an end of a vertical stud;

Detailed Description

Figure 1 depicts a device 100 according to an embodiment the present invention. The device 100 comprises a body 102 that is attachable to an end of a wall frame component, as shall be described in further detail below. The device 100 further comprises a magnetic portion 104 shown in Figure 1 as two disc magnets housed within recesses of the body 102.

Although the magnetic portion 104 is depicted as two disc magnets, any number of magnets may be used and the magnets may be of any shape. Similarly, in all of the other embodiments described herein, the magnetic portions of those embodiments may each comprise any number of magnets and the magnets may each be of any shape.

The magnetic portion 104 of the device 100 and those of all of the devices described herein are configured to form removable magnetic connections with a magnetic surface of a further wall frame component comprising a magnetic material.

The magnetic portion 104 of the device 100, and those of all of the devices described herein, may be provided in the form of magnets attached to the body 102 of the device or may comprise a part of the body 102 of the device, for instance where the body is at least partially made of a magnetic material.

The devices described herein can form a magnetic connection with a magnetic surface of a further wall frame component, thereby holding the wall frame component to which they are attached in place relative to the further wall frame component. Additionally, the devices enable repositioning of the wall frame component on the further wall frame component.

The device 100 shown in Figure 1 further comprises a lip portion 106, configured to abut an end of a wall frame component when the device 100 is inserted into the end of a wall frame component so as to restrict the depth of insertion of the device 100.

The device 100 may be in the form of a block, as shown in Figure 1, although other forms are envisaged, dependent upon the configuration of the wall frame component to which the device 100 is attachable. The device 100 is designed to be inserted into an end of wall frame member with c-shaped cross section, such as the aforementioned GypFrame™ studs.

It will be understood that the form of the device 100, and all of the devices according to embodiments described herein, can be altered dependent on the configuration of a particular wall frame component and/or dependent on the nature of the attachment between the device 100 and wall frame component.

When attached to the end of a wall frame component, the device 100, as well as all of the devices according to embodiments described herein, is configured to form a magnetic connection with the surface of a further wall frame component thereby attaching the two wall frame components together, as shall be described in more detail in what follows.

The device 100 shown in Figure 1 is configured such that it can be press fitted into an end of a conventional wall frame member. As such, the device 100 can be retrofitted to existing wall frame components without any modification of the wall frame components required. Preferably, this is also true of all of the devices according to embodiments described herein.

It will be appreciated that other types of engagements between the device 100, as well as all of the devices according to embodiments described herein, and a wall frame member are possible and that the design of the device 100 can be altered accordingly.

For example, the device 100, as well as all of the devices according to embodiments described herein, could be fixed to the end of a wall frame member via a screw or screws, in which case the device 100 could comprise a pilot hole for a screw or via use of an adhesive.

Figure 2 depicts an alternative embodiment which is a device 200 for providing a magnetic connection between two wall frame components. The device 200 comprises a body 202, wherein the body comprises a first portion 202a and a second portion 202b which is movable relative to the first portion 202a. The first portion 202a of the body 202 further comprises a lip portion 206 which performs the same function as the lip portion 106 of the device 100 shown in Figure 1.

The second portion 202b of the body 202 comprises recesses within which magnetic rods 204 are inserted. The magnetic rods 204 are fixed to the second portion 202b of the body 202 such that they move with the second portion of the body 202b.

The first portion 202a of the body 202 comprises a vertical portion 208 with a c-shaped cross section and a horizontal portion 210. The horizontal portion 210 comprises two orifices through which the magnetic rods 204 are inserted in such a way that the magnetic rods 204 are free to move relative to the horizontal portion 210 and, therefore, also relative to the first portion 202a of the body 202.

The second portion 202b of the body 202 is housed within the c-shaped cross section of the first portion 202a of the body 202 and is able to slide relative to the first portion 202a of the body 202.

The magnetic rods 204 are shown in Figure 2 in their fully retracted position. As the second portion 202b of the body 202 moves toward the horizontal portion 210 of the first portion 202a of the body 202, the magnetic rods 204 protrude further and further from the horizontal portion 210 of the first portion 202a of the body 202. It is by this mechanism that the device 200 shown in Figure 2 is able to account for any deflection in an assembled wall frame, as shall be described in more detail in what follows.

When attached to the end of a wall frame component, the device 200 is configured to form a magnetic connection with the surface of a further wall frame component thereby attaching the two wall frame components together. Further, a degree of movement of the further wall frame component away from the wall frame component to which the device 200 is attached is permitted by the above described construction of the device 200. The degree of movement is defined by the extent to which the first and second portions can move relative to each other.

It will be understood that the form of the device 200 can be altered dependent on the configuration of a particular wall frame component and/or dependent on the nature of the attachment between the device 200 and wall frame component.

The device 200 shown in Figure 2 is configured such that it can be press fitted into an end of a conventional wall frame member. As such, the device 200 can be retrofitted to existing wall frame components without any modification of the wall frame components required.

It will be appreciated that other types of engagements between the device 200 and a wall frame member are possible and that the design of the device 200 can be altered accordingly.

For example, the device 200 could be fixed to the end of a wall frame member via a screw or screws, in which case the device 200 could comprise a pilot hole for a screw, of via use of an adhesive.

Figures 3a and 3b depict a vertical stud 300 of the type used in conventional steel wall frames, such as the GypFrame™ studs used in the GypWall™ manufactured and sold by British Gypsom™. Studs of this type are commonly made of steel and commonly have a c-shaped cross section.

The stud 300 shown in Figures 3a and 3b is shown with a device 100 of the type shown in Figure 1 inserted into its lower end and a device 200 of the type shown in Figure 2 inserted into its upper end.

Figure 3a shows a cross section of the stud 300 with the devices 100, 200 inserted at either end and Figure 3b shows a perspective view of the same stud 300.

An outer surface of each of the devices 100, 200 which is configured to be inserted into the stud 300 in the manner shown in Figure 3a may comprise grooves to facilitate attachment of the devices 100, 200 to the stud 300, or any other wall frame components within which they are designed to be inserted.

The devices 100, 200 are configured to be held securely in place via their press fitting engagement with the stud 300.

It will be understood that once the stud has been assembled in the way shown in Figures 3a and 3b, it can be attached to a magnetic surface at either end via the magnetic connection provided by the magnetic portions 104, 204 of each of the devices 100, as shall be described in greater detail in what follows.

With regard to the deflection ability of the device 200, it will be clear that, when the magnetic rods 204 are adhered to a particular magnetic surface, movement of said magnetic surface relative to the stud 300 within which the device 200 is inserted in a direction away from the stud 300 will cause the magnetic rods 204 and the second portion 202b of the body 202 of the device 200 to move relative to the first portion 202a of the body 202. In this way, the device 200 is able to provide a predetermined deflection tolerance which is useful where movement of a wall frame is anticipated, for example in high rise buildings.

Figures 4 and 5 depict a pair of devices 400, 500 according to alternative embodiments configured to be inserted into ends of a horizontal wall frame member, such as a cross rail or a transom.

The devices 400 and 500 shown in Figures 4 and 5 are configured such that they can be press fitted into an end of a conventional wall frame member. As such, the devices 400 and 500 can be retrofitted to existing wall frame components without any modification of the wall frame components required.

The device 400 shown in Figure 4 comprises a body 402 much the same as the body 102 of the device 100. The device 400 comprises a magnetic portion 404 in the form of two magnetic discs placed within recesses of the body 402, as shown in Figure 4. The body 402 of the device 400 comprises a lip portion 406 which is configured to abut an end of a wall frame component when the device 400 is inserted into an end of a wall frame component so as to restrict the depth of insertion of the device. Preferably, the lip portion of the device is larger than the lip portion 106 of the device 100.

The body 402 of the device 400 shown in Figure 4 comprises grooves to facilitate attachment of the device to a wall frame component via a press fit, although these grooves are not an essential feature.

The device 400 comprises a front portion 410 configured to abut against the flat surface of a vertical stud, such as the stud 300 shown in Figures 3a and 3b, as shall be described in more detail below.

Figure 5 depicts a device 500 comprising a body 502. The body comprises a lip portion 506 which may have the same geometry as the lip portion 406 of the device 400.

The body 502 of the device 500 shown in Figure 5 comprises grooves to facilitate attachment of the device to a wall frame component via a press fit, although these grooves are not an essential feature.

The device 500 further comprises a male portion 510 (or protrusion) configured to be inserted within the cavity defined by the c-shaped cross section of a stud such as the stud 300 shown in Figures 3a and 3b. The male portion 510 of the device 500 comprises a magnetic portion 504 in the form of two disc magnets disposed within recesses in the male portion 510.

The magnetic potion 504 may be disposed on a surface 508 of the male portion 510 furthest from the lip portion 506, as shown in Figure 5. As is shown in Figure 8, the magnetic potion 504 would engage with the rearmost surface of the cavity defined by the c-shaped cross section of a stud.

In an alternative embodiment, the magnetic potion 504 may be disposed on a side surface 512 of the male portion 510. The magnetic potion 504 would engage with the surfaces either side of the rearmost surface of the cavity defined by the c-shaped cross section of a stud.

The device 500 can also be adapted to attach two wall frame members together collinearly to make a longer wall frame member.

Figure 6 shows a cross rail or transom 600 with the device 400 inserted into an end of the transom or cross rail 600.

Figure 7 shows the cross rail or transom 600 shown in Figure 6 with the device 500 inserted into an end of the cross rail or transom.

Figure 8 depicts an exploded diagram of an example wall frame assembly 800. The wall frame assembly 800 comprises a floor track 802 and a ceiling track 804 which can respectively be fixed to a floor and a ceiling between which a wall frame assembly 800 is to be constructed.

The wall frame assembly 800 further comprises two vertical studs 300, each with a device 200 at a top end thereof and a device 100 at a bottom end thereof.

The wall frame assembly 800 further comprises a cross rail or transom 600 with a device 400 at a first end and a device 500 at a second end thereof.

It will be appreciated that once the wall frame is assembled, upward movement of the ceiling track 804 relative to the vertical studs 300 is possible because of the aforementioned deflection mechanism of the device 200.

The wall frame assembly 800 can be constructed by inserting the various devices 100, 200, 400 and 500 into the ends of their respective studs 300 or cross rail 600.

The length of the vertical studs 300 is such that the stud 300 can be inserted between the floor track 802 and the ceiling track 804 with the device 100 magnetically connecting the stud 300 to the floor track 802 and the device 200 magnetically connecting the stud 300 to the ceiling track 804, thus holding the stud in place between the floor track 802 and the ceiling track 804. In this way, both the studs 300 shown in Figure 8 can be held in place between the floor track 802 and the ceiling track 804 via the magnetic connections provided by the devices 100, 200.

The length of the transom/cross rail 600 is such that it can be placed between the two vertical studs 300, as shown in Figure 8. The male portion 510 of the device 500 is inserted within the recess defined by the c-shaped cross section of the stud 300, such that the magnetic portion 504 holds the cross rail/transom 600 in place via a magnetic connection with the stud 300. The device 400 abuts against the outer surface of the other stud 300 such that the magnetic portion 404 of the device 400 is able to fix the cross rail/transom 600 in place relative to the two studs 300, as shown in Figure 8.

Once the wall frame assembly 800 has been assembled, plaster boards can be fixed to the wall frame via conventional techniques.

Figure 9 depicts a cross section of a device 900 according to an alternative embodiment comprising a body 902 that is attachable to an end of a wall frame component. The device 900 is similar in construction to the device 100 shown in Figure 1.

The device 900 is shown inserted into the end of a stud 300 in Figure 9.

The device further comprises a magnetic portion 904 shown in Figure 9 as two disc magnets housed within recesses of the body 902.

The magnetic portion 904 of the device 900 is configured to form removable magnetic connections with a magnetic surface of a further wall frame component comprising a magnetic material.

The device 900 further comprises a lip portion 906, configured to abut an end of a wall frame component when the device is inserted into the end of a wall frame component so as to restrict the depth of insertion of the device, as shown in Figure 9.

The device 900 may be in the form of a block, as shown in Figure 9, although other forms are envisaged, dependent upon the configuration of the wall frame component to which the device is attachable.

As shown in Figure 9, the body 902 of the device 900 is tapered in such a way that its width decreases toward the lip portion 906.

The device 900 can be inserted into an end of a wall frame member, such as the stud 300 shown in Figure 9, in the same manner that the devices 100 and 200 are inserted into stud 300, as shown in Figures 3a and 3b.

For example, as shown in Figure 9, the portion of the body 902 of the device 900 furthest from the lip portion 906 may engage with the inner surface of the stud 300 to provide a sufficiently strong press fitting engagement to hold the device 900 in place within the stud 300.

The tapering feature of the body 902 of the device 900 enables the device 900, when inserted into an end of a wall frame member, to permit a certain amount of deflection of the wall frame member or stud 300 inwardly at the portion of the wall frame member or stud 300 which is closest to the lip 906 of the device 900.

Distance A shown in figure 9 indicates the size of the gap between the inner surface of the stud 300 and the body 902 created by the tapering feature of the body 902. If the stud 300 is made of a flexible material, the device and/or the top of the stud 300 will be permitted to deflect inwardly across the distance A.

Preferably, the one or more of the corners of the lip portion 906 of the device 900 are contoured, rounded and/or removed.

Advantageously, when the end of a wall frame member or stud 300 within which the device 900 is inserted is slotted into a track, such as the floor track 802 shown in Figure 8, which is only slightly wider than the width of the a wall frame member or stud 300, the tapering of the body 902 enables the wall frame member or stud 300 to be easily rotated about its longitudinal axis as a result of the above described inward deflection of the stud 300.

The tapering of the body 902 may be applied to any of the other herein described devices according to the embodiments.

The devices according to the embodiments described herein can be manufactured by additive manufacturing, injection moulding, 3D printing, or any other suitable means as would be understood by a person skilled in the art.

The devices according to the embodiments described herein can be made of plastic, metal or any other suitable type of material as would be understood by a person skilled in the art.

Figure 10 depicts a flowchart of the steps involved in constructing a wall frame.

At step 1001, a device comprising a body and a magnetic portion is attached to a wall frame component.

At step 1002, the device is attached to a magnetic surface, such that the wall frame component is held in place relative to the magnetic surface.

The device of these method steps may be any of the devices according to the embodiments described herein.

Optionally, step 1002 may additionally comprise attaching the device to a magnetic surface of a second wall frame component, such that the wall frame component is held in place relative to the second wall frame component.

Optionally, step 1001 may additionally comprise attaching the device to a first end of the wall frame component.

At optional step 1003, a second device comprising a body and a magnetic portion is attached to a second end of the wall frame component opposite the first end.

At optional step 1004, the second device is attached to a second magnetic surface, such that the wall frame component is held in place relative to the second magnetic surface.

The second device of method step 1004 may be any of the devices of the embodiments described herein.

Optionally, step 1004 may additionally comprise attaching the second device to a magnetic surface of a third wall frame component, such that the wall frame component is held in place relative to the third wall frame component.

The magnetic portion of the second device may be configured to form a removable magnetic connection with the second magnetic surface, such that the device can be repositioned on the second magnetic surface.

The magnetic portion of the device may be configured to form a removable magnetic connection with the magnetic surface, such that the device can be repositioned on the magnetic surface.

The above described embodiments allow fast construction of wall frames. As such, the construction of wall frames is less expensive as labour time is significantly reduced.

The above described embodiments allow easy repositioning of wall frame components after they have been assembled. Again, this reduces labour time, reducing the associated cost.

The above described embodiments can be used for the construction of other types of frames. The above described embodiments can be used for the construction prototypes of other frames, or indeed for any type of frame.

Where the herein described wall frame components are not made of a magnetic material or where the herein described wall frame components are not sufficiently magnetic, a magnetic material or strip may be inserted into the wall frame components so as to facilitate the herein described wall frame construction method.

Figure 11 depicts a device 1100 according to an embodiment of the present invention. The device 1100 comprises a body 1102 which may be attachable to an end of a wall frame component in the same manner as the other devices described herein. The device 1100 further comprises a magnetic portion 1104 shown in Figure 11 as two disc magnets housed within recesses of the body 1102.

The device 1100 further comprises a lip portion 1106, configured to abut an end of a wall frame component when the device 1100 is inserted into the end of a wall frame component so as to restrict the depth of insertion of the device 1100.

The device 1100 may have substantially all of the same features as the device 100.

The device 1100 shown in Figure 11 preferably further comprises a second magnetic portion 1108, shown in Figure 11 as two disc magnets housed within recesses of the body 1102. The second magnetic portion 1108 acts as an attachment means to attach the device 1100 to an end of a wall frame component by magnetically interacting with the wall frame component, where the wall frame component comprises a magnetic material.

The second magnetic portion 1108 acts to increase the strength of an existing press fit type attachment to an end of a wall frame component or indeed to increase the strength of any of the other types of attachment to an end of a wall frame component described herein.

Any of the devices of the embodiments described herein may further comprise a second magnetic portion of the type shown in Figure 11.

Figure 12 depicts a device 1200 comprising a body 1202. The body comprises a lip portion 1206 which may have the same geometry as the lip portion 506 of the device 500, shown in Figure 5.

The body 1202 of the device 1200 shown in Figure 12 comprises grooves to facilitate attachment of the device to a wall frame component via a press fit, although these grooves are not an essential feature.

The device 1200 further comprises a male portion 1210 configured to be inserted within the cavity defined by the c-shaped cross section of a stud such as the stud 300 shown in Figures 3a and 3b. The male portion 1210 of the device 1200 comprises a magnetic portion 1204 in the form of two disc magnets disposed within recesses on an upper surface of the male portion 1210 (although they may be disposed on any other surface or surfaces of the male portion 1210).

The device 1200 shown in Figure 12 further comprises a second magnetic portion 1208, shown in Figure 12 as two disc magnets housed within recesses of the body 1202. The second magnetic portion 1208 acts as an attachment means to attach the device 1200 to an end of a wall frame component by magnetically interacting with the wall frame component, where the wall frame component comprises a magnetic material. The second magnetic portion 1208 may be disposed on any surface or surfaces of the body 1202, other than the surfaces of the male portion 1210.

The second magnetic portion 1208 acts to increase the strength of an existing press fit type attachment to an end of a wall frame component or indeed to increase the strength of any of the other types of attachment to an end of a wall frame component described herein.

The device 1200 can be adapted to attach two wall frame members together collinearly to make a longer wall frame member.

Figure 13 depicts a device 1300 according to an embodiment of the present invention. The device 1300 comprises a body 1302 which may be attachable to an end of a wall frame component in the same manner as the other devices described herein.

The device 1300 further comprises two protrusions in the form of two protruding ridges 1308. Other shapes of protrusions are also possible.

Preferably, the device 1300 has a square cross-section when viewed end on.

The two protruding ridges 1308 are arranged to engage corresponding channels in a frame component, such as the channels 1402 of the frame component 1400 shown in Figures 14 and 15, as will be described in greater detail below.

The device 1300 further comprises magnetic portions that are two disc magnets housed recesses in each of the ridges 1308.

When the protruding ridges 1308 of the device 1300 are engaged with the channels 1402 of the frame component 1400, a more secure connection can be achieved between the device 1300 and the frame component 1400 than those in previous embodiments. The device is able to withstand larger lateral forces.

The device 1300 further comprises a lip portion 1306, configured to abut an end of a wall frame component when the device 1300 is inserted into the end of a wall frame component so as to restrict the depth of insertion of the device 1300.

Although the device is shown comprising two protruding ridges 1308, any other suitable form of protrusion or protrusions may be used which are arranged to engage a corresponding recess or recesses in a frame component so as to achieve a more secure connection between the device 1300 and a frame component. For example, there may be a single ridge are arranged to engage a corresponding channel of greater than two ridges arranged to engage a corresponding number of channels.

The device 1300 may further comprise a second magnetic portion of the type shown in Figure 11.

Figure 14 depicts a diagram of an example wall frame assembly 1600 and Figure 15 depicts an exploded diagram of the same example wall frame assembly 1600.

The wall frame assembly 1600 comprises two frame components 1400, shown in Figures 14 and 15 as studs. Each frame component 1400 comprises recesses 1402, shown in Figures 14 and 15 as two channels 1402 which run along the length of the stud.

The wall frame assembly 1600 further comprises a cross rail or transom 1500 with a device 1300 of the type shown in Figure 13 inserted into each end. The transom 1500 is arranged to be inserted in between the two frame components 1400.

Disposed on either side of the transom 1500 is an abutment member 1502 which may be of the type described in WO 2007/116189 A1. The use of such an abutment member 1502 is optional.

The wall frame assembly 1600 may be used for the construction of a door frame or any other frame where increased lateral strength is desired.

The length of the transom/cross rail 1500 is such that it can be placed between the two frame components 1400, as shown in Figures 14 and 15. The two protruding ridges 1308 of each device 1300 are inserted within the corresponding channels 1402 of the frame component 1400, such that the magnetic portion 1304 holds the cross rail/transom 1500 in place via a magnetic connection with the frame component 1400 and such that additional strength is provided by the engagement between the protruding ridges 1308 and the channels 1402.

Once the wall frame assembly 1600 has been assembled, plaster boards can be fixed to the wall frame via conventional techniques.

The resulting wall frame is sturdy and is suitable for use with applications in which large resistance to lateral forces is required.

It is also simple to assemble as the interactions between the protruding ridges 1308 and the channels 1402 act as guides when assembling the wall frame. As such, the skill level required for assembly is reduced meaning that the wall frame assembly 1600 is more suitable for domestic uses such as DIY where the user is not highly skilled.

Figure 16 depicts a cross-section of a frame component 1400 as shown in Figure 15. It can be seen that the frame component 1400 has a substantially c-shaped cross section with two channels 1402 arranged to receive the ridges 1304 of the device 1300.

Figure 17 depicts an exploded diagram of an example wall frame assembly 1700. The frame assembly 1700 is identical to the wall frame assembly 1600 shown in Figures 14 and 15, except that the cross rail or transom 1500 has been inverted and a cripple stud or C-stud 1800 has been placed within the recess defined by the u-shaped housing of the transom 1500 defined by its c-shaped cross-section.

Figure 18 depicts a side on wireframe diagram of the wall frame assembly 1700 shown in Figure 17;

Figure 19 depicts a top down wireframe diagram of an example wall frame assembly 1700 shown in Figures 17 and 18.

Further embodiments include a number of modifications and variations that can be made to the embodiments as described above.

In particular, all of the dimensions provided in the figures are approximate and embodiments include designs with different dimensions.

The devices according to embodiments may be made of a flexible material to allow a degree of inward deflection of the wall frame member within which it is inserted.

In one embodiment, only the lip portion of each of the devices is made of a flexible material.

The flexible material may be a suitable plastic or zinc with fire proofing properties.

Advantageously, when the end of a wall frame member within which any such device is inserted is slotted into a track, such as the floor track 802 shown in Figure 8, which is only slightly wider than the width of the a wall frame member, the flexibility of the device enables the wall frame member to be easily rotated about its longitudinal axis as a result of the above described inward deflection of the wall frame member permitted by the flexibility of the device.

This is comparable to the effect of the tapered device 900 and the tapered device 900 may also me made of a suitably flexible material to enhance this functionality. In one embodiment, only the lip portion 906 is made of a flexible material.

Figure 20 depicts three views of a device 2000 according to an embodiment the present invention. The device 2000 comprises a body 2002 that is attachable to an end of a wall frame component, as shall be described in further detail below. The device 2000 further comprises a magnetic portion 2004 shown in Figure 1 as two disc magnets housed within recesses of the body 2002.

The magnetic portion 2004 of the device 2000 is configured to form a removable magnetic connection with a magnetic surface of a further wall frame component comprising a magnetic material.

The device 2000 shown in Figure 20 further comprises a lip portion 2006, configured to abut an end of a wall frame component when the device 100 is inserted into the end of a wall frame component so as to restrict the depth of insertion of the device 2000.

The device 2000 shown in Figure 2000 comprises abutment protrusions 2020 arranged to engage with the inner surface of a conventional wall frame member in such a way that the device 2000 can be press fitted into an end of a conventional wall frame member. As such, the device 2000 can be retrofitted to existing wall frame components without any modification of the wall frame components required.

In addition to the press fitting engagement provided by the abutment protrusions 2020, the body 2002 of the device 2000 comprises a clip portion 2002c and a back portion 2002d, as shown in Figure 20, which provides an additional engagement with the end of a conventional wall frame member. The clip portion 2002c and the back portion 2002d are together considered to a clip for clipping the device 2000 to the end of wall frame member. Preferably, the clip portion 2002c and the back portion 2002d are integral with the body 2002 of the device 2000.

The device 2000 is designed to be inserted into an end of wall frame member with c-shaped cross section, such that clip portion 2002c is located on the inside of the wall frame member and the back portion 2002d is located on the inside of the wall frame member. The clip portion 2002c and the back portion 2002d are arranged such that, when a conventional wall frame member is inserted between them, they are moved apart and biasing force is generated toward each other, thereby providing the additional engagement with a wall frame member.

The press fit engagement provided by the abutment protrusions 2020 may be strong enough to hold the device 2000 in place relative to the wall frame component without the need for the additional engagement force provided by the clip. As such, in an embodiment, the device 2000 has no integral clip portion 2002c.

It will be appreciated that the device 2000 is lightweight and has reduced material costs, while maintaining a strong engagement with a wall frame member via the two aforementioned engagement mechanisms.

Figure 21 depicts an alternative embodiment of a device 2100 for providing a magnetic connection between two wall frame components. Figure 22 depicts an exploded diagram of the device 2100. The device 2100 comprises a body 2102, wherein the body comprises a first portion 2102a and a second portion 2102b which is movable relative to the first portion 2102a. The first portion 2102a of the body 2102 further comprises a lip portion 2106 which performs the same function as the lip portion 106 of the device 100 shown in Figure 1. The first portion 2102a further comprises a clip portion 2102c and a back portion 2102d, which function in the same way as the clip portion 2002c and the back portion 2002d of the device 2000.

The second portion 2102b of the body 2102 comprises recesses within which magnetic discs 2104 are inserted. The magnetic discs 2104 are fixed to the second portion 2102b of the body 202 such that they move with the second portion of the body 2102b.

The first portion 2102a of the body 202 comprises a recess for receiving the second portion 2102b in such a way that the second portion 2102b is free to slide relative to the first portion 202a of the body 202.

The second portion 2102b is shown in Figure 21 in its retracted position. The second portion 2102b is able to slide away from the first portion 2102a in an upward direction in the orientation shown in Figure 21.

It is by this mechanism that the device 2100 is able to account for any deflection in an assembled wall frame, as also described in relation to the device 200 shown in Figure 2.

As can be seen in Figure 22, the second portion 2102b of the device 2100 further comprises retaining protrusions 2122 which are arranged to engage with the first portion 2102a once the second portion 2102b is inserted into the recess of the first portion 2102a to retain the second portion 2102b within the first portion 2102a.

As can be seen in Figure 22, the device 2100 further comprises two springs 2124 which, act to outwardly bias the second portion 2102b toward its fully protruded position. This helps ensure that the magnetic engagement with a wall frame member is retained.

When attached to the end of a wall frame component, the device 2100 is configured to form a magnetic connection with the surface of a further wall frame component thereby attaching the two wall frame components together. Further, a degree of movement of the further wall frame component away from the wall frame component to which the device 2100 is attached is permitted by the above described construction of the device 2100. The degree of movement is defined by the extent to which the first and second portions can move relative to each other.

The device 2100 shown in Figures 21 and 22 is comprises abutment protrusions 2120 arranged to engage with the inner surface of a conventional wall frame member such that it can be press fitted into an end of a conventional wall frame member. The first portion 2102a further comprises a clip portion 2102c and a back portion 2102d. Via these two engagements, the device 2100 can be retrofitted to existing wall frame components without any modification of the wall frame components required.

Figure 23 depicts three views of the device 2100 inserted into an end of a vertical stud 300. The device 2100 protruded position and the mechanism by which the clip portion 2102c and a back portion 2102d engage the stud 300 can clearly be seen.

It is noted that the clip portion 2102c and a back portion 2102d of the device 2100 could be applied to any of the embodiments described herein.

The devices according to embodiments may be adapted to have a u-shaped body.

Any of the devices according to embodiments described herein may further comprise a damping element. The damping element may comprise a piece of neoprene bonded to the device and is configured to act as a sound buffer so as to absorb sound waves travelling through the wall frame.

The flowcharts and description thereof herein should not be understood to prescribe a fixed order of performing the method steps described therein. Rather, the method steps may be performed in any order that is practicable. Although the present invention has been described in connection with specific exemplary embodiments, it should be understood that various changes, substitutions, and alterations apparent to those skilled in the art can be made to the disclosed embodiments without departing from the spirit and scope of the invention as set forth in the appended claims.

Other embodiments of the invention will be apparent to those skilled in the art from consideration of the specification and practice of the embodiments disclosed herein. It is intended that the specification and examples be considered as exemplary only, with a true scope and spirit of the invention being indicated by the following claims. In addition, where this application has listed the steps of a method or procedure in a specific order, it may be possible, or even expedient in certain circumstances, to change the order in which some steps are performed, and it is intended that the particular steps of the method or procedure claims set forth herebelow not be construed as being order-specific unless such order specificity is expressly stated in the claim.

Claims

Claims:

1. A device for providing a magnetic connection between first and second frame components, the device comprising: a body that is attachable to a first frame component; and a magnetic portion for forming a magnetic connection with a magnetic surface of a second frame component.

2. The device of claim 1, wherein the device is configured to be inserted into an end of the first frame component.

3. The device of claim 2, wherein the device is configured to be press fitted into an end of the first frame component.

4. The device of claim 3, wherein an outer surface of the device comprises grooves to facilitate attachment of the device to the first frame component via a press fit.

5. The device of any of claims 2 to 4, the body further comprising a lip portion configured to abut an end of the first frame component when the device is inserted into an end of the first frame component so as to restrict the depth of insertion of the device.

6. The device of any preceding claim, the magnetic portion further comprising a magnet and the body further comprising a recess for receiving the magnet.

7. The device of any preceding claim, the body further comprising: a first portion configured to be attached to the first frame component; and a second portion moveable relative to the first portion, wherein the second portion comprises the magnetic portion.

8. The device according to claim 7, wherein the movement of the second portion relative to the first portion allows a magnetic connection between the first and second frame components to be maintained during relative movement between the first and second frame components. 8a. The device according to claim 7 of claim 8, the device further comprising a biasing member to bias the second portion toward a fully protruded position. 8b. The device of any preceding claim, the device further comprising one or more abutment protrusions arranged to engage with the first frame component to enable a press fitting engagement between the first frame component and the device. 8c. The device of any preceding claim, the device further comprising a clip for clipping the device to the end of the first frame component.

9. The device of any preceding claim, wherein the magnetic portion is configured to form a removable magnetic connection with a magnetic surface of the second frame component such that the device can be repositioned on a magnetic surface of the second frame component.

10. The device of any preceding claim, wherein the body is tapered.

11. The device of any preceding claim, the device further comprising a second magnetic portion for forming a magnetic connection with the first frame component.

12. The device of any preceding claim, the device further comprising a damping element.

13. The device of any preceding claim, the device further comprising at least a single protrusion for engaging a recess in the second frame component.

14. The device of claim 13, wherein the protrusion is in the form of ridge arranged to engage with a channel in the second frame component.

15. The device of claim 13 or claim 14, wherein the protrusion is arranged to engage with the cavity defined by the c-shaped cross section of a stud.

16. The device of any of claims 13 to 15, wherein the magnetic portion is disposed on the protrusion.

17. The device of any of claims 1 to 12, the device comprising two or more protrusions for engaging recesses in the second frame component.

18. The device of claim 17, wherein the protrusions are in the form of ridges arranged to engage with channels in the second frame component.

19. The device of claim 17 or claim 18, wherein the magnetic portion comprises a magnetic portion disposed on each of the protrusions.

20. The device of any preceding claim, wherein the first frame component is a first wall frame component and/or wherein the second frame component is a second wall frame component.

21. A frame assembly comprising: a frame component; and the device of any preceding claim, wherein the device is attached to the frame component.

22. The frame assembly of claim 21, further comprising a second device that is a device according to any of claims 1 to 20, wherein the device is attached to a first end of the frame component and the second device is attached to a second end of the frame component opposite first end, such that both ends of the frame component are attachable to a magnetic surface.

23. The frame assembly of claim 22, further comprising a first track and a second track, wherein the frame component is magnetically attached to the first track via the device and, wherein the frame component is magnetically attached to the second track via the second device.

24. The frame assembly of claim 23, further comprising a plurality of frame components, wherein each frame component is magnetically attached to the first track via a device according to any of claims 1 to 20 and, wherein each frame component is magnetically attached to the second track via a second device according to any of clams 1 to 20.

25. The frame assembly of claim 24, further comprising a transverse frame component, wherein the transverse frame component is magnetically attached between two of the plurality of frame components via a device according to any of claims 1 to 20 attached to a first end of the transverse frame component and a second device according to any of claims 1 to 20 attached to a second end of the transverse frame component opposite the first end.

26. The frame assembly of any of claims 21 to 25, wherein the frame component is a wall frame component and, preferably, wherein the wall frame component is one or more of a stud, transom or lintel.

27. The frame assembly of any of claims 21 to 26, wherein the frame assembly is a wall frame assembly.

28. The frame assembly of any of claims 21 to 27, wherein the frame component, or frame components, comprises a recess or recesses arranged to receive a protrusion of the device.

29. The frame assembly of any of claims 21 to 28, wherein the frame component, or frame components, comprises channels arranged to receive a ridge or ridges of the device.

30. A method of constructing a frame, the method comprising the steps of: attaching a device comprising a body and a magnetic portion to a frame component; and attaching the device to a magnetic surface, such that the frame component is held in place relative to the magnetic surface.

31. The method of claim 30, wherein the device is a device according to any of claims 1 to 20.

32. The method of claim 30 or 31, wherein the step of attaching the device to a magnetic surface comprises attaching the device to a magnetic surface of a second frame component, such that the frame component is held in place relative to the second frame component.

33. The method of any of claims 30 to 32, wherein the step of attaching a device comprising a body and a magnetic portion to a frame component comprises attaching the device to a first end of the frame component, the method further comprising the steps of: attaching a second device comprising a body and a magnetic portion to a second end of the frame component opposite the first end; and attaching the second device to a second magnetic surface, such that the frame component is held in place relative to the second magnetic surface.

34. The method of any of claim 33, wherein the second device is a device according to any of claims 1 to 20.

35. The method of claim 33 or 34, wherein the step of attaching the second device to the second magnetic surface comprises attaching the second device to a magnetic surface of a third frame component, such that the frame component is held in place relative to the third frame component.

36. The method of any of claims 33 to 35, wherein the magnetic portion of the second device is configured to form a removable magnetic connection with the second magnetic surface, such that the device can be repositioned on the second magnetic surface.

37. The method of any of claims 30 to 36, wherein the magnetic portion of the device is configured to form a removable magnetic connection with the magnetic surface, such that the device can be repositioned on the magnetic surface.

38. The method of any of claims 30 to 37, wherein the frame component(s) is a wall frame component.

39. A device for providing a magnetic connection between first and second frame components substantially as described herein with reference to the accompanying figures.

40. A frame assembly substantially as described herein with reference to the accompanying figures.

41. A method of constructing a frame substantially as described herein with reference to the accompanying figures.

42. A frame component for use in a frame assembly, the frame component comprising a recess arranged to receive the protrusion of the device of any of claims 13 to 19.

43. The frame component of claim 42, wherein the recess is in the form of two channels.