IE20190150A1 - A wall and construction method - Google Patents

Abstract

A wall frame has a floor plate (10), a ceiling plate (20), and studs (1). Each stud has a lower end with a dovetail (5, 6) which fits to the floor plate by only a rotation movement about the axis of the stud. An upper stud end fits to the ceiling plate (20) between its flanges. There is a series of apertures (3) in each stud, through which bridging members (30) interconnect while spanning across the studs. The bridging members (30) have interlock parts (33, 34) which allow them to be interconnected in the apertures without fasteners. Hence, they can span through the width of the wall to therefore provide excellent structural integrity, and the wall may be assembled easily and quickly from an assembly or kit with prior knowledge of properties such as fire certification compliance.

Description

“A Wall and Construction Method” Introduction The invention relates to construction of walls for buildings.

At present, it is often time—consuming and expensive to erect an internal wall in a building as part of a building renovation or extension, especially with a requirement to certify that it conforms to fire standards. The conventional method involves erecting studs onto a floor plate and a ceiling plate, the studs being joined by interconnecting bridging members, or “noggings”.

They are typically joined by nails, and a good deal of care is required to ensure that all pieces are cut to an exact length and are spaced accurately.

Typically, it is required to hold the studs steady at the floor and ceiling plate, often by a second person, and fix them to the floor plate with nails skewed at an angle from both sides of the stud.

Similarly, the bridging members are fit horizontally between the studs and secured with nails.

The bridging members also need to be staggered in their positions, so that nails can be driven straight through the studs into the ends of the bridging members. This is time—consuming for the builder, and due to the variability in building techniques there is little consistency in fire retarding properties, leading to difficulties in certification.

US8205402 describes use of metal channel—shaped studs and spacers, the spacers being fastened at flanges to the stud webs.

US40758lO describes metal channel—shaped studs and spacers, the latter being wedged into horizontal positions against the studs.

USZOO3/0037494 also describes channel—shaped metal studs, and spacers which are of channel section with slots engaging the stud webs where they pass through.

The invention is directed towards providing improved simplicity and reduced time for erecting a stud wall, without comprising on structural integrity.

Summary We describe a wall construction assembly comprising: a floor plate, a ceiling plate, and a plurality of studs, each having a body with: a lower end configured to fit to the floor plate, an upper end configured to fit to the ceiling plate, and a plurality of apertures in series in the body, a plurality of bridging members, at least some of which: are arranged to interconnect in a bridging longitudinal direction while spanning across the studs and extending through at least some of the apertures of the studs, and have an interlock part at each end for engaging an interlock part of another bridging member within a stud aperture.

Preferably, the interlock parts are arranged to engage with a movement from out—of—plane to in- plane of the adjoining bridging member, wherein upon engagement one interlock part engages behind the other in the longitudinal direction. Preferably, the interlock parts comprise a protrusion on one bridging member configured to engage behind, in the longitudinal direction, a protrusion on another aligned bridging member.

Preferably, the interlock parts are configured to rest against and to be supported by lower edges of the apertures of the studs.

Preferably, the stud apertures include elongate slots extending in a stud longitudinal direction and which allow said bridging member movement from out—of—plane to in—plane. Preferably, at least some bridging members each have end shoulders arranged for engaging surfaces of a stud on either side of an aperture.

Preferably, the bridging member interlock parts are configured for engaging substantially fully within a stud aperture. Preferably, each stud lower end is configured to fit to the floor plate without fasteners.

Preferably, the floor plate is channel—shaped with a web and flanges, and each stud lower end is configured to fit between the flanges. Preferably, the flanges are in—turned and each stud lower end is in the form of a dovetail for fitting into the floor plate with a rotation movement.

Preferably, each stud upper end is configured to fit to the ceiling plate without fasteners.

Preferably, the ceiling plate is channel—shaped with a web and flanges and each stud top end is configured to fit between the flanges.

Preferably, the studs and the bridging members are each of substantially rectangular or square cross—sectional shape. Preferably, the studs and the bridging members are of wood material.

Preferably, the assembly further comprises a plurality of insulation blocks configured a fit within standard spaces between the studs and wherein the blocks are configured according to depth of the studs, and length of the bridging members with allowance for engagement of the bridging members within the Volumes between the studs.

Preferably, the assembly further comprises panels for connection to the studs on at least one side of the assembly.

We also describe a method of erecting a wall using an assembly of any example described herein, the method comprising the steps, in any order, of: securing the floor plate to a building floor; securing the ceiling plate to a building ceiling; fitting the stud lower ends to the floor plate; fitting the stud upper ends to the ceiling plate; and placing bridging members between and through the studs, in which the ends of at least some of the bridging members are within the stud apertures, with an end of a bridging member engaging an adjacent end of another aligned bridging member with engagement of said interlock parts.

Preferably, the bridging members align from out—of—plane to in—plane, in which an end of a bridging member is moved from out—of—plant to in—plane to align with and interlock with a corresponding next bridging member.

Preferably, the floor plate is channel—shaped and the lower stud ends are fitted without fasteners to the channel of the floor plate.

Preferably, the ceiling plate is channel—shaped and the upper stud ends are fitted without fasteners within the channel of the ceiling plate. Preferably, the method comprises connecting each stud lower end to the floor plate by rotation of the stud about its axis. Preferably, the method comprises securing panels to a first side of the studs. Preferably, the method comprises inserting insulation panels between the studs and the bridging members. Preferably, the method comprises securing panels to a second side of the studs.

We also describe a wall comprising: a frame comprising: a floor plate, a ceiling plate, a plurality of studs, each having a body with: a lower end fitted to the floor plate, an upper end fitted to the ceiling plate, and a plurality of apertures in series in the body, a plurality of aligned and interconnected bridging members spanning across and through the studs, by extending through the apertures of the studs; wherein the bridging member interlock parts interlock within the stud apertures, at least one panel secured to a first and/or to a second side of the frame.

Additional Statements We describe a wall construction assembly comprising: a floor plate, a ceiling plate, and a plurality of studs, each having a body with: a lower end configured to fit to the floor plate, an upper end configured to fit to the ceiling plate, and a plurality of apertures in series in the body, a plurality of bridging members arranged to interconnect while spanning across the studs and extending through at least some of the apertures of the studs.

Preferably, each stud lower end is configured to fit to the floor plate without fasteners.

Preferably, the floor plate is channel—shaped with a web and flanges, and each stud lower end is configured to fit between the flanges.

Preferably, the flanges are in—turned and each stud lower end is in the form of a dovetail for fitting into the floor plate with a rotation movement.

Preferably, each stud upper end configured to fit to the ceiling plate without fasteners.

Preferably, the ceiling plate is channel—shaped with a web and flanges, and each stud top end is configured to fit between the flanges. Preferably, the bridging members each has an interlock part at each end for engaging an interlock part of another bridging member within a stud aperture. Preferably, the interlock parts are arranged to engage with a movement from out—of— plane to in—plane, wherein upon engagement one interlock part engaging behind the other in the longitudinal direction. Preferably, the interlock parts comprise a protrusion on one bridging member configured to engage behind, in the longitudinal direction, a protrusion on another aligned bridging member. Preferably, the interlock parts are configured to rest against, and to be supported by lower edges of the apertures of the studs.

Preferably, the bridging members are configured to span across and through each stud.

Preferably, the stud apertures include elongate slots which allow said movement from out—of— plane to in—plane.

Preferably, the assembly further comprises a plurality of insulation blocks configured a fit within standard spaces between the studs. Preferably, the blocks are configured according to depth of the studs, and length of the bridging members with allowance for engagement of the bridging members within the volumes of the studs.

Preferably, the assembly further comprises panels for connection to the studs on at least one side of the assembly.

We also describe a method of erecting a wall using an assembly of any embodiment, the method comprising the steps, in any order, of: securing the floor plate to a building floor; securing the ceiling plate to a building ceiling; fitting the stud lower ends to the floor plate; fitting the stud upper ends to the ceiling plate; and placing bridging members between and through the studs, in which the ends of at least some of the bridging members are received within the stud apertures, with an end of a bridging member engaging an adjacent end of another aligned bridging member.

Preferably, the floor plate is channel—shaped and the lower stud end is fitted within without fasteners to the channel of the floor plate.

Preferably, the ceiling plate is channel—shaped and the upper stud end is fitted without fasteners within the channel of the ceiling plate.

Preferably, the method comprises connecting each stud lower end to the floor plate by rotation of the stud about its axis.

Preferably, the bridging members align from out—of—plane to in—plane, in which an end of one bridging member is moved downwards to align with and interlock with a corresponding next bridging member. Preferably, the bridging members each have an interlock part at each end for engaging the interlock part of another bridging member, when brought into alignment by movement from out—of—plane to in—plane.

The method may comprise securing panels to a first side of the studs and/or inserting insulation panels between the studs and the bridging members, and/or securing panels to a second side of the studs.

We also describe a wall comprising: a frame comprising: a floor plate, a ceiling plate, a plurality of studs, each having a body with: a lower end fitted to the floor plate, an upper end fitted to the ceiling plate, and a plurality of apertures in series in the body, a plurality of aligned and interconnected bridging members spanning across and through the studs, by extending through the apertures of the studs; at least one panel secured to a first and/or to a second side of the frame.

The components of the wall may have any of the features of the assembly of any embodiment.

We also describe a building including a wall of any embodiment.

Hence, in various embodiments, a wall frame has a floor plate, a ceiling plate, and studs. Each stud has a lower end with a dovetail which fits to the floor plate by only a rotation movement about the axis of the stud. An upper stud end fits to the ceiling plate between its flanges. There is a series of apertures in each stud, through which bridging members interconnect while spanning across the studs. The bridging members have interlock parts which allow them to be interconnected in the apertures without fasteners. Hence they can span through the width of the wall to therefore provide excellent structural integrity, and the wall may be assembled easily and quickly from an assembly or kit with prior knowledge of properties such as fire certification compliance.

Detailed Description of the Invention The invention will be more clearly understood from the following description of some embodiments thereof, given by way of example only with reference to the accompanying drawings in which:— Figs. l to 6 are a series of perspective views showing erection of an internal wall; Fig. 7 shows a stage of erection of a different wall, for abutment with a sloped ceiling; Fig. 8 shows a final stage for a wall with panels on both sides; Fig. 9 shows insertion of insulation in a wall; Fig. 10 shows more detail of placement of a bridging member to bridge studs; Fig. 11 shows a stage of a different wall, having panels applied over internal insulation, the panels being applied with staggered joints for fire resistance; Fig. 12 is a detailed view showing insertion of a stud in a floor plate; and Fig. 13 is a cross—sectional view of an alternative floor plate in use.

Detailed Description Referring to Figs. 1 to 6, stages of erection of an internal wall are shown as follows: Fig. 1 Fig. 2 Fig. 3 Figs. 4 and 5 Studs l are provided, being of timber lengths and having a series of slots 3 and apertures through the length. Each stud 1 has a feature at a lower end for convenient connection to a floor plate channel. Each feature comprises a dovetail formed by the length being pre—cut with recesses to form a neck 6. Each stud 1 also has a series of apertures 4 for utility cables.

The studs 1 are connected to a floor plate 10 having a web 11 and flanges 12 with in—turned lips forming a channel. The channel is shaped with the web 11 and the in—turned flanges 12, to correspond to the dovetail 5 and neck 6 of the stud. In use, the stud 1 lower end is brought into contact with the floor plate 10, with the width dimension of the stud l substantially parallel to the flanges 12. Rotation of the stud 1 through approximately 90° results in interlocking of the stud 1 within the channel 10. The channel is shaped to tightly receive the stud dovetail fixtures 5 without need for fasteners.

A ceiling or head plate 20 is secured along the upper ends of the studs 1. The ceiling plate 20 has a web 21 and flanges 22 forming a channel. In this case, the flanges 22 are not in—turned. However, in other embodiments they may be. The channel 20 is shaped to tightly receive the tops of the studs 1. In this position, the studs 1 are equally spaced and are secured at the bottom and the top by the floor plate 10 and ceiling plate 20, respectively. Fasteners, such as nails, may be used to further secure the upper ends of the studs 1 to the ceiling plate, however it is not necessary.

Bridging members or “noggings” 30 are placed between the studs 1. Each bridging member 30 is a short, horizontal brace and has a body 31 with a slot 32 for cables. At each end each bridging member has one of a left or right tongue 33, 34 which are shaped to engage in the plane of the members 30 within the space of a stud slot 3, and to interlock with an adjacent bridging member within the stud slot 3. The bridging members 30 are arranged to engage with a movement from out—of—plane to in—plane, one interlock part engaging behind the other in the axial direction. As shown in Fig. 4, the engagement of the bridging members is achieved by a bridging member end being moved downwards to engage another corresponding bridging member. The interlock parts 33 and 34 rest against and are supported by a bottom edge of the stud slots 3. A plurality of bridging members 30 are so assembled and thus provide for a continuous line spanning across and through the studs, and provide a rigid frame made up of the studs and the bridging members 30.

Fig. 6 A panel such as plasterboard 40 is secured to the studs by stapling. This provides racking resistance, and a wall surface.

As shown in Fig. 7, when the ceiling is sloped, the studs may be easily cut to the applicable length and the wall plate channel cut to provide a section 120 for the shaped part.

Fig. 8 shows that there may be panels of plasterboard 40 on a first side and a second side. Fig. 9 shows that insulation such as Rockwoolm panels 50 may be inserted between the studs 1 and the bridging members 30, before application of plasterboard to the second side. These are sized for a close friction fit into these spaces.

Fig. 10 shows in more detail the manner in which the bridging members 30 interlock within the stud slots 3. The interlock parts 33 and 34 are in the form of tongues and are configured for engaging one behind the other, in the longitudinal direction of the members 30. This provides convenience of insertion and structural continuity. As previously described, this is achieved by engaging the bridging members 30 with a movement from out—of—plane to in—plane, one interlock part engaging behind the other in the axial (longitudinal) direction.

The engaged tongues 33 and 34 rest against and are supported by lower edges of the apertures 3 of the studs 1, and are a friction—fit within the aperture 3.

Further, each bridging member 30 has shoulders 35 and 36, which in the engaged position, abut against the stud l on each side of the stud slot 3. The engagement of the interlock parts 33 and 34 together, combined with the friction fit within the aperture 3, and further combined with the abutment of the shoulders 35 and 36 against the stud, provides for a simple and effective means to assemble rigid and secure structural frame for a wall. There is bridging member to bridging member tight engagement, and also bridging member to stud tight engagement. This is all achieved without need for fasteners such as bolts or screws.

Fig. 11 shows mounting of panels at staggered joints for excellent fire resistance once the insulation has been inserted. It is envisaged that the panels may be panels of plasterboard approximately of 12.5mm thickness each. The combination of the insulation and the panels provides for additional fire resistance and sound proofing. Further, the panels provide for additional bracing support.

Fig. 12 shows a detail from Fig. 11 showing how the stud dovetail 5 fits into the floor plate channel formed by the web 11 and the flanges 12 with in—turned li8ps 13.

Referring to Fig. 13, an alternative floor plate 100, has a web 101 and flanges 102 with rounded in—turned lips 103. In this case the in—turned lips are in a curved shape extending inwardly and downwardly. This arrangement provides improved safety by avoiding exposed edges, and provides additional rigidity. Moreover, it allows a smoother engagement due to absence of potentially sharp edges.

Advantages and Use In use, the interlocking of the studs 1 within the floor plate channel 10 allows the user to quickly and efficiently secure the studs 1 to the floor plate channel 10 without the need for tools. By interlocking each stud 1 within the channel, the lower ends of the studs are secured within the floor plate channel 10. Interlocking engagement of the studs 1 to the floor plate 10 advantageously provides for engagement of the studs 1 to the plate 10 without the need for tools or fasteners such as screws, or indeed another user to hold the studs in place while being fastened. When the studs 1 and plate 10 are engaged and secured, the floor plate 10 provides an element of support to the studs 1. This support provided by the floor plate 10 allows for the user to secure the studs along the length of the channel 10.

The interlocking engagement of the studs 1 to the floor plate 10 is quick and user—friendly and thus allows the user to quickly and efficiently space apart and secure the studs along the length of the channel 10.

As described above, the inter—engagement of the bridging members is achieved by a bridging member end being moved downwards to engage another corresponding bridging member. This action is carried out for each of a plurality of bridging members, which form a line of continuous support across and through the studs 1. This interlocking engagement of the bridging members provides for efficient and secure assembly of the bridging members 30. Once the bridging members are all assembled, a rigid and secure structural frame for a wall is provided.

It is envisaged that the wall may be internal or external.

As shown the wall assembly kit allows for very versatile erection of a wall, whether internal or external (possibly as an internal wall leaf for example).

The builder (or indeed DIY enthusiast) can build the wall with prior knowledge of the fire certification resistance parameters.

Further advantageously, the kit allows for a pre—certified load capacity to be achieved, and the kit can also be acoustically rated.

There is minimal need for use of power tools — merely for fixing the floor and ceiling plates to the floor and ceiling respectively. The studs merely need to be cut to the desired length, and the bridging members can be manually inserted as shown in Figs. 4 and 10. Likewise, the insulation merely needs to be placed in the spaces as they are configured to fit within the spaces defined by the locations of the slots 3 in the studs 1 and the lengths of the bridging members.

The invention is not limited to the embodiments described but may be varied in construction and detail. For example, the wall plate may have a configuration akin to that of the floor plate. Either of the floor or ceiling plate channels may be of steel, or any other suitable material including timber or plastics, and where it is of metal it may for example be extruded aluminium.

It is envisaged that the bridging member interlock parts may be different, such as a male/female arrangement which may for example be a dovetail and slot arrangement. Any interlock arrangement in which the bridging members are interlocked by relative vertical (out—of—plane) movement is advantageous.

It is envisaged that the studs 1 may of a material other than timber, such as metal or plastics. The different components of the wall assembly may be any of a variety of materials such as plastics or metal or a hybrid material. However, it is preferred that the material have significant cross- sectional area to accommodate the bridging members. The bridging arrangement is particularly suited to studs and bridging members being of wood or plastics material. This is because the bulk nature with a full cross—section provides significant surfaces for engagement of: — the interlock features 33 and 34, — the bridging member shoulders 35 and 36 against the studs, — the lower and side surfaces of the slots 3 against the interlock features.

It is particularly advantageous that there is interlocking engagement with engaging surfaces being at least partly axially facing. The interlock tongues 33 and 34 are an advantageous way of doing this. However as noted above, this may be achieved by a dovetail/dovetail socket or by a neck and head end engaging with vertical movement in a corresponding cut—out in the adjoining bridging member.

It is also envisaged that the engagement of the upper and/or lower ends of the stud and the plates may comprise the use of fasteners, such as nails.

It is also envisaged that the engagement of the upper end of the stud and the ceiling plate may be similar to the engagement of the lower end of the stud and the floor plate. For example, the ceiling plate may be of similar web and flange configuration to the floor plate and the upper end of the studs may be configured to fit between said flanges.

Claims (1)

1. A wall construction assembly comprising: a floor plate, a ceiling plate, and a plurality of studs, each having a body with: a lower end configured to fit to the floor plate, an upper end configured to fit to the ceiling plate, and a plurality of apertures in series in the body, a plurality of bridging members, at least some of which: are arranged to interconnect in a bridging longitudinal direction while spanning across the studs and extending through at least some of the apertures of the studs, and have an interlock part at each end for engaging an interlock part of another bridging member within a stud aperture. A wall construction assembly as claimed in claim 1, wherein the interlock parts are arranged to engage with a movement from out—of—plane to in—plane of the adjoining bridging member, wherein upon engagement one interlock part engages behind the other in the longitudinal direction. A wall construction assembly as claimed in claims 1 or 2, wherein the interlock parts comprise a protrusion on one bridging member configured to engage behind, in the longitudinal direction, a protrusion on another aligned bridging member. A wall construction assembly as claimed in any of claims 1 to 3, wherein the interlock parts are configured to rest against and to be supported by lower edges of the apertures of the studs. A wall construction assembly as claimed in any of claims 2 to 4, wherein the stud apertures include elongate slots extending in a stud longitudinal direction and which allow said bridging member movement from out—of—plane to in—plane. 10. ll. l2. l3. 14. .14. A wall construction assembly as claimed in any preceding claim, wherein at least some bridging members each have end shoulders arranged for engaging surfaces of a stud on either side of an aperture. A wall construction assembly as claimed in any preceding claim, wherein the bridging member interlock parts are configured for engaging substantially fully within a stud aperture. A wall construction assembly as claimed in any preceding claim, wherein each stud lower end is configured to fit to the floor plate without fasteners. A wall construction assembly as claimed in claim 8, wherein the floor plate is channel- shaped with a web and flanges, and each stud lower end is configured to fit between the flanges. A wall construction assembly as claimed in claim 9, wherein the flanges are in—turned and each stud lower end is in the form of a dovetail for fitting into the floor plate with a rotation movement. A wall construction assembly as claimed in any preceding claim, wherein each stud upper end is configured to fit to the ceiling plate without fasteners. A wall construction assembly as claimed in any preceding claim, wherein the ceiling plate is channel—shaped with a web and flanges and each stud top end is configured to fit between the flanges. A wall construction assembly as claimed in any preceding claim, wherein the studs and the bridging members are each of substantially rectangular or square cross—sectional shape. A wall construction assembly as claimed in any preceding claim, wherein the studs and the bridging members are of wood material. l5. l6. l7. l8. 19. 20. 21. A wall construction assembly as claimed in any preceding claim, further comprising a plurality of insulation blocks configured a fit within standard spaces between the studs and wherein the blocks are configured according to depth of the studs, and length of the bridging members with allowance for engagement of the bridging members within the Volumes between the studs. A wall construction assembly as claimed in any preceding claim, further comprising panels for connection to the studs on at least one side of the assembly. A method of erecting a wall using an assembly of any preceding claim, the method comprising the steps, in any order, of: securing the floor plate to a building floor; securing the ceiling plate to a building ceiling; fitting the stud lower ends to the floor plate; fitting the stud upper ends to the ceiling plate; and placing bridging members between and through the studs, in which the ends of at least some of the bridging members are within the stud apertures, with an end of a bridging member engaging an adjacent end of another aligned bridging member with engagement of said interlock parts. A method as claimed in claim 17, wherein the bridging members align from out—of—plane to in—plane, in which an end of a bridging member is moved from out—of—plant to in—plane to align with and interlock with a corresponding next bridging member. A method as claimed in claims 17 or 18, wherein the floor plate is channel—shaped and the lower stud ends are fitted without fasteners to the channel of the floor plate. A method as claimed in any of claims 17 to 19, wherein the ceiling plate is channel- shaped and the upper stud ends are fitted without fasteners within the channel of the ceiling plate. A method as claimed in any of claims 17 to 20, comprising connecting each stud lower end to the floor plate by rotation of the stud about its axis. 20 22. 23. 24. 25. A method as claimed in any of claims 17 to 21, comprising securing panels to a first side of the studs. A method as claimed in any of claims 17 to 22, comprising inserting insulation panels between the studs and the bridging members. A method as claimed in either of claims 22 or 23, comprising securing panels to a second side of the studs. A wall comprising: a frame comprising: a floor plate, a ceiling plate, a plurality of studs, each having a body with: a lower end fitted to the floor plate, an upper end fitted to the ceiling plate, and a plurality of apertures in series in the body, a plurality of aligned and interconnected bridging members spanning across and through the studs, by extending through the apertures of the studs; wherein the bridging member interlock parts interlock within the stud apertures, at least one panel secured to a first and/or to a second side of the frame.