NZ248482A - Partitioning system has a building element assembly comprising u and j shaped elements having flanges glued to webs to form frames with a settable material - Google Patents

Description

24 8 4 Patents Form No. 5 Our Ref: PZ500394 NEW ZEALAND PATENTS ACT 1953 Complete After Provisional No. 248482 Filed: 24 August 1993 COMPLETE SPECIFICATION PARTITIONING 1/ IAN BRUCE PIRRETT, a citizen of New Zealand of 19 Cecil Roadr Milford, Auckland, New Zealand hereby declare the invention, for which I pray that a patent may be granted to me and the method by which it is to be performed, to be particularly described in and by the following statement: M.2. PATSWT OmCE 29 AUG 1994 FIELD OF THE INVENTION This invention relates to a partitioning system and more particularly, relates to a system for providing a partitioning framework for use in supporting walls and similar structures in building construction.

The invention has particular application to timber in its processed forms including fibre board, however, the invention is not limited to such application and in other forms of the invention can be alternatively constructed.

BACKGROUND Traditionally partitioning framework assemblies have been provided utilising load bearing or non-load bearing structural elements such as studs and bottom and top plates formed either in elongate sawp timber fixed with fixing means, such as nails, staples, nail plates and the like or, alternatively, metal formed elements, such as sheet metal elements formed into U, box or C-shaped sections by folding or roll forming, fixed together with fixing means for example screws, blind rivets and the like.

The sawn timber framework assemblies have in the past been relatively inefficient in materials usage, *4 suffer difficulties of twisting and warping and can require a relatively high level of skill for erection. Such ausemblies are also relatively heavy and some instances can result in wasteful "over-engineering" .

Sawn timber framework assemblies also require a relatively higher level of skill to plan, cost and set out, leading to higher costs in some circumstances than alternatives.

A trend internationally is generally for timber costs to increase at a higher rate than most other products used as alternatives and therefore, in view of the relatively high timber usage of such arrangements, increasingly, traditional sawn timber framework construction is relatively more expensive than in the past.

Alternative forms of construction for partitioning framework assemblies or systems have been developed in metal. The most common forms are in sheet steel, either folded or roll formed. Alternatively, extruded metal materials, such as aluminium alloy are used. Most metal systems have included common section, bottom and top plate members which are generally C-shaped in configuration and are arranged for securement to a floor and ceiling and have stud members similarly formed, although perhaps in C, Z or I-beam construction with flange sizes being such that ends of the studs will engage within the channels of the bottom and top plate for inter-flange fixing by screws, blind rivets and the like.

Such metal framework systems, whilst being relatively cost effective and quick to construct, have had only limited universal application in building constimetion owing to their generally inherent "floppiness" and a difficulty in making such arrangements appropriately load bearing without the use of substantial fixing means or specific fixing assemblies (which leads to complication in construction) and a difficulty for the construction to be made to accommodate "tolerances" which tend to be inevitable in building construction.

As traditionally, most building construction work, particularly domestic and light commercial building work involves a high degree of timber work and carpentry, the introduction of another material and material skill requirement into the building cycle can lead to inefficiencies and market resistance.

OBJECT OF THE INVENTION 24 8 4 8 2 It is an object of this invention to come some way in overcoming the abovementioned problems or at least provide the public with a useful choice.

Other objects of this invention will become apparent from the following description.

SUMMARY OF THE INVENTION According to one aspect of this invention there is provided a building element assembly for a framework construction, said assembly formed from building elements, each said element having a substantially elongate web member, flange portions mounted to opposing edges of said web member substantially transversely thereof, and said web and/or flange portions being porous and absorbent to a settable material used to secure the flanges and web member, said settable material providing lines of strengthening for the element, and wherein said assembly comprises a first building element having a substantially U-shaped longitudinal cross-section, with first longitudinal edges of each flange portion together with a first longitudinal side of the web member forming a substantially planar base of thje V ^ p/\TENf 6FFIQIE "U", and a second building element having a J i Nov m 248482 substantially J-shaped longitudinal cross-section such that its first flange portion has a width greater than its second flange portion, and the width of the first flange portion of the second building element is greater than the width of the base of the first building element, said first and second building elements juxtaposed in the assembly such that the base of the first building element abuts the first flange portion of the second building element.

BRIEF DESCRIPTION OF THE DRAWINGS The drawings of the preferred form of the invention and alternatives are as follows ' -J!frENT 0rFI0£ 11 NOV 199? RECEIVED 8 Figure It is a substantially diagrammatic exploded perspective view of a typical top plate, stud and bottom plate assembly of the preferred form of the invention; Figure 2: is a cut-away perspective view of an end of a stud element of Figure 1; Figure 3t is a substantially diagrammatic cross-sectional plan view showing engagement of a door frame assembly within a framework structure according to the invention; Figures 4 A. B and C: shows the joint of Figure 1 in substantially diagrammatic cross-sectional plan view (A), cross-sectional side elevation (B) and cross-sectional end elevation (C); Figures 5 A, B and C: shows diagrammatically the joint of Figure 4 in the same views, the joint is shown reinforced; Figures 6 A, B and Ct shows diagrammatical ly an alternative joint configuration to that depicted in Figures 1 and 4 in the same views; Figures 7 A, B and C» shows diagrammatically a further alternative joint configuration to that depicted in Figures 1 and 4 in the same views; Figures 8 A, Band C» shows diagrammatically yet a further joint configuration in the same views; Figures 9 A, B and C: shows diagrammatically yet a further joint configuration in the same views; Figures iO A, B and C: shows diagrammatically a longitudinal joint between two building elements, in this instance, bottom or top plate members in the same views; Figures 11 A, B and C: shows diagrammatically ah alternative longitudiml joint configuration to that shown in Figure 11 in the same views; Figure 12s shows diagrammatically an internal T-joint configuration in cross-sectional plan view; Figure 13i shows diagrammatically a corner joint in substantially cross-sectional plan view; Figure 14t shows diagrammatically an alternative corner joint assembly in cross-sectional plan view; 8 Figure 15: shows in substantially diagrammatic cross-sectional plan view a T-joint between walls showing the use of an alternative connecting stud between walls to that of Figure 12; Figure 16: shows an alternative stud assembly to that disclosed in Figure 15 in cross-sectional plan view; Figure 17t shows a further alternative stud to that disclosed in Figure 15 in substantially cross-sectional plan view; Figure 18: shows a still further alternative stud to that of Figure 15 in partial perspective view connected with a solid timber bottom plate assembly.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The preferred form of the invention is preferably formed in fibre board, in particular medium density fibre board (MDF), being sheet timber material formed frpm waste or inferior grade timber products.

Preferably the framework elements of the invention are formed by slicing or slitting sheets of the preformed fibre board into strips of the required sizes from predetermined thicknesses of board. In the preferred embodiment preferably board used to form element "web" members is of a greater thickness than board used to form "flange" members, although this is not essential to the invention and is dependent on the ultimate strength/use requirements for the element created.

The preferred form of the invention has particular although not exclusive application to light commercial and domestic partitioning, such as that used in offices, in dwelling construction and the like; preferably in a substantially non or light load bearing assembly. The invention is not limited to such a construction emd it is envisaged that the invention can be alternatively developed for use in load bearing and structural situations using similar techniques, however with possibly different material sizes.

Referring to the drawings and in particular Figures 1 and 2, the framing assembly as indicated by arrow 1 incorporates in the preferred form a stud element 2 and top and bottom plate channels 3. It will be appreciated that the stud element 2 and top and bottom plates 3 are each formed in fibre board material, preferably MDF and each incorporate a web 4 and flanges 5, said flanges 5 »♦ • p 24 8 4 8 2 being mounted transversely according to edges 6 of the webs 4 and being preferably fixed thereon by gluing with a suitable settable adhesive, such as polyvinyl acetate glues (pva) or alternatively settable adhesives.

In the preferred form of the invention, the flanges 5 are temporarily fixed with the web 4 via fixing means, such as staples and the like to hold the elements in the required position until the adhesive sets. This is however not essential to the invention in all forms, particularly where clamping of the parts together during setting of the adhesive can be achieved.

Preferably the webs 4 are provided of substantially thicker material than the flanges 2 and the depth (width) of the web is such that in conjunction with the thickness of the flanges 2, the framework structure provides a wall thickness suitable for engaging with other building structures, such as a thickness which equates with sawn timber framework or substantially standard modular wall thicknesses currently used.

Referring predominantly to Figure 2, the elements 2 and 3 are each formed with opposing edges 6 of the web 4 formed with a substantially roughened surface. This roughening is normally achieved by sawing a sheet of MDF into the webs 4, for example, by a circular saw and the like, such that a substantially fibrous or hairy surface is provided which 24 8 4 - n - readily absorbs liquid adhesive prior to setting of that adhesive.

In construction of the elements 2 and 3, it will be appreciated that upon an adhesive being applied to the edge surfaces 6 (and in some instances, surfaces of the flanges 5) there adjacent, an absorption of the liquid adhesive into the edges 6 and adjacent portions of the flanges 5 will occur, such as is shown by the cross-hatched region 7 in Figure 2.

It will be appreciated that upon setting of the adhesive, a region of increased density or hardness of the material forming the element is provided. In view of the spacing of this "region of hardness" on either side of the web 4, it will be appreciated that strengthening of the resultant element is achieved.

Enhanced absorption of the adhesive into the fibrous board material forming the element is achieved by the roughened surface as the result of the sawn nature of the edges 6.

In the preferred form of the invention and with reference to Figures 1, 2 and 4, preferably end portions 8 of the studs 2 are arranged to extend outwardly beyond end portions 9 of flanges 5 a distance commensurate with the depth of the channel in the top and bottom plate members 3. It will be appreciated that when the stud 2 is engaged 24 8 4 in the channel, the projecting end portion 8 of the web 4 engages in the channel with an outer end 10 thereof, impinging against a side surface of the top or bottom plate web 4 for load bearing. Additional load bearing is achieved between the ends 9 of the stud flanges 5 and opposing edges of the top and bottom plate flanges 5.

Securement of the stud 2 and top and bottom plates 3 with one another is achieved by fixing means passed through the top and bottom plate flanges 5 into the adjacent projecting end portion 8 of the stud web 4.

It will be appreciated that stud 2 can be preformed to a predetermined length suitable to the stud height in the area to be partitioned.

Once the framework is erected, it will readily accept the application of cladding sheets, for example, plaster board and the like which can be fixed in the traditional method utilising nails, adhesives and the like.

It will be appreciated that the partitioning system is normally provided as a permanent or semi-permanent structure. Alternatively the partitioning can be provided as a demountable arrangement utilising removable fixing means and in the absence of glued joints between these studs 2 and top and bottom plates 3. 24 8 Referring to Figures 5 A, B and C, reinforcing means 11 in the form of blocks of material similar to that forming webs 4 are engaged in the vicinity of the joint between the stud flanges 4 and top and bottom plate flange portions 5 and web 4. It will be appreciated that suitable fixing means such as nails, glues and the like can be used to hold the reinforcing means 11 in position to substantially strengthen the joint between the elements 2 and 3.

Referring now to Figure 6, it will be seen that the engagement between the top and bottom plate elements 3 and the stud element 2 is alternatively provided.

In this arrangement, it will be seen that the stud flanges 5 extend beyond the end 10 of the stud web 4. The flanges 5 thus projecting alongside the edges 6 of the top and bottom plate web 4, where fixing means can be engaged. In this arrangement, the top and bottom plate 3 flanges 5 must be cut out in the area of engagement.

With reference to Figure 7 A, B and C, alternative reinforcing means are provided in the form of L-shaped metal brackets 12. These brackets 12 are, for example, provided in extruded aluminium or the like and are engaged by nails, adhesives and the like into the joint.

Preferably the brackets 12 are provided as portions cut from a length of material and are preferably engaged one on either side, or to one side of the joint between the web portions 4 of the stud 2 and top and bottom plate portions 3. Preferably, the width of the brackets 12 is such that they readily fit between the stud 2 and top and bottom plate 3 flange 5.

Figure 8 A, B and C shows a stud 2 engaged in a framework structure where the top and bottom plates 3 are dispensed with and replaced by sawn timber framework F to form top and bottom plates F.

In this arrangement, the width of the top and bottom plates F is substantially commensurate with an overall width of the stud web 4 and flanges 5.

Preferably the stud 2 is retained in position adjacent the appropriate surface of the top and bottom plate F by block portions 13 of timber, such as off-cuts of the web 4 which are fixed to the framework portions F and between the flanges 5 of the stud 2. In this form it will be understood the ends of the stud web 4 and flanges 5 are formed substantially flush.

Referring now to Figure 9 A, B and C, the top and bottom plate 3 may be provided in similar cross-section material to the stud 2; that is, in a substantially I-beam configuration. In this assembly, preferably small load 24 8 4 bearing blocks 14 are engaged in the unused recess remote from the stud 2 end in the vicinity of engagement of the str.d 2 so as to absorb any loads imposed by t>e stud 2 on the web 4 of the top and bottom plate members 3.

Referring to Figures 10 and 11, it will be appreciated that top and bottom plate members 3 may be conjoined longitudinally by butt joints utilising a block 15; such as an off-cut of web portion 4, which fits between flanges 5 spanning the joint. The joint is preferably held in position by glue and/or fixing means engaged between the block 15 and adjacent portions of the web 4 and flanges 5.

Referring to Figure 11, in an alternative form of the invention, the 'blocked" joint of Figures 10 A, B and C is alternatively provided in a "stepped" joint where one end of an element forming the top and bottom plate portions 3 is recessed with the end of the Web 4 shorter than projecting flange portions 5. An opposite end of the element 3 is oppositely arranged to enable a similarly formed top and bottom plate member 3 to be inter-engaged and fixed one with the other, as shown in the drawings.

Turning now to Figures 12, 13 and 14, it will be appreciated that whilst the stud 2 as described with reference to Figures 1, 2 and 4 A, B and C is provided for substantially linear walls, where corners are encountered, suitable arrangements have to be made for the support and 24 8 4 securement of wall cladding and the engagement of walls arranged at an angle one relative to the other.

With reference to Figure 12, it will be appreciated that an internal corner in the form of a "T"-shaped cross-section corner can be provided by a corner stud member 20, which is preferably provided in substantially similar materials to the stud 2 with a web member 4 and flanges 5 arranged into a substantially C-shaped channel, along the lines of the top and bottom plate members 3 described hereinbefore. In addition, a back flange 21 is provided which extends across the back of the web 4 remote from the channel and projects beyond outer side surfaces 5A of the webs 5.

It will be appreciated that the back flange 21 provides a pair of oppositely arranged flanges 22 extending orthogonally relative to the flanges 5 to thus facilitate support of wall cladding C in an internal corner. It will be appreciated that an additional stud 2 is not then required behind the corner as is traditional, the back flange 21 providing the support for the cladding C alternatively.

Referring to Figure 13, it will be appreciated that a right-angle corner can be provided by a corner stud 200 which in the preferred form of the invention is arranged in a first wall and of a substantially channel-like Z4 8 4 - 17 - r configuration substantially similar to the top and bottom plate members 3.

In this form of the invention, preferably an intended internal corner flange 50 is provided of a greater width than the proposed thickness of a second wall to be arranged at an angle to the first wall, such that when the corner stud 200 is engaged in a corner with the second wall projecting therefrom as is shown in Figure 13 in cross-sectional plan view, the internal flange 50 projects inwardly of the orthogonal wall thickness to define a corner flange portion 51 which readily accepts the cladding C into the internal corner.

It will be appreciated that the corner stud 200 can be used for both left and right handed corners by merely inverting the stud 200.

Refeirring to Figure 14, an alternative arrangement for a more robust corner stud assembly is provided where the corner stud assembly provided in a pair of substantially open "Z"-shaped assemblies 2000 having a web portion 4 preferably formed in a thinner material and flanges 5 arranged to project on opposite sides of the web 4 substantially orthogonally relative thereto.

In the preferred form of the invention, preferably two substantially Z-shaped stud portions 2000 are each inter- engaged with one another, one rotated through 90° relative to the other. The stud members 2000 are engaged one relative to the other such that internally of the corner, flange portions 5 project outwardly of the corner to facilitate engagement of cladding.

The external corner assembly created is provided as a substantially "boxed" corner in substantially robust materials. This arrangement is regarded as particularly attractive where the arrangement is provided in a load bearing or semi-load bearing condition, particularly where the external corner is provided in an external wall construction of a building and may assist in the positioning of ties between the sub-floor and roof structures.

Whilst not shown, it is envisaged that end portions of the stud portions 2000 are each formed to inter-engage with adjacent top and bottom plate portions and be secured therewith along the lines described hereinbefore.

Returning now to Figure 3, in the preferred form of the invention, preferably partitioning systems according to the present invention require openings therein. In the preferred form of the invention, it is envisaged that the fitting and trimming for the opening can be conveniently provided by positioning studs 2a predetermined distance away from one another to accommodate a door frame assembly , having perimeter jambs 31 and door 32 hingeably mounted therein.

Mounting blocks 33 in this form are secured on the door jambs 31 positioned outwardly thereof and are of such a width that they will engage within the recess defined between the flanges 5 of the studs 2. The mounting blocks 33 are preferably provided from off-cuts of material used to form the webs 4.

Positioning of the studs 2 in the wall structure is arranged so that the complete door frame assembly 30 can be inserted into position in a rough opening defined in the wall framing by engaging the mounting blocks 33 of one door jamb 31 in the recess defined between the flanges 5 of the stud 2 £ud by pushing the engagement of the mounting blocks 33 fully home, while the door assembly 30 is situated at an angle to the line of the wall and rough opening. It will be appreciated the rough opening is formed of a sufficient size that when the engagement of the mounting blocks 33 is pushed fully home on one side, the door frame assembly 30 can be rotated to align with the wall; the mounting blocks 33 passing the stud flanges 5 on the opposite side of the rough opening. When aligned, the door frame assembly 30 can be moved in an opposite direction and centralised in the rough opening, such that mounting blocks 33 provided on the opposite door jambs 31 engage within the recesses between flanges 5 of the opposing stud of the rough opening and the door frame assembly 30 is held by the inter-engagement of the juxtaposed faces of the mounting blocks 33 and stud flanges 5 defining the rough opening, oh both sides of the rough opening.

Fixing of the door frame assembly 30 can then be achieved by passing fixing means through the stud flanges 5 into the mounting blocks 33 fixed with the door jambs 31.

It will thus be appreciated that by this arrangement, a convenient means of inserting and aligning door frame assemblies 30 can be provided.

A slight recess or gap provided between the door jambs 31 and flanges 5 of the studs 2, when engaged, can be covered over by cladding subsequently engaged with the wall.

This method and apparatus is also suited to engagement of other structures within the building framework, such as other closures, cabinetry and the like.

Whilst the invention has been described with reference to a substantially all timber based framing product, in certain instances, a "hybrid" arrangement of the framing assembly can be useful, where some parts are manufactured from sheet steel and others from timber based products.

Referring specifically to the drawings, and Figures 15 to 18, an alternative corner stud member 20 is provided where the back flanges 21 is substantially integrally formed with flanges portions 5.

It will be appreciated that along with the format of corner stud 20 as shown in Figure 12, the corner stud of Figures 15 to 18 can substitute for the traditional use of three or four traditional studs normally used to create the corner and fixing for cladding in the corner.

With reference specifically to Figure 15, preferably a medial portion 50 of the stud is provided of a "v" configuration or additional reinforcement of the stud in use. And referring to Figure 16 and 17, preferably alternative studding arrangements are provided whereby the flanges 5 are bent, for example by folding or roll forming into an integral formation substantially as shown in the drawing.

End fixing of the stud assembly of Figure 18, which is essentially a top hat section, is preferably effected by slipping a base portion of the flanges to release a flap 51 of the flanges to lie substantially along an upper portion of upper portion 3A of a bottom plate 3 and to facilitate fixing with the bottom plate 3. - 22 - £4 Q It will thus be appreciated that in this arrangement the corner studs 20 of Figures 12, 15 to 18 provide a convenient means of securely engaging dissecting walls one with the other in a partitioning frame work construction.

Whilst the stud 20 configuration has been described incorporated into the partitioning assembly of the present invention, it is to be appreciated that the particular corner stud member 20 can alternatively be applied to traditional sawn timber frame work systems, metal studding systems and the like and in such uses overcome the need for additional studs in that area, thus leading to considerable savings in materials utilisation and labour in formation of the structure.

In addition, studs and top and bottom plate members in accordance with this invention can comprise the necessary elements of bracing units in framing construction. For example, three studs at say 600 millimetre centres made in accordance with this invention and connected to the top and bottom plates may be provided with suitable sheet bracing such as 9.5 millimetre gibraltor board to form a bracing element within the framing. Although this example is described with studs at 600 millimetre centres, any suitable length could be used although it is unusual for such braces to be provided of less than one metre in length. The fixing of the gibraltor board to the frame work may be through the use of both glue and screws in accordance with normal procedures. - 23 24 8 4 Thus by this invention there is provided a partitioning method and apparatus for the convenient partitioning of a building area. The method and apparatus provides a timber based configuration, yet one which is relatively efficient in timber utilisation and assembly skill requirements.

It will be appreciated that the partitioning system is readily adaptable to factory manufacture, and substantially kit set supply and enables far greater levels of accuracy in erection to be achieved than with traditional timber construction techniques, yet the system is readily adaptable to meet specific requirements by normal carpentry techniques.

Where in the foregoing description, reference has been made to specific components or integers of the invention having known equivalents, then such equivalents are herein incorporated as if individually set forth.

Although this invention has been described by way of example and with reference to possible embodiments thereof, it is to be understood that modifications or improvements may be made thereto without departing from the scope or spirit of the invention as defined in the appended claims.

Claims (4)

- 24 - 248482 WHAT I CLAIM IS;

1. A building element assembly for a framework construction, said assembly formed from building elements, each said element having a substantially elongate web member, flange portions mounted to opposing edges of said web member substantially transversely thereof, and said web and/or flange portions being porous and absorbent to a settable material used to secure the flanges and web member, said settable material providing lines of strengthening for the element, and wherein said assembly comprises a first building element having a substantially U-shaped longitudinal cross-section, with first longitudinal edges of each flange portion together with a first longitudinal side of the web member forming a substantially planar base of the "U", and a second building element having a substantially J-shaped longitudinal cross-section such that its first flange portion has a width greater than its second flange portion, and the width of the first flange portion of the second building element is greater than the width of the base of the first building element, said first and second building elements juxtaposed in the assembly such that the base of N.7. PATENT OFFICE i 1 NOV 1997 ~ RECEIVED ~ 25 - 24 8 4 8 2 the first building element abuts the first flange portion of the second building element.

2. A building element assembly according to claim 1 forming a corner unit for a framework construction, wherein an outer side of a flange portion of the first building element is aligned with the base of said second building element.

3. A building element assembly according to either claim 1 or claim 2 wherein said first building element forms a support for a framing member for an opening.

4. A building element assembly substantially as herein described and with reference to the drawings. IAN B1 CJCE PIRRETT ttorneys CN SON and CAREY END OF CLAIMS ls/dict/COPY15859 N.Z. PATEN I OFFICE 11 NOV 199? ' RECEIVED