WO2003069084A1

WO2003069084A1 - Longitudinal building frame component

Info

Publication number: WO2003069084A1
Application number: PCT/AU2003/000046
Authority: WO
Inventors: Grant Charlwood
Original assignee: Charlwood Industries Wholesalers Pty Ltd
Priority date: 2002-02-14
Filing date: 2003-01-20
Publication date: 2003-08-21
Also published as: AUPS055102A0

Abstract

A longitudinal building frame component (20) is disclosed. The component (20) includes a longitudinal first member having an engagement formation (28, 30) thereon and a pair of longitudinal second members (24, 26) extending from one side of the first member. The second member (24, 26) adapted for connection to other building components. The engagement formation (108, 110) is adapted for longitudinal sliding engagement with a corresponding engagement formation (28, 30) on a substantially like other building frame component (100). A longitudinal building frame component assembly (20, 100), a corner building frame component assembly (130) and window frame and transom components (70, 72) are also disclosed.

Description

Longitudinal Building Frame Component

Field of the Invention

The present invention relates to improvements in building construction, particularly to an improved: longitudinal building frame component; longitudinal building frame component assembly; corner building frame component assembly; window frame component; and window transom component.

The invention has been developed primarily for use in home extensions and will be described hereinafter with reference to this application. However, the invention is not limited to this particular application and is also suitable for new building construction and renovations.

Background of the Invention

Building components are known that are prefabricated to order and then shipped to a building site for assembly and construction. Such prefabricated building components are particularly suited for home extensions, which are undertaken by professional builders and home handymen. Problems arise with such prefabricated building components if they are: produced inaccurately; produced according to incorrect measurements; or attempted to be used with other components that have been installed inaccurately, then they will often not fit. If the supplied components are too large then, in some circumstances, they may be able to be trimmed to size. However, if the supplied components are too small, then they generally always need to be returned to the manufacturer and replaced. These problems can result in delays in construction, customer dissatisfaction and increased building costs.

It is an object of the present invention to substantially overcome or at least ameliorate one or more of the prior art deficiencies noted above. Summary of the Invention

Accordingly, in a first aspect, the present invention provides a longitudinal building frame component, the component including: a longitudinal first member having an engagement formation thereon; and a pair of longitudinal second members extending from one side of the first member, the second members adapted for connection to other building components; wherein the engagement formation is adapted for longitudinal sliding engagement with a corresponding engagement formation on a substantially like other building frame component.

The first member, the second members and the engagement formation are preferably formed integrally in the building frame component. The building frame component is preferably formed by extruding, most preferably from aluminium.

The second members are preferably parallel to each other and normal to the first member. The second members preferably each include a barbed rail along their distal edge. One of the second members is preferably adjacent an end of the first member. The other of the second members is preferably adjacent the middle of the first member.

In one form, the engagement formation is preferably a pair of outwardly facing recesses provided along each outside edge of the first member of the building component. The corresponding engagement formation is preferably a pair of inwardly facing flanges provided adjacent each outside edge of the first member of the like building component.

In another form, the engagement formation is preferably a pair of inwardly facing flanges provided adjacent each outside edge of the first member of the building component. The corresponding engagement formation is preferably a pair of outwardly facing recesses provided along provided adjacent each outside edge of the first member of the like building component. In this form, each outside edge of the first member preferably includes an engaging channel extending therealong, the channels adapted to snap-engagingly receive other building components therein. The flanges preferably extend from the convex side of the channels. In a second aspect, the present invention provides a longitudinal building frame component assembly, the assembly including: a first building frame component having: a longitudinal first member with an engagement formation; a pair of longitudinal second members extending from one side of the first member, the second members adapted for connection to other building components; and a second building frame component having: a longitudinal first member with a corresponding engagement formation; a pair of longitudinal second members extending from one side of the first member, the second members adapted for connection to other building components, wherein the engagement formations of the first and second building frame components are adapted for longitudinal sliding engagement to permit the overall length of the building frame component assembly to be adjusted.

The first member, the second members and the engagement formation are preferably formed integrally in the each of respective first and second building frame components. The building frame components are each preferably formed by extruding, most preferably from aluminium.

The second members are preferably parallel to each other and normal to their respective first member. The second members preferably each include a barbed rail along their distal edge. One of the second members is preferably adjacent an end of their respective first member. The other of the second members is preferably substantially adjacent the middle of their respective first member.

In one form, the engagement formation is preferably a pair of outwardly facing recesses provided along each outside edge of the first member of the first building component. The corresponding engagement formation is preferably a pair of inwardly facing flanges provided adjacent each outside edge of the first member of the second building component.

In another form, the engagement formation is preferably a pair of inwardly facing flanges provided adjacent each outside edge of the first member of the first building component. The corresponding engagement formation is preferably a pair of outwardly facing recesses provided along provided adjacent each outside edge of the first member of the second building component. In this form, each outside edge of the first member of the first building component preferably includes an engaging channel extending therealong, the channels adapted to snap-engagingly receive other building components therein. The flanges preferably extend from the convex side of the channels.

In a third aspect, the present invention provides a corner building frame component assembly, the assembly including: a longitudinal first member having a face portion adapted for connection to other building components and an engagement formation; and a longitudinal second member having a face portion adapted for connection to other building components and an engagement formation, wherein the engagement formations of the first and second members are adapted for angular pivoting engagement to permit the angle between the face portions of the first and second members to be adjusted.

The first and second members preferably each include at least one arcuate guiding portion adapted to abut and travel over one another during angular adjustment of the first and second members.

The first and second members preferably each include an internally facing and an externally facing arcuate guiding portions, each external portion of one of the first or second member adapted to abut and travel over each internal portion of the other of the first or second member during angular adjustment of the first and second members.

The engagement formation of the first member is preferably a curved flange having an enlarged head portion. The engagement formation of the second member is preferably a recessed channel having a opening larger than the flange and smaller than the head portion. The channel is preferably quadrant shaped in cross section and adapted to allow the head portion to pivot therein.

The first and second components are preferably adapted to pivot relative to each other by approximately 90 degrees. The first and second components are preferably adapted to pivot relative to each other between a first position in which the face portions are substantially parallel to one another and a second position in which the face portions are substantially normal to one another.

In a fourth aspect, the present invention provides a window frame component, the component including: a first longitudinal planar member; a second longitudinal planar member extending from the first planar member and adapted for fixing to a building frame component; a longitudinal channel member extending from the first planar member and adapted to receive a window panel edge therein; and a longitudinal box member extending from the first planar member and adapted to engage with a window sash assembly, wherein the first planar member, second planar member, channel member and box member are formed integrally in the component.

The window frame component is preferably formed by extruding, most preferably from aluminium.

In a fifth aspect, the present invention provides a window transom component, the component including: a first longitudinal planar member; a second longitudinal planar member extending from the first planar member and adapted for fixing to another window assembly; a longitudinal channel member extending from the first planar member and adapted to receive a window panel edge therein; and a longitudinal box member extending from the first planar member and adapted to engage with a window sash assembly, wherein the first planar member, second planar member, channel member and box member are formed integrally in the component.

The window transom component is preferably formed by extruding, most preferably from aluminium. Brief Description of the Drawings

Preferred embodiments of the invention will now be described, by way of examples only, with reference to the accompanying drawings in which:

Fig. 1 is a cross sectional schematic side view of a longitudinal building frame component according to an embodiment of the invention in a modular wall construction;

Fig. 2 is a cross sectional schematic side view of the component shown in Fig. 1 in a stud wall construction; Fig. 3 is a cross sectional schematic side view of the frame member shown in Fig. 1 in a window base construction;

Fig. 4 is a cross sectional schematic top view of a longitudinal building frame component assembly according to an embodiment of the invention in a modular wall construction; Fig. 5 is a cross sectional schematic view of the assembly shown in Fig. 4 in a window sill construction;

Fig. 6 is a cross sectional schematic top view of the assembly shown in Fig. 5 in an intermediate post window construction;

Fig. 7 is a cross sectional schematic side view of the frame component shown in Fig. 1 engaged with a like component in a stud wall construction;

Fig. 8 is a cross sectional schematic side view of the frame component shown in Fig. 1 engaged with a like component in a stud wall construction;

Fig. 9 is a cross sectional schematic end view of a corner building frame assembly according to an embodiment of the invention in a modular wall construction; Fig. 10 is a cross sectional schematic end view of the assembly shown in Fig. 9 in a

90° orientation;

Fig. 11 is a cross sectional schematic end view of the assembly shown in Fig. 9 in a 180° orientation;

Fig. 12 is a cross sectional schematic end view of the assembly shown in Fig. 10 in a glass wall construction;

Fig. 13 is a cross sectional schematic end view of a window frame component according to an embodiment of the invention;

Fig. 14 is a cross sectional schematic end view of a window transom component according to an embodiment of the invention; and Fig. 15 is a partial perspective schematic view of a building frame formed constructed using the components and assemblies shown in the previous figures.

Detailed Description of the Preferred Embodiment

Fig. 1 shows a cross-sectional schematic side view of a modular wall construction using a "male" version of a longitudinal building frame component 20 according to an embodiment of the invention. The component 20 includes a first member 22, a pair of second members 24 and 26 extending from one side of the member 22 and an engagement formation, in the form of inwardly facing flanges 28 and 30. The outside edges of the member 22 include channels 32 and 34 therealong. The component 20 is manufactured from aluminium by extrusion moulding.

Fig. 1 also shows a modular wall panel 36, formed from a foam core 38 with a plaster panel 40, a building floor slab 42, an internal horizontal skirting architrave 44, a base flashing 46 and a base flashing weather strip 48. The plaster panel 40 is preferably that sold under the Trade Mark GYPROCK.

The architrave 44 and flashing 46 are formed from a resilient plastic and include grooved ends 50 and 52 which are adapted to snap-engage with the channels 32 and 34 respectively. The flashing 46 also includes a recessed part 54 adapted to engage an enlarged head 56 of the flashing 48. The dashed line 58 indicates a clearance slot between the flashing 46 and the core 38 for a flashing sold under the Trade Mark COLORBOND.

To construct the wall shown, the component 20 and the architrave 44 and flashing 46 are cut to length on site and snap engaged in the manner shown. The component 20 is then fixed to the slab 42 by bolts if the floor is concrete or screws if wooden. The foam core 38 of the wall panel 36 is then recessed as shown and is then lowered over the second members 24 and 26 and flashing 46.

The construction shown above is also suitable for use in a construction of a ply modular wall in which a wooden ply panel is substituted for the plaster panel 40. Fig. 2 shows the component 20 used in a stud wall construction with a GYPROCK facing panel. Like features to those described in relation to Fig. 1 shall be denoted with like reference numerals in Fig. 2. The construction of Fig. 2 is substantially identical to that of Fig. 1 except inner and outer face panels 60 and 62 are produced from GYPROCK and fastened to horizontal pressed steel studs 64. The bottom end of the steel studs 64 have a punched recessed portion 66, formed by punching, that receives the second members 24 and 26, which are fastened to the stud 64 by screws (not shown). This construction is also suitable for use in a stud wall with a ply base assembly, in which a ply panel is substituted for the internal GYPROCK panel 60.

Fig. 3 shows the component 20 of earlier Figs, in a window base construction. Once again like features to those shown in earlier Figs, shall be denoted using like reference numerals. In Fig. 3 there is also shown a window frame component 70 according to an embodiment of the invention. The component 70 has a first longitudinal planar member 72, a second longitudinal planar member 74, which is adapted for fixing to a building frame component, a longitudinal channel member 76 and a longitudinal box member 78. All of the members 72, 74, 76 and 78 are integrally formed from aluminium by extrusion moulding. In the construction shown, the member 74 is attached by screws (not shown) to the second member 26 of the component 20. The channel member 76 is adapted to receive a window panel edge therein or, when not required, a plastic window snap-in 80. The box member 78 is adapted to support a window sash assembly 82, comprising a window channel 84 with a window panel edge receiving recess 86 and a sash roller 88.

To complete the construction, an internal window trim 90 and a base window sill 94 are attached to the component 70 by virtue of their barbed ends 96 and 98 being received within corresponding recesses 100 and 102.

The advantages of the window base construction shown in Fig. 3 over those of the prior art include: a reduction in component pieces due to the use of the component 70; the ability to interact and be used with other building components, such as the component 20 and the various skirting components. Fig. 4 shows the male version of the component 20 used in conjunction with a like "female" version of the component 100 in an intermediate vertical post frame modular wall construction. The component 100 also includes a longitudinal first member 102, a pair of longitudinal second members 104 and 106 and an engagement formation, in the form of a pair of outwardly facing recesses 108 and 110 provided on the outside edges of the member 102. The second member 104 and 106 are attached to the core 38 in the same manner as that previously described in relation to the second members 24 and 26 with reference to Fig. 1 of the construction.

The flanges 28 and 30 on the component 20 are adapted to slide into engagement with the recesses 108 and 110 respectively to slidably engage the component 20 with the component 100. If the components 20 and 100 are not exactly to the desired length for the proposed construction then, when engaged as a building frame component assembly, they can be slid relative to one another to increase the overall length of the assembly to suit site requirements. When the preferred length of the assembly is determined, the components 20 and 100 are locked relative to one another by screws (not shown) passing through the first members 22 and 102. To complete the wall constructions shown the foam core 38 are engaged with respective second members 24, 26, 104 and 106 in the manner previously described.

As an example, for a specified assembly length of 2000mm, the members 20 and 100 are preferably manufactured in 1900mm lengths and can together be adjusted between an overall minimum length of 1900mm and an overall maximum length of 2100mm. The ability to adjust the length in this way is particularly advantageous for home renovators or other builders who may have measured their site inaccurately or constructed other components inaccurately.

Fig. 5 shows the components 20, 100 (together forming an adjustable length assembly) and component 70 used in a horizontal window wall sill construction. As before, like features to those shown in earlier Figs, denoted with like reference numerals. Fig. 5, also shows internal and external cladding clips 112 and 114 and modified forms of architrave 90 and sill flashing 94. The construction is similar to that previously described except that the relative positioning of components 20 and 100 is adjusted to account for any discrepancies in the horizontal distance between adjacent studs, providing the same advantages as previously discussed. Further, the ability to use common components in various parts of building construction reduces in the overall number of components required providing a reduction in manufacturing and inventory costs. The components are preferably produced with a timber mold profile section.

Fig. 6 shows a similar construction to that of Fig. 5 when used in the construction of a wall window head assembly (ie. at the top of a window). Very similar components can also be used in the construction of a wall sliding door head assembly.

Fig's. 7 and 8 illustrate how the component 20 can be used both as the horizontal base and the vertical stud or post of a framed wall by suitable recessing (by punching) of the lower end of the (stud or post) component 20. Barbs 116 and 118 on the ends of the ends of the second members 24 and 26 of the (base) component 20 engage in the notched recesses 120 and 122 cut into the (stud or post) component 20. The two members 20 are then fixed to one another by screws (not shown).

Fig. 9 shows a vertical cross-section of a corner building frame component assembly 130 according to an embodiment of the invention. The assembly 130 includes a longitudinal first member 132 and a longitudinal second member 134. Each of the members 132 and 134 have a face portion 136 and 138 respectively, which are adapted for connection to other building components, as is illustrated by the attachment of the face portion 136 to the modular wall 36 by screws (not shown). The member 132 include an engagement formation, in the form of recessed channel 140. The member 134 includes a corresponding engagement formation, in the form of curved flange 142 with an enlarged head portion 144. The channel 140 includes an opening 146 which is larger than the flange 142 but smaller then the head portion 146. Each of the members 132 and 134 include an internally facing guiding portions, in the form of arcuate surfaces 148 and 150 respectively, and external guiding portions, in the form of arcuate surfaces 152 and 154 respectively.

The members 132 and 134 are assembled by being longitudinally slid into engagement with each other with the head portion 144 being received within the channel 140 and the internal and external guiding formations abutting and sliding over adjacent external and internal guiding formations respectively. As best shown in Fig's 10 and 11, the members 132 and 134 can be rotated relative to one another between a position where the face portions (and therefore the walls they are attached to) are at 90° to one another (see Fig. 10) and a position where the face portions (and thus the attached walls) are at 180° to one another (see Fig. 11). The members 132 and 134 therefore find application in joining adjacent and parallel wall components or as a corner post between adjacent and angled wall components. Importantly, the assembly 130 can be adjusted to account for any variations in site construction due to inaccurate measurements or other inaccurate components that result in the walls meeting at a less then preferred angles (e.g. 85° or 95°). The members also present a finished internal and external appearance and do not require further decorative finishing such as a plaster covering or the like.

As is consistent with other building components previously described, the members 132 and 134 have provision for attachment of corner post adaptors 156 and 158 and a short vertical corner architrave 160 and a long vertical corner architrave 162.

Fig. 12 shows the assembly 130 used in conjunction with earlier described component adjacent a glass wall construction.

Fig. 13 is a isolated view of the component 70 shown in Fig. 3, which, as previously described, is used in the construction of a window base. Fig. 14 is a similar view of modified component 70 suitable for use in the construction of a window transom and which includes a transom glass snap-in 164.

Fig. 15 is a partial perspective view of a wall construction demonstrating how the previously described components can be used to minimise the overall number of different components required in a building construction and also to illustrate how they can be adjusted to account for construction inaccuracies.

In summary, the advantages provided by the previously described components include: a reduction in individual component requirements due to integrally formed nature of components; the ability to interact with each other in different construction applications to further reduce the overall number of different components required; the ability to adjust in length or angle as the case may be; suitability for use in council approved habitable structures or non-habitable structures; and reduced external and internal finishing requirements.

Although the invention has been described with reference to specific examples, it would be appreciated by those skilled in the art that the invention may be embodied in many other forms.

Claims

CLAIMS:

1. A longitudinal building frame component, the component including: a longitudinal first member having an engagement formation thereon; and a pair of longitudinal second members extending from one side of the first member, the second members adapted for connection to other building components; wherein the engagement formation is adapted for longitudinal sliding engagement with a corresponding engagement formation on a substantially like other building frame component.

2. The component as claimed in claim 1, wherein the first member, the second members and the engagement formation are formed integrally.

3. The component as claimed in claim 1 or 2, wherein the component is formed by extruding.

4. The component as claimed in claim 3, wherein the component is formed from aluminium.

5. The component as claimed in any one of the preceding claims, wherein the second members are parallel to each other and normal to the first member.

6. The component as claimed in any one of the preceding claims, wherein the second members each include a barbed rail along their distal edge.

7. The component as claimed in any one of the preceding claims, wherein one of the second members is adjacent an end of the first member.

8. The component as claimed in claim 7, wherein the other of the second members is adjacent the middle of the first member.

9. The component as claimed in any one of the preceding claims, wherein the engagement formation is a pair of outwardly facing recesses provided along each outside edge of the first member of the building component.

10. The component as claimed in claim 9, wherein the corresponding engagement formation is a pair of inwardly facing flanges provided adjacent each outside edge of the first member of the like building component.

11. The component as claimed in any one of claims 1 to 8, wherein the engagement formation is a pair of inwardly facing flanges provided adjacent each outside edge of the first member of the building component.

12. The component as claimed in claim 11, wherein the corresponding engagement formation is a pair of outwardly facing recesses provided along provided adjacent each outside edge, of the first member of the like building component.

13. The component as claimed in claim 11 or 12, wherein each outside edge of the first member includes an engaging channel extending therealong, the channels adapted to snap-engagingly receive other building components therein.

14. The component as claimed in claim 13, wherein the flanges extend from the convex side of the channels.

15. A longitudinal building frame component assembly, the assembly including: a first building frame component having: a longitudinal first member with an engagement formation; a pair of longitudinal second members extending from one side of the first member, the second members adapted for connection to other building components; and a second building frame component having: a longitudinal first member with a corresponding engagement formation; a pair of longitudinal second members extending from one side of the first member, the second members adapted for connection to other building components, wherein the engagement formations of the first and second building frame components are adapted for longitudinal sliding engagement to permit the overall length of the building frame component assembly to be adjusted.

16. The assembly as claimed in claim 15, wherein the first member, the second members and the engagement formation are formed integrally in each of the respective first and second building frame components.

17. The assembly as claimed in claim 15 and 16, wherein the building frame components are each formed by extruding.

18. The assembly as claimed in claims 15, 16 or 17, wherein the building frame components are formed from aluminium.

19. The assembly as claimed in any one of claims 15 to 18, wherein the second members are parallel to each other and normal to their respective first member.

20. The assembly as claimed in any one of claims 15 to 19, wherein the second members each include a barbed rail along their distal edge.

21. The assembly as claimed in any one of claims 15 to 20, wherein one of the second members is adjacent an end of their respective first member.

22. The assembly as claimed in any one of claims 21, wherein the other of the second members is substantially adjacent the middle of their respective first member.

23. The assembly as claimed in claims 15 to 22, wherein the engagement formation is a pair of outwardly facing recesses provided along each outside edge of the first member of the first building component.

24. The assembly as claimed in claim 23, wherein the corresponding engagement formation is a pair of inwardly facing flanges provided adjacent each outside edge of the first member of the second building component.

25. The assembly as claimed in claims 15 to 22, wherein the engagement formation is a pair of inwardly facing flanges provided adjacent each outside edge of the first member of the first building component.

26. The assembly as claimed in claim 25, wherein the corresponding engagement formation is a pair of outwardly facing recesses provided along provided adjacent each outside edge of the first member of the second building component.

27. The assembly as claimed in claims 23 and 26, wherein each outside edge of the first member of the first building component includes an engaging channel extending therealong, the channels adapted to snap-engagingly receive other building components therein.

28. The assembly as claimed in claim 27, wherein the flanges extend from the convex side of the channels.

29. A corner building frame component assembly, the assembly including: a longitudinal first member having a face portion adapted for connection to other building components and an engagement formation; and a longitudinal second member having a face portion adapted for connection to other building components and an engagement formation, wherein the engagement formations of the first and second members are adapted for angular pivoting engagement to permit the angle between the face portions of the first and second members to be adjusted.

30. The assembly as claimed in claim 29, wherein the first and second members preferably each include at least one arcuate guiding portion adapted to abut and travel over one another during angular adjustment of the first and second members.

31. The assembly as claimed in claim 29 or 30, wherein the first and second members each include an internally facing and an externally facing arcuate guiding portions, each external portion of one of the first or second member adapted to abut and travel over each internal portion of the other of the first or second member during angular adjustment of the first and second members.

32. The assembly as claimed in claim 29, 30 and or 31, wherein the engagement formation of the first member is a curved flange having an enlarged head portion.

33. The assembly as claimed in claim 32, wherein the engagement formation of the second member is a recessed channel having a opening larger than the flange and smaller than the head portion.

34. The assembly as claimed in claim 33, wherein the channel is quadrant shaped in cross section and adapted to allow the head portion to pivot therein.

35. The assembly as claimed in any one of claims 29 to 34, wherein the first and second components are adapted to pivot relative to each other by approximately 90 degrees.

36. The assembly as claimed in any one of claims 29 to 33, wherein the first and second components are adapted to pivot relative to each other between a first position in which the face portions are substantially parallel to one another and a second position in which the face portions are substantially normal to one another.

37. A window frame component, the component including: a first longitudinal planar member; a second longitudinal planar member extending from the first planar member and adapted for fixing to a building frame component; a longitudinal channel member extending from the first planar member and adapted to receive a window panel edge therein; and a longitudinal box member extending from the first planar member and adapted to engage with a window sash assembly, wherein the first planar member, second planar member, channel member and box member are formed integrally in the component.

38. The component as claimed in claim 37, wherein the component is formed by extruding.

39. The component as claimed in claim 38, wherein the component is formed from aluminium.

40. A window transom component, the component including: a first longitudinal planar member; a second longitudinal planar member extending from the first planar member and adapted for fixing to another window assembly; a longitudinal channel member extending from the first planar member and adapted to receive a window panel edge therein; and a longitudinal box member extending from the first planar member and adapted to engage with a window sash assembly, wherein the first planar member, second planar member, channel member and box member are formed integrally in the component.

41. The component as claimed in claim 40, wherein the component is formed by extruding.

42. The component as claimed in claim 41, wherein the component is formed from aluminium.