Note: Descriptions are shown in the official language in which they were submitted.
CA 02293091 1999-12-23
FRAME SYSTEM FOR BUILDINGS
FIELD OF THE INVENTION
This invention relates to frame system for buildings and more
particularly to a kit of parts having couplings on respective ends of studs of
the kit for
mounting the studs into a frame structure without requiring additional
fasteners.
BACKGROUND
It is common practice in the construction of commercial buildings to
make use of metal studs formed from sheet metal for framing interior walls of
the
building. These metal studs are received at respective top and bottom ends
into
respective header and footer channels also formed from sheet metal. In order
to
assemble a frame structure having a header and footer with a plurality of
spaced
apart studs extending therebetween, the studs must be cut to length and
secured
within the header and footer channels using screws or some other similar
fasteners.
The task of cutting and mounting the studs is time consuming and generates a
significant amount of waste in the form of cut ends which require further
disposal.
The use of screws which are required to secure the studs in place is
particularly time
consuming and desirably avoided.
SUMMARY
According to the present invention there is provided a kit of parts for use
in assembling a frame structure, the kit of parts comprising:
a plurality of studs, each stud having a lower portion and an upper
portion coupled to the lower portion for longitudinal sliding movement
relative to the
lower portion such that a length between respective top and bottom ends of
each stud
is adjustable;
a stud coupling at each end of each stud;
a header;
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a plurality of header couplings longitudinally spaced along the header,
each header coupling being arranged to secure a respective stud coupling at a
top
end of a corresponding stud thereon;
a footer; and
a plurality of footer couplings longitudinally spaced along the footer,
each footer coupling being arranged to secure a respective stud coupling at a
bottom
end of a corresponding stud thereon.
Using the kit of parts of the present invention, the studs are assembled
in a substantially vertical and parallel arrangement and coupled at top and
bottom
ends on the respective header and footer to form a frame structure generally
for use
as a wall of a building. Using stud couplings formed at each end of the studs
as well
as the respective mating header and footer couplings, the studs can be mounted
to
the header and footer without requiring any additional fasteners. The header
and
footer couplings are located along the respective header and footer at a
selected
spacing therebetween such that measuring and marking the stud spacing is not
required. This further simplifies the task of assembling a frame for saving
time and
labour cost during construction. The studs are also adjustable in length such
that
each stud can accommodate various required heights without wasted cut ends.
The
adjustable stud length also permits the stud couplings to be formed when the
studs
are manufactured for further saving time during construction of the building
and
assembly of the frame system.
Each stud coupling may comprise a pair of tongues extending from
respective front and back sides of the corresponding stud and the header and
footer
couplings each comprise a corresponding pair of receiving slots arranged to
receive
the respective tongues therein.
The tongues preferably extend longitudinally outward from the
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respective ends of the studs.
There may be provided at least one catch on each tongue, the catch
being arranged to engage the corresponding slot when assembled such that
removal
of the tongue from the corresponding slot is restricted. Preferably there is
provided
four catches on each tongue, the catches being arranged to engage the
corresponding slot at four spaced apart locations thereon.
Each catch may comprise a raised protrusion, the protrusion being
flexible, permitting minimal deflection of the protrusion as the corresponding
tongue is
inserted into the respective slot while restricting the removal of the tongue
from the
corresponding slot once the tongue has been inserted therein.
Each receiving slot may comprise an outer slot in a side flange of the
respective header and footer adjacent a base of the respective header and
footer and
an inner slot in the side flange spaced from the base such that the inner slot
is
arranged to receive a base of the corresponding tongue therethrough and the
outer
slot is arranged to receive a free end of the corresponding tongue
therethrough in an
assembled position.
There may be provided an outer catch and an inner catch spaced
longitudinally inward therefrom on each tongue, the outer and inner catches
being
arranged to engage the outer and inner slots respectively for restricting both
inward
and outward deflection of the ends of the studs relative to the respective
header and
footer.
The outer and inner slots are preferably arranged to extend
perpendicularly to the respective tongues when assembled.
Each catch preferably comprises a pair of protrusions arranged to
engage the respective outer and inner slots at spaced locations thereon for
restricting
pivotal deflection of the studs relative to the respective header and footer
when
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assembled.
The respective upper and lower portions of the studs preferably each
comprise a metal channel wherein the upper portion is slidably received within
the
lower portion.
The header and footer couplings are preferably evenly spaced
longitudinally along the respective header and footer, a spacing between the
couplings corresponding to a spacing of the studs when assembled.
BRIEF DESCRIPTION OF THE DRAWINGS
In the accompanying drawings, which illustrate an exemplary
embodiment of the present invention:
Figure 1 is an isometric view of the frame system.
Figure 2 is a cross sectional view along the line 2-2 of Figure 1.
Figure 3 is a side elevational view along the line 3-3 of Figure 2.
Figure 4 is a cross sectional view along the line 4-4 of Figure 1.
DETAILED DESCRIPTION
Referring to the accompanying drawings, there is illustrated a frame
system generally indicated by reference numeral 10. The frame system 10 is a
kit of
parts generally of the type which is used for assembling wall structures in
building.
The system 10 includes a header 12 and a footer 14. The header and
footer are metal channels which are generally U-shaped, each having a base 16,
a
front side 18 and a back side 20. The header and footer are mounted in use to
extend substantially horizontally wherein the header is spaced above the
footer.
The system 10 further includes a plurality of studs 22 wherein each stud
includes a lower channel 24 and an upper channel 26. Each of the channels is a
generally U-shaped member having a base 28, a front side 30 and a back side
32.
The front and back side extend perpendicularly outward from the base 28 and
include
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laterally inwardly extending flanges 34 at respective free ends thereof. As
shown in
Figure 4, each channel has a substantially rectangular cross section wherein
the
upper channel 26 is smaller in cross section than the lower channel 24 so as
to be
slidably received therein. In this arrangement the overall length of each stud
between
a respective top end 36 and a respective bottom end 38 is adjustable. The
channels
24 and 26 are oriented with the respective base 28 of each channel being
mounted on
an opposite side of the stud to form a rectangular enclosure for an
overlapping portion
of the channels as shown in Figure 4.
The studs 22 are thus able to accommodate a variety of standard stud
lengths. For example, a stud may be arranged to extend from 6 to 10 feet or
from 8 to
12 feet while preserving at least a portion of the stud wherein the upper and
lower
channels are overlapping.
A stud coupling 40 is located at each respective top and bottom end 36
and 38 of each stud 22. Each stud coupling 40 comprises a pair of
longitudinally
outwardly extending tongues 42 formed in the respective front and back sides
of the
stud. Each tongue 42 includes a pair of outer notches 44 in opposite sides of
the
tongue adjacent a free end 46 thereof and a pair of inner notches 48 in
opposing
sides adjacent a base end 50 of the tongue. The outer and inner notches 44 and
48
define four inner corners 52 formed in the tongue which are bent laterally
outwardly
from the tongue as well as four outer corners 53 which are bent laterally
inwardly from
the tongue to form respective sets of outer and inner catches.
The stud couplings 40 are arranged to engage respective channel
couplings 54 mounted in the header and footer. Each channel coupling 54
comprises
a pair of receiving slots 56 on respective front and back sides of the
respective header
and footer. Each receiving slot 56 includes an outer slot 58 which extends
horizontally adjacent the base 16 of the corresponding channel and a
corresponding
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inner slot 60 extending horizontally spaced inwardly from the respective outer
slot 58.
Each receiving slot 56 is arranged to receive one of the tongues 42 therein
such that
the free end of the tongue extends through the outer slot while a base of the
tongue
extends through the inner slot. A strap 62 is defined between each outer and
inner
slot 58 and 60 for securing a corresponding tongue to the respective header
and
footer.
The channel couplings 54 are evenly spaced longitudinally along the
respective header and footer. A spacing between the channel couplings 54
corresponds to a standard stud spacing such as 16 or 24 inches such that the
studs
are properly spaced in a parallel and vertical orientation once the frame
system 10 is
assembled. The pre-formed channel couplings thus makes stud placement very
easy
requiring no layout time of measuring and marking of the stud placement.
In use the header 12 and footer 14 are first cut to length and prepared
for assembly into a wall structure. The stud couplings 40 at respective top
ends of a
plurality of respective studs 22 are inserted into the corresponding channel
couplings
54 in the header by securing the tongues into the respective receiving slots.
Subsequently the stud couplings 40 at a bottom end of each stud is secured to
the
corresponding channel couplings of the footer such that the studs extend
substantially
parallel and spaced apart between the header and footer. The studs 22 may then
be
erected into a wall structure and extended in a longitudinal direction such
that the
footer remains engaged on the floor while the header engages a ceiling of the
building. Subsequent securement of the header 12 and footer 14 results in a
completed frame for a wall structure which is ready to accept a wall covering
thereon.
The only fasteners required are those used to secure the header and footer in
place.
The studs are formed from sheet metal such that the catches 52, 53
have some limited resiliency. This permits the catches 52, 53 to deflect
inwardly to be
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flush with the respective tongues as the tongues are inserted into the
respective
receiving slots. Once the tongue has been inserted into the receiving slot the
respective upper and lower pairs of catches engage the respective inner and
outer
slots of each receiving slot for securing the tongue to a respective side of a
respective
header or footer at spaced locations thereon. By engaging the slots at four
spaced
apart locations, the studs are adequately secured to restrict any pivotal
deflections
relative to the respective header and footer. The resulting joint is much more
rigid
than conventional joints using a single screw or fastener that allows limited
twisting or
pivotal deflection between the stud and the respective header or footer.
Because the catches 52, 53 are formed of sheet metal having some
limited flexibility, the catches 52, 53 may be deflected to release the
tongues by
flexing the catches inwardly such that they are substantially flush with the
respective
tongues. Assembly and subsequent disassembly of the frame system is thus
accomplished as desired with little effort required.
In this arrangement, couplings are used to secure the studs to the
respective header and footer without requiring any additional fasteners such
as
screws. This represents a significant savings in time and labour costs. The
adjustable length of the studs allows the coupling to be pre-formed when the
studs
and header and footer are manufactured as there is no cutting of the stud
length
required. This represents a further savings of time and labour costs during
building
construction.
The stud couplings are arranged such that the studs may also be
screwed in place to the respective header or footer when forming a window or
door or
the last stud in a wall placement which does not correspond to a location of a
respective channel coupling. The remaining stud placement is quickly and
easily
assembled as little or no screws are required and no additional layout time is
required
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for measuring and marking the stud placement.
The frame system 10 is also advantageous in regards to worker safety
as there is significantly less cutting and tooling involved in assembling a
frame
structure. The reduction of noise in the working environment which would
otherwise
result from chop saws and drills results in a further benefit to worker
safety.
While one embodiment of the present invention has been described in
the foregoing, it is to be understood that other embodiments are possible
within the
scope of the invention. The invention is to be considered limited solely by
the scope
of the appended claims.
