AU2016222313B2

AU2016222313B2 - Furring channel

Info

Publication number: AU2016222313B2
Application number: AU2016222313A
Authority: AU
Inventors: Brenton Craig Brewer; Michael Charles Dunlop
Original assignee: Nashco Holdings Nsw Pty Ltd
Current assignee: Nashco Holdings Nsw Pty Ltd
Priority date: 2015-08-28
Filing date: 2016-08-29
Publication date: 2022-06-02
Anticipated expiration: 2036-08-29
Also published as: AU2016222313A1

Abstract

A furring channel having a base wall and two opposed side walls extending from the base wall, wherein first and second opposite end portions of the channel are differently configured such that two such channels can be connected to provide a channel assembly of extended length by engagement of the second end portion of a first channel into the first end portion of a second channel. 8/8 74' 82' 68' 80' 70' D 64' 68 74 82 70 80 64 68 FIG 20 68 64' 74 74' 80 80' 64 72 FIG 21 68' 72 70 80, 780' FIG 22

Description

8/8

74' 82'

68'

80' 70' D 64' 68 74 82

80 70

64 68 FIG 20 68 64'

74 74'

80 80' 64 72 FIG 21

68' 72

70

80, 780' FIG 22

FURRING CHANNEL

[0001] Embodiments of the invention relate to a furring channel and a method of manufacturing thereof.

[0002] Furring channels (also known as battens in residential ceiling applications) can be used to mount plasterboard to form interior walls or ceilings in buildings. Furring channels come in a variety of standard lengths. However, the furring channels rarely fit the specific dimensions of the wall or ceiling and therefore more than one furring channel may be required to span the wall or ceiling. In such a case, the furring channels may be mounted such that they are staggered, however this provides a weaker support for the plasterboard than if continuous furring channels are used. Alternatively, a joiner can be used which clamps the ends of adjoining channels together, however the use of joiners adds to the cost and complexity of the process.

[0003] Examples of the invention seek to avoid or at least ameliorate problems of existing battens and furring channels.

[0004] According to a first aspect of the present invention, there is provided a furring channel having a base wall, two opposed side walls extending from the base wall, and a pair of opposed flanges extending substantially along the length of the channel, wherein first and second opposite end portions of the channel are differently configured such that two such channels can be connected to provide a channel assembly of extended length by engagement of the second end portion of a first channel into the first end portion of a second channel, wherein at one of the end portions each of the flanges form a cavity, the open ends of the cavities facing in a direction towards the base wall, and at the other one of the end portions each of the flanges includes a modified flange portion adapted to engage with the cavities, such that the second end portion of the first channel can firmly engage into the first end portion of the second channel thereby joining the channels and extending the length of the first channel.

[0005] The flanges can be inwardly directed flanges, the second end portion of the first channel being of reduced size in relation to the first end portion and having walls and modified flange portions adapted to interact with the flanges at the first end portion, such that said second end portion can firmly engage into the first end portion of the second channel therebyjoining the channels and extending the length of the first channel.

[0006] Each of the flanges can be directed inwardly at an angle to the walls thereby forming the cavities at the first end portion. For each of the modified flange portions of the second end portion of the first channel, the flange can lie parallel to and adjacent to the walls.

[0007] The walls of the second end portion of the first channel can taper in height towards the outer end of the first channel so as to facilitate insertion of the second end portion into a first end portion of the second channel.

[0008] The flanges can be outwardly directed flanges, the second end portion of the first channel being of enlarged size in relation to said first end portion and having walls and modified flange portions adapted to interact with the flanges at the first end portion, such that the second end portion of the first channel can firmly engage into the first end portion of the second channel thereby joining the channels and extending the length of the first channel.

[0009] Each of the flanges can include an edge portion extending from an outwardly directed portion of the flange, the edge portion directed inwardly at an angle to the walls thereby forming the cavities at the first end portion. For each of the modified flange portions of the second end portion of the first channel, the edge portion can lie parallel to the outwardly directed portion of the flange.

[0010] The modified flange portions at the second end portion of the first channel can be of reduced size in relation to the outwardly directed portions of the flanges at the first end portion of the first channel so as to facilitate insertion of said second end portion of the first channel into the first end portion of the second channel.

Paragraph [0011] has been intentionally deleted.

- 2A

[0012] According to an embodiment, the second end portion of the first channel is insertable into the first end portion of the second channel along a longitudinal axis of the channels.

[0013] According to an embodiment, the second end portion of the first channel is insertable into the first end portion of the second channel transverse to a longitudinal axis of the channels.

[0014] Preferably, the walls of the first end portion are resiliently spreadable from each other to facilitate insertion of the second end portion into the first end portion thereby providing a snap-fit locking arrangement.

[0015] Preferably, the walls of the second end portion are resiliently compressible towards each other to facilitate insertion of the second end portion into the first end portion thereby providing a snap-fit locking arrangement.

[0016] Therefore, the embodiments of the present invention allow one channel to be joined to another like channel in a simple and easy manner so as to fonn a channel assembly that is of extended length. The applicant has found that the connection of these two channels is stronger and more robust than prior art methods of joining or extending furring channels. Further, forming a strong join of two channels without use of a separate joiner reduces waste and provides a more cost-effective and efficient process of mounting ceilings and walls.

[0017] In order that the present invention can be more readily understood, preferred embodiments thereof will now be described, by way of non-limiting example only, with reference to the accompanying drawings, in which:

[0018] Figure 1 shows a top perspective view of a furring channel according to a first embodiment of the present invention;

[0019] Figure 2 shows a bottom perspective view of the furring channel of Figure 1;

[0020] Figure 3 shows a side view of the furring channel of Figure 1;

[0021] Figure 4 shows a top perspective view of a furring channel assembly of extended length formed by the connection of two furring channels of Figure 1;

[0022] Figure 5 shows a bottom perspective view of a furring channel assembly of Figure 4;

[0023] Figure 6 shows a side view of the furring channel assembly of Figure 4;

[0024] Figure 7 shows a bottom perspective view of a furring channel according to a second embodiment of the present invention;

[0025] Figure 8 shows a top perspective view of the furring channel of Figure 7;

[0026] Figure 9 shows a side view of the furring channel of Figure 7;

[0027] Figure 10 shows a bottom perspective view of a furring channel assembly of extended length formed by the connection of two furring channels of Figure 7;

[0028] Figure 11 shows a top perspective view of a furring channel assembly of Figure 10;

[0029] Figure 12 shows a side view of the furring channel assembly of Figure 10;

[0030] Figures 13 and 14 are top and bottom perspective views of a furring channel according to a third embodiment of the present invention;

[0031] Figures 15 and 16 shows the formation of a furring channel assembly of extended length by the connection of two furring channels of Figures 13 and 14;

[0032] Figure 17 is a cross-section of the join of the furring channel assembly of Figure 16;

[0033] Figures 18 and 19 are top and bottom perspective views of a furring channel according to a fourth embodiment of the present invention;

[0034] Figures 20 and 21 shows the formation of a furring channel assembly of extended length by the connection of two furring channels of Figures 18 and 19; and

[0035] Figure 22 is a cross-section of the join of the furring channel assembly of Figure 21.

[0036] Figures 1to 3, 7 to 9, 13, 14, 18 and 19 are views of furring channels 2, 24, 44, 64 according to preferred embodiments of the present invention, which have opposed ends 4, 6, 26, 28, 46, 48, 68, 70 each of which is configured differently so that two like channels 2, 24, 44, 64 can be joined to form a channel assembly 8, 30, 50, 72 of extended length, as shown in Figures 3 to 6, 10 to 12, 15 to 17, 20 to 22.

[0037] According to first and third embodiments of the present invention of Figures 1 to 3, 13 and 14, the furring channel 2, 44 comprises a pair of spaced apart walls 10, 16, 52, 58 having a base 12, 18, 54, 60 therebetween. The walls 10, 52 of a first end portion 4, 46 of the furring channel 2, 44 have inwardly directed flanges 14, 56. A second end portion 6, 48 of the furring channel 2, 44 has a reduced cross-sectional profile, such that the walls 16, 58 and base 18, 60 are of a reduced size in relation to the walls 10, 52 and base 12, 54 of the first end portion 4, 46. The walls 16, 58 of the second end portion 6, 48 also have inwardly directed flanges 20, 62. The inwardly directed flanges 20 of the second end portion 6 in the first embodiment lie parallel to and adjacent to the walls 16. In comparison, in the third embodiment, the second end portion 48 is in the shape of a semi cylinder, the walls 52 being formed by the edges of that semi-cylinder.

[0038] The length of the second end portion 6, 48 of the channel 2, 44 can range between 45 to 60 mm.

[0039] As shown in the embodiments of Figures 4 to 6, 15 to 17, the second end portion 6, 48 is arranged such that the edges of the walls 16, 58 are adapted to interact with the flanges 14', 56' of the first end portion 4', 46' of a like channel 2', 44'. In the embodiment shown in Figures 4 to 6, the second end portion 6 of the channel 2 can be inserted into a first end portion 4' of the like channel 2' by moving the second end portion 6 in a direction along a longitudinal axis of the channels 2, 2' (indicated by arrow A) to frictionally lock the channels 2, 2' together to form the channel assembly 8, thereby extending the length of the channel 2 (note that the second end portion of the channel 2' is not shown).

[0040] In comparison, in the embodiment shown in Figures 15 to 17, the second end portion 48 of the channel 44 can be inserted into a first end portion 46' of the like channel 44' by moving the second end portion 48 in a direction transverse to the longitudinal axis of the channels 44, 44' (indicated by arrow C) to lock the channels 44, 44' together in a snap-fit arrangement to form the channel assembly 50, thereby extending the length of the channel 44. To facilitate this snap-fit arrangement, the walls 52' are resiliently spreadable apart from each other thereby allowing insertion of the second end portion 48 into the first end portion 46'. Alternatively, the walls 58 can be resiliently compressible towards each other thereby allowing insertion of the second end portion 48 into the first end portion 46'. It is also envisaged that the walls 46' and 58 can both be resiliently spreadable or compressible so as to facilitate the insertion of the second end portion 48 into the first end portion 46'.

[0041] Specifically, the flanges 14', 56' of the first end portion 4', 46' of the second channel 2', 44' are directed substantially inwardly, for example, at a 450 angle to the walls ', 52 thereby forming cavities, open ends of which face the base 12', 54'. The cavities are adapted to engage with edge portions of the walls 16, 58 of the second end portion 6, 48 of a first channel 2, 44 so that the two channels 2, 2', 44, 44' can be connected with a tight frictional or snap-fit locking arrangement thereby forming a channel assembly 8, 50. While the flanges 14', 56' are shown to be directed inwardly at a 450 angle, it will be understood by a person skilled in the art that the flanges 14', 56' can be directed inwardly at a range of angles (even 900) so as to be able to interact with the wall edges 16, 58 of the second end portion 6, 48 of the channel 2, 44 when the two channels 2, 2' or 44, 44' are joined together.

[0042] A section 22 of the walls 16 of the second end portion 6 of the channel 2 tapers in height towards the outer end of the channel 2 which facilitates easy insertion of the second end portion 6 into a first end portion 4' of the second channel 2'.

[0043] According to second and fourth embodiments of the present invention shown in Figures 7 to 9, 18 and 19, there is shown a furring channel 24, 64 which comprises a pair of spaced apart walls 32, 38, 74, 82 having a base 34, 40, 76, 84 therebetween. The walls 32, 74 of a first end portion 26, 68 of the furring channel 24, 64 have a pair of outwardly directed flanges 36, 80 and has a enlarged cross-sectional profile, such that the walls 32, 74 and base 34, 76 are of an enlarged size in relation to the walls 38, 82 and base , 84 of a second end portion 28, 70. The walls 38 of the second end portion 28 of the second embodiment also have outwardly directed flanges 42, which, for example, can extend substantially perpendicular to the walls 38. The length of the second end portion 28, 70 of the channel 24, 64 can also range between 45 to 60 mm.

[0044] As shown in Figures 10 to 12, the second end portion 28 is arranged such that the edges of the walls 38 are adapted to interact with the flanges 36' of the first end portion 26' of a like channel 24'. In this way, the second end portion 28 of the channel 24 can be inserted into a first end portion 26' of the channel 24' and can frictionally lock the channels 24, 24' together to form the channel assembly 30, thereby extending the length of the channel 24 (note that the first end portion of the channel 24' is not shown). In particular, the second end portion 28 is inserted into the first end portion 26' by moving the second end portion 28 along a longitudinal axis of the channels 24, 24', indicated by arrow B.

[0045] Specifically, the flanges 36' of the first end portion 26' of the channel 24' are directed substantially outwardly, for example, perpendicular to the walls 32'. Edge portions of the flanges 36' are directed towards the walls 32' thereby forming cavities, open ends of which face in the direction towards the base 34'. The cavities are adapted to engage with edge portions, for example flanges 42, of the walls 38 of the second end portion 28 of the channel 24 so that the two channels 24, 24' can be connected with a tight fit thereby forming a channel assembly 30. While the flanges 36' are shown to be directed outwardly substantially perpendicular to the walls 32', it will be understood by a person skilled in the art that the flanges 36' can be directed outwardly at a range of angles (even 900) so as to be able to interact with the wall edges 42 of the second end portion 28 of the channel 24 when the two channels 24, 24' are joined together.

[0046] The edge portions of walls 38 of the second end portion 28 can also have flanges 42, which can be adapted to engage with the cavities formed by the flanges 36'.

[0047] With regard to Figures 20 to 22, the second end portion 70 of the channel 64 can be inserted into a first end portion 68' of a like channel 64' in a direction transverse to a longitudinal axis of the channels 64, 64' (indicated by arrow D) such that the second end portion 70, fits within the first end portion 68' in a snap-fit locking arrangement such that channels 64, 64' join together to form the channel assembly 72, thereby extending the length of the channel 64 (note that the first end portion of the channel 64' is not shown). To facilitate this snap-fit arrangement, the walls 74' can be resiliently spreadable apart from each other thereby allowing insertion of the second end portion 70 into the first end portion 68'. Alternatively, the walls 82 can be resiliently compressible towards each other thereby allowing insertion of the second end portion 70 into the first end portion 68'. It is also envisaged that the walls 74' and 82 can both be resiliently spreadable or compressible so as to facilitate the insertion of the second end portion 70 into the first end portion 68.

[0048] In an example of the use of the invention, the furring channels 2, 24, 44, 64 are typically sold in standard lengths and thus may not be of sufficient length to span a dimension of a ceiling or wall of a room. In such a case, the second channel 2', 24', 44', 64' can be joined to the first channel 2, 24, 44, 64 as described above to form a channel assembly 8, 30, 50, 72 that is of extended length which can span the specific dimension of the ceiling or wall. The applicant has found that such a channel assembly 8, 30, 50, 72 has a join that is stroger than using separate joiners or by staggering the channels. Therefore the arrangement as described in the embodiments above makes the process of joining channels and subsequently the suspension of a ceiling or wall easier.

[0049] Advantageously, the embodiments described in Figures 13 to 22 allows for the channels 44, 44', 64, 64' to be joined in situ to form a channel assembly 50, 72 which is substantially the length or width of the ceiling or wall space. In an example use of the furring channels 44, 64, the combined length of the first end portions 46, 68 of the furring channels 44, 64 to be joined can be chosen to substantially conform to the specific dimension of the ceiling or wall. Next, the two or more separate like furring channels 44 or 64 can be positioned on the wall or ceiling and then the furring channels 44 or 64 can be joined by applying force to the second end portions 48 or 70 in a direction transverse to the longitudinal axis of the channels 44 or 64 such that the second end portions 48 or 70 engage with respective first end portions 46, 68, thereby easily forming a channel assembly or 72 which conforms to the specific dimension of the ceiling or wall.

[0050] Further modifications and improvements can be made without departing from the scope of the present invention. In particular, furring channels can be provided in a range of standard lengths from 2700 to 6000 mm, although it can be understood by a person skilled in the art that a furring channel can be provided in any length or having such dimensions so as to function as described above. Further, although furring channels have been referenced in the specification, they can also be understood to refer to ceiling battens, which function in the same way as the furring channels although battens are understood to be applied for mounting suspended ceilings in residential applications.

[0051] While various embodiments of the present invention have been described above, it should be understood that they have been presented by way of example only, and not by way of limitation. It would be apparent to a person skilled in the relevant art that various changes, modifications and improvements can be made therein without departing from the spirit and the scope of the invention. Thus, the present invention should not be limited by any of the above-described exemplary embodiments.

[0052] Throughout this specification and the claims which follow, unless the context requires otherwise, the word "comprise", and variations such as "comprises" and "comprising", will be understood to imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any other integer or step or group of integers or steps.

[0053] The reference in this specification to any prior publication (or information derived from it), or to any matter which is known, is not, and should not be taken as an acknowledgment or admission or any form of suggestion that that prior publication (or information derived from it) or known matter forms part of the common general knowledge in the field of endeavour to which this specification relates.

Claims

THE CLAIMS DEFINING THE INVENTION ARE AS FOLLOWS:

1. A furring channel having a base wall, two opposed side walls extending from the base wall, and a pair of opposed flanges extending substantially along the length of the channel, wherein first and second opposite end portions of the channel are differently configured such that two such channels can be connected to provide a channel assembly of extended length by engagement of the second end portion of a first channel into the first end portion of a second channel, wherein at one of the end portions each of the flanges form a cavity, the open ends of the cavities facing in a direction towards the base wall, and at the other one of the end portions each of the flanges includes a modified flange portion adapted to engage with the cavities, such that the second end portion of the first channel can firmly engage into the first end portion of the second channel thereby joining the channels and extending the length of the first channel.

2. A furring channel according to claim 1, wherein the flanges are inwardly directed flanges, the second end portion of the first channel being of reduced size in relation to the first end portion and having walls and modified flange portions adapted to interact with the flanges at the first end portion, such that said second end portion can firmly engage into the first end portion of the second channel thereby joining the channels and extending the length of the first channel.

3. A furring channel according to claim 2, wherein each of the flanges are directed inwardly at an angle to the walls thereby forming the cavities at the first end portion.

4. A furring channel according to claim 3, wherein, for each of the modified flange portions of the second end portion of the first channel, the flange lies parallel to and adjacent to the walls.

5. A furring channel according to any one of claims 2 to 4, wherein the walls of the second end portion of the first channel taper in height towards the outer end of the first channel so as to facilitate insertion of said second end portion into the first end portion of the second channel.

6. A furring channel according to claim 1, wherein the flanges are outwardly directed flanges, the second end portion of the first channel being of enlarged size in relation to said first end portion and having walls and modified flange portions adapted to interact with the flanges at the first end portion, such that the second end portion of the first channel can firmly engage into the first end portion of the second channel thereby joining the channels and extending the length of the first channel.

7. A furring channel according to claim 6, wherein each of the flanges includes an edge portion extending from an outwardly directed portion of the flange, the edge portion directed inwardly at an angle to the walls thereby forming the cavities at the first end portion.

8. A furring channel according to claim 7, wherein, for each of the modified flange portions of the second end portion of the first channel, the edge portion lies parallel to the outwardly directed portion of the flange.

9. A furring channel according to claim 8, wherein the modified flange portions at the second end portion of the first channel are of reduced size in relation to the outwardly directed portions of the flanges at the first end portion of the second channel so as to facilitate insertion of said second end portion of the first channel into the first end portion of the second channel.

10. A furring channel according to any one of the preceding claims, wherein the second end portion of the first channel is insertable into the first end portion of the second channel along a longitudinal axis of the channels.

11. A furring channel according to any one of the preceding claims, wherein the second end portion of the first channel is insertable into the first end portion of the second channel transverse to a longitudinal axis of the channels.

12. A furring channel according to claim 11, wherein the walls of the first end portion are resiliently spreadable from each other to facilitate insertion of the second end portion into the first end portion thereby providing a snap-fit locking arrangement.

13. A furring channel according to claim 11 or claim 12, wherein the walls of the second end portion are resiliently compressible towards each other to facilitate insertion of the second end portion into the first end portion thereby providing a snap-fit locking arrangement.