WO2021083890A1

WO2021083890A1 - Wall frame assembly

Info

Publication number: WO2021083890A1
Application number: PCT/EP2020/080169
Authority: WO
Inventors: Mauro Sica
Original assignee: Pre Framing Corp
Priority date: 2019-10-28
Filing date: 2020-10-27
Publication date: 2021-05-06

Abstract

A structural frame for a wall in buildings comprises a plurality of studs having opposite end portions connected together by flexible spacers, two track elements adapted to receive said end portions of the studs, a plurality of tabs or locking portions formed at least on said walls of the track elements to lock into a position the studs; the distance between two adjacent studs is controlled by said spacers and is such that the studs are located at the required locking position when the spacers are extended and the studs spaced at the maximum distance.

Description

WALL FRAME ASSEMBLY

FIELD OF THE INVENTION

The present invention relates to a frame for a wall in buildings and to a method of producing and assembling said frame. In particular, the invention relates to an at least partially pre-assembled frame comprised of structural components of a wall frame, in metal or other similar material, in particular for the construction of interior and exterior walls of a building.

The frame is assembled at the construction site starting from studs that are initially packed together in a bundle; the bundle is deployed to provide studs positioned as required in the final design of the wall frame and are attached to connecting top and bottom elements that extend the length of the wall. The faces of the wall are then completed with panels in a known way.

With the wording walls it is intended to comprise any structure that is suitable to be obtained from the frame, including e.g. interior and exterior walls, floors, ceilings, roof trusses and roofs of buildings.

BACKGROUND

The typical platform framing technique, which is also the most common light framing construction technique (in USA, Canada, Australia, UK) requires the interpretation of blueprints, often designed using a CAD software, and the selection, measurement, marking, cut and assembly of many components, (as studs) that need to be spaced at specific distances. All the work is made on the construction site where weather may impede construction.

This phase requires the presence on site of highly qualified personnel, it is the most complex and it is subject to errors caused by incorrect interpretation of the drawings or by human error in the marking process or cutting of the components. Moreover, after having correctly positioned the various components to the ground, components as studs typically are repositioned elsewhere for cutting and then placed back in position, an operation which requires additional time. EP3004482 discloses a pre-distancing collapsible system particularly for the elements of a structural frame of a building. An embodiment of the invention comprises at least three studs providing the vertical components of the structural frame and at least two spacers, fastened to the heads of the studs, i.e. to the bottom and the top of the studs. The spacers are not a part of the structural frame; the lengths of spacers between two adjacent studs correspond to the distance between said studs in the final frame design. The studs are initially packed together in a bundle that is deployed at the construction site to be assembled into a final wall frame with a least top and bottom connecting elements. An exemplary material for EP30044482 is wood.

A problem with wall frames is to provide fire resistance and continued structural strength in case of a fire. Metal frames for walls are known in the art and may be suitable to this purpose. As an example, a metal frame is comprised of a framing member comprising two parallel tracks combined with interlocking adjustable stud components that are individually positioned in the tracks. The adjustable studs allow for telescopic length adjustments for positioning in different frames; they are provided with swaged end formation, suitable to fit with a swaged forming of the two tracks, providing interlock with no need for screws, so that each individual stud is twisted and locked in a predetermined position along the framing member.

The above disclosed metal frames have the problem that they should be rigid enough to provide a secure lock in the requested position without screws. To be rigid enough, the studs and the tracks are relatively thick, which results in increasing difficulty when fixing, usually by screws or similar fasteners, the panels (e.g. dry wall panels) forming the faces of the final wall to the studs.

A further problem of the known metal walls is still to correctly positioning the individual studs.

SUMMARY OF THE INVENTION

The above problems are solved by means of the present invention that provides a wall frame according to claim 1 and a wall according to claim 10. The invention also provides a method of producing a structural frame of a wall according to claim 7 and a method of preparing a wall according to claim 9.

Dependent claims refer to preferred embodiments.

BRIEF DESCRIPTION OF THE DRAWINGS Fig 1 shows a standard metal track and stud system ; Fig 2a illustrates two metal studs connected by at least two straps secured to the edges of the stud web in almost completely “closed” or “collapsed” initial position, forming part of a bundle of studs;

Fig 2b illustrates the same two metal studs connected by at least two straps secured to the edges of the stud web in intermediate position, during assembly of the wall frame; Fig 2c illustrates the same two metal studs in completely “open” or “pulled out” position;

Fig 3 a shows an exploded view of the components of one of the features of the invention;

Fig 3b shows the same components of Fig 3a, with the stud already inserted in the top and bottom tracks;

Fig 3c is a top view from under the top track of the partially assembly of fig. 3b;

Figures 3d, 3e and 3f are schematic views of the locking steps of the end ortion of the stub in the bottom track;

Figures 4a and 4b are schematic views of another embodiment of locking tabs; Fig 5a shows an example of a metal stud wall with a door opening showing studs in a bundled condition;

Fig. 5b is a view of the wall assembly of Fig 5a where the studs have been deployed and spaced into their final positions;

Figures 5c-5e are enlarged views of details of the wall frame assembly; Fig. 5f is a view of the wall assembly of Fig. 5b at a later assemblage stage;

Fig 5g is a partial view of the top part of the wall assembly of Fig 5f in a final condition;

Fig. 5h is a partial view of the bottom part of the wall assembly of Fig 5g;

Fig 5i is a top view of the bottom track of the wall frame of Fig 5h. DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION With reference to fig. 2a to 2c, in the shown embodiment two straps 7 at the top edge and two equivalent straps at the bottom edge are secured to the edges, or end portions, of the studs 10. The straps are folded around the edges in a U shape fashion, each along the three fold lines 3 and 4. The straps are further secured in position, thru spot welding or rivets 5 or any other suitable securing means.

The length of the strap portion between the fold lines 4 will determine the final distance of the studs once the wall is “opened” or deployed or “pulled out” accordion style and the studs fully separated by the builder, as illustrated in Fig 2b and 2c.

Reference to above mentioned EP3004482 (here enclosed by reference) is here made concerning the basic concept of the bundle of studs. According to an embodiment of the invention, the wall frame assembly may be provided without spacers: In this embodiment, the studs are prepared and packaged in a bundle in the correct sequence, but without spacers, so that the operator can take one stud at a time from the bundle and position it on the tracks in the required sequence at the locking positions defined by the tabs that are disclosed here below.

Fig 3 a shows an exploded view of the components of one of the features of the invention, a quick snapping system to secure the vertical components of the wall framing system, called studs, to horizontal components, commonly called tracks (or runners, U-channels, channels). The common studs are unchanged, while the track flanges are punched (or cut) preferably when manufacturing the track, and then pushed inward, mechanically or manually, leaving an opening on the lateral walls (or flange) of the stud.

The purpose of the tabs is to eliminate the need to measuring, marking, positioning each stud in the track and then screw studs and tracks together, all those steps combined being time consuming and subject to human error.

The position of the tabs along the tracks are preferable taken by a computer software able to generate the shop drawing of the wall framing with the positioning of each stud, special stud, kind and jack studs for the openings, etc.. A mechanical machinery can then receive the instructions and laser cut, plasma cut, mechanically cut or simply punch the tabs with the proper offset.

In alternative the tracks can be provided with regular longitudinal intervals, such as 16” or 24”.

The tracks can be cut or punched either before mechanically cold forming the stud itself, as traditionally is done during the fabrication, or after the stud is fully formed.

Fig 3b shows the same components of Fig 3a, with the stud already inserted in the top and bottom track and ready to be pushed toward the tabs to be locked in place.

Fig 3c also shows the same components of Fig 3a, with the stud already inserted in the top and bottom track and ready to be pushed toward the tabs to be locked in place, showing in detail the innovative shape of the tabs 48, able to lock in place the stud once snapped on it. Each tab 48 has a pointy end part 48b (or 48c) with a notch 48a able to receive and lock a portion of the edge of the stud lip 12. The pointy end part 48b is slightly tapered to easily receive the stud lip 12 when pushed in. The tab is folded inward at approximately 45 degrees. Changing this angle the track will be able to accommodate studs with different lip 12 sizes. The tab is inheritably flexible and will fold further, compared to the resting position, by a few degrees, once the stud is pushed into it, contacting first the pointy ends 48b and 48c and sliding till the notch 48a, as shown in Fig 3d and Fig 3e. At this point the tab will fold back a few degrees locking all lips 12 in place. The studs, once locked will not be able to move longitudinaly in the track in any direction.

The tabs 48 also serves the purpose to avoid that, during the drywall installation, the flexible end part of the flange of the stud folds, while receiving the screw, making more difficult to install the drywall. This is why usually a thicker metal gauge is chosen by the builders, to avoid this unwanted flexibility which slows down the drywall installation. The thicker steel, at the same time is more difficult to penetrate, also slowing down operations. The invention can be key to reduce both material cost, off-site manufacturing and installation time.

Additional tapered tabs 49 are optionally punched, including holes 50 in the middle of the tab.

The purpose of the optional tab is to further secure the position of the studs in place, if required.

Fig 3f shows the stud in final position and the tabs 49 pushed inward to further securing the stud in position.

The purpose of the holes 50 is speeding up the operation to push the tab inward, using the tip of a screwdriver or impact driver or electrical drill, all tools usually used by the crew to secure the studs together and installing the drywall afterwards.

Fig 4a and 4b show an alternative shape and configuration of the tabs, where tabs 91 create a simpler stop for the stud and tabs 90 will lock the stud in position in the other longitudinal direction. The tabs 90, pre-folded by about 20-30 degrees inward, will fold outward from the resting position while the stud is pushed toward the tabs 91, being inheritably flexible, and will then flex back in resting position, snapping behind the stud web and locking the stud in position once the studs hits the stop tabs 91.

Fig 5a shows an example of a metal stud wall with a door opening, where the vertical studs, the door header track and the cripple stud to position above the door opening, are still compacted in a bundle and positioned in the top and bottom tracks.

In Fig 5a the vertical studs 32,33,34,35,37,38,39, the door header track 36 and the cripple stud or cripple studs (40, Fig 5b), intended to position above the door opening in the final configuration, are still compacted in a bundle, being each stud or header touching each other.

The header track 36 + cripple stud 40 serves the purpose to allow the folding of the strap between the jack studs 35 and 37 of the door opening, being the jack stud 35 web surface flipped 180 degrees toward the door opening (refer to Fig 5c).

Fig 5a shows the stud bundle inserted in the top and bottom track, ready to be “pulled out” accordion style. After inserting the stud bundle in the tracks 30 and 31, the first stud 32 needs to be fastened, on both sides of the stud, to both the top track 30, thru the slots 51a and the bottom track 31, thru the slots 42a, at the beginning of the bottom track. Optionally a floating stud, not attached to the rest of the bundle of studs, can be provided and fastened, to both top and bottom tracks. This extra stud will keep the tracks parallel to each other avoiding the stud bundle to derail during the expansion of the bundle and will remain fastened as last stud of the completed wall.

At this point the builder can pull the last stud of the bundle 39 toward the end of the track (Fig 5b. Being all the studs connected together with at least one straps at the top and one at the bottom of the studs, the pulling operation will position all the studs according the design. In Fig 5b the straps are illustrated, as an example, with four straps in total ( 61a, 61b showing an example of typical connection at the bottom between two generic studs, and 62a, 62b showing an example of connection in a door opening between the two door jack studs 35 and 37.

Once the builder reaches the end of the track with the last stud of the bundle 39, the tabs 76, rectangularly shaped and bended inward by approximately 15 degrees, inheritably elastic, will first bend outward, due to the stud 39 pushing them, and then, once the stud 39 will pass the tabs 76, those will snap behind the stud 39 web, bending back to the previous position.

Fig 5d shows the tabs 76 in this final position behind the web of stud 39. As shown in Fig. 5d, the final stud of the bundle 39 will stay in position without further operation if the straps connecting all studs are made of a material, such as steel, which will tend to return in the previously folded position between the studs when the bundle was closed or collapsed, therefore trying to “close” the bundle and pulling the stud 39 against the tabs 76, creating a safe lock. The stud 39 can be fastened to the top and bottom tracks, to both the top track 30, thru the slots 51b, and the bottom track 31, thru the holes 42b. At this point the wall can be raised, if the pulling operation was executed on the floor, and fastened to the other side of the studs, thru the slots 51b, and the bottom track 31, thru the holes 42b.

The slots 51a and 51b serve the purpose to allow to raise the wall indoor, with a ceiling already being present. The fasteners can be screwed loosely at the top of the slot, so that the wall will be shorter by, for example, ¼”, so that, once the wall is raised in position, the top track 30 can slide up along the fasteners in slot 51a and 51b touching the ceiling surface once fastened with traditional means to the ceiling.

Additionally, the slots will avoid damaging the finished wall framing due to the well know issue, in new buildings, of the defection of the ceiling over time. This problem is usually solved with a double top track able to slide on each other or a slotted deflection track, both solutions being significantly more expensive than the top track object of this invention.

The door header track 36 and the cripple stud 40 will stay secured to one of the jack studs 35 and 37, where Fig 5b shows those components still secured to the jack stud 37. As an example, in Fig 5b, 5f and 5g only one cripple stud is shown. Usually, one cripple stud every 16” or 24” is required, so, whenever the opening is larger and consequently the header track 36 is longer, multiple cripple studs similar to cripple stud 40 (usually two) can be inserted in the header track 36 during transportation and pulling operation of the bundle.

Those components, the header track 36 and cripple studs 40, could also be provided separately or not provided with the system.

Fig 5c shows a possible embodiment of the door (or window) header track 36 and the supporting jack studs 35 and 37, including an example of the system locking the header track 36 to the jack studs 35 and 37, both during transportation and in final configuration. The jack stud 35 will have at least one slot (in fig 5c the slot is split in two) able to receive the tabs 41a and 41b, which extend over the designed header length for the opening.

The jack stud 37 will also have at least one slot able to receive a tab that can be shaped as a rectangle or, as shown in the example, combines the protrusions 44a, 43 and 44b. In fig 5c the slot is larger in the middle with a curved opening 46, able to receive the tongue 43, while the side of the tab, protrusion 44a, will slip, once the header is its final position, inside the slot portion identified as 45a while the side of the slot 44b will slip, once the header is its final position, inside the slot portion identified as 45b.

All the tabs of the header track 41a, 41b, 44a, 43 and 44b extend over the designed header length for the opening. The header, once in final position, will be hold in position by the tabs resting into the correspondent slots.

In addition, the jack studs with the larger slot 45a / 46 / 45b will optionally include an additional tab 47 (also shown in Fig 5e), approximately folded at 45 degrees from the jack stud web, able to keep in position the header track and the cripple studs during the transportation and the initial wall expansion, raising and fastening on existing floor and ceiling surfaces.

The tab 47 will lock the header track 36 against the jack stud 37, like illustrated in Fig 5b, making contact between the tabs 41a and 41b which prevent the header track to slide sideways. Because the tongue 43, while inserted in transportation configuration like illustrated in Fig 5b will deform, the stud web 37a will create substantial friction thus preventing the header track to freely move up and disengaging from the tab 47. The cripple studs will be kept inside the header tracks by friction and the tab 47 will further prevent the cripple to slide out of the header.

The builder can disengage the header forcing up the header track or simply deforming the tab 47 to a greater angle (example 90 degrees) forcing the rotation of the header track in the final position as illustrated in Fig 5f. The tongue 43 will hinge into the curved slot 46 while the track flange extensions 42b will help guiding the protrusions 44a and 44b to be properly inserted in the matching slots 45a and 45b.

Once the header track is almost in horizontal position, the tabs, extending over the designed header length for the opening, will hit the web surface 35a of the jack stud 35. If the builder keeps pushing the header track up, the tabs 41a and 41b deform the web surface 35a ultimately reaching the dual slots 40a and 40b, which, in the example, are positioned at the same height of the slot 45a /46 /45b keeping the header track in horizontal position, as shown in Fig 5f. Optionally, the tabs 41a and 41b can be slightly curved (as in the example) to follow the deformation of the web surface 35a and create less friction.

Referring to Fig 5f showing the header in final position, the builder could optionally further secure the header, with screws, rivets or other means, thru the optional holes 42 located on the flange extensions 42a and 42b. Fig 5g shows the cripple stud above the door opening in final position, after being rotated in position and snapped on the tabs 48 and 48b as previously explained and illustrated in Fig 3a to 3f. The tab 48b will be pre-cut but not be pre-folded in final position, and can be pushed inward manually by the builder just before the installation of the cripple stud. 3 tabs are sufficient to secure in position the cripple stud. Additional tabs 49 could be used to further secure the cripple stud in position if required.

Fig 5h shows the detail of the bottom track, with additional, optional tabs, marks and pre-cuts.

The marking 71 can be used to identify the bottom track and include the specific wall section identification number and/or letter.

The optional tabs 70 and 73 can be manually pushed inward in case, prior to the installation of the drywall, would be necessary to prematurely remove the spacing straps 61a. In this case the tabs 70 would prevent the king stud 34 and jack stud 35 to move, while tabs 73 would prevent the king stud 38 and jack stud 37 to move. The straps still connected to the other studs would prevent the movement, longitudinal to the track, in the opposite direction.

The optional partial cuts 74 and 75 are designed to facilitate the removal of the section of bottom track in the door opening. The portion of the cut 74 and 75 in the track web (the track bottom) could optionally be interrupted in the middle or in other position, so avoiding to excessively weaken the bottom track during transportation and installation. The remaining portion of the flanges that is not cut can be easily removed using tools such as a shear cutter or an angular grinder.

Claims

1. A structural frame for a wall in buildings comprising: a plurality of studs having opposite end portions, said end portions being connected together by flexible spacers to provide a pre-assembled portion of said frame; the studs having an elongated axially extending central portion and at least two lateral portions extending along said central portion; two track elements adapted to receive said end portions of the studs, said track elements including a base portion and lateral walls extending from said base portion; a plurality of tabs or locking portions formed at least on said walls of the track elements to lock into a position said studs; wherein when said studs are spaced the distance between two adjacent studs is controlled by said spacers and is such that the studs are located at the required locking position.

2. The wall frame of claim 1 wherein said studs and said spacers are made of metal.

3. The wall frame of claim 1 or 2, wherein the studs are initially packed together in a bundle and when deployed in said frame are biased to each other by said spacers.

4. The wall frame of any previous claim, wherein said studs have a C-shaped transversal section.

5. The wall frame of any previous claim wherein at least some of the said plurality of tabs or locking portions are configured to extend into the space defined by said studs and retain the lateral portions of said studs in a flat condition.

6. The wall frame of any previous claim, including a cripple stud having opposite endo portions, wherein two adjacent studs are transversally connected by said cripple stud, the end portions of the cripple stud being snap fitted into said adjacent studs.

7. A method of producing a structural frame of a wall, the method including the steps of:

- providing a plurality of studs having opposite end portions, the studs having an elongated axially extending central portion and at least two lateral portions extending along said central portion;

1 - connecting together said end portions by flexible spacers to provide a pre assembled portion of said frame;

- providing two track elements adapted to receive said end portions of the studs, said track elements including a base portion and lateral walls extending from said base portion;

- providing a plurality of tabs or locking portions formed at least on said walls of the track elements to lock into a position said studs; wherein when connecting together said studs, the studs are spaced by a distance that is controlled by said spacers and that is such that the studs are located at the required locking position along said receiving tracks.

8. The method according to claim 7, wherein said connected studs are packed together in a bundle.

9. A method of preparing a wall, including the step of assembling a wall frame produced according to claims 7 or 8, said frame including a partially pre-assembled frame comprised of structural components of a wall frame, in metal or other similar material, wherein a bundle of studs according to claim 8 is deployed and connected to tracks housing the end portions of said studs, whereby the studs are spaced by a distance that is controlled by said spacers and that is such that the studs are located at the required locking position along said receiving tracks; locking into the required position the studs by folding a plurality of tabs or locking portions formed at least on said walls of the track elements; attaching panels to said frame.

10. A wall as obtainable by a method according to claim 9.

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