阅读说明：本技术 紧固件和壁组件 (Fastener and wall assembly ) 是由 格伦·海顿·普林 于 2018-03-29 设计创作，主要内容包括：本发明公开了一种壁组件10包括顶盖11和底盖12,所述顶盖和底盖通常是U形的沟道,并且这些顶盖和底盖被固定到地板13和混凝土板天花板14,在这种情况下,所述混凝土板天花板包括多层建筑中下一层的混凝土地板的底面。在这些布置中,必须相对于壁15布置天花板14,用于天花板14的偏斜,因此,轨道11与底面表面16间隔开通常20mm的距离,并且合适的可压缩间隔件布置17被定位在轨道11的上表面18和底面表面16之间。间隔件布置17可以是任何合适的填充物,并且一个实例可以是防火/吸音的单面粘合性层状的可膨胀/可压缩的胶带或泡沫材料。该胶带可以施加到沟道的上外表面,其另一侧粘合性地压靠混凝土的底面。(a wall assembly 10 includes a top cover 11 and a bottom cover 12 which are generally U-shaped channels and which are secured to a floor 13 and a concrete slab ceiling 14 which in this case comprises the underside of the concrete floor of the next level in a multi-level building. In these arrangements, the ceiling 14 must be arranged relative to the wall 15 for deflection of the ceiling 14, so that the rail 11 is spaced from the floor surface 16 by a distance of typically 20mm, and a suitable compressible spacer arrangement 17 is positioned between the upper surface 18 and the floor surface 16 of the rail 11. The spacer arrangement 17 may be any suitable filler and one example may be a fire/sound absorbing single sided adhesive layered expandable/compressible tape or foam. The tape may be applied to the upper outer surface of the trench with the other side adhesively pressed against the bottom surface of the concrete.)

1. A wall frame comprising:

Top and bottom rails fixed on the top and bottom surfaces;

Spaced apart studs extending between the channels in fixed spaced relation to form a rigid frame with the top and bottom rails;

spaced apart fasteners for securing the top and bottom rails to the top and bottom surfaces to account for surface deflection;

each fastener includes a retaining portion, a head portion and a deflection guide ramp in axially slidable engagement with the track to account for surface deflection;

The fastener has a stop adapted to set the distance of the head from the surface, and thus the track distance from the surface.

2. The wall frame of claim 1, wherein the skewing guide ramp is a shank portion of the fastener and the stop comprises a physical stop to limit penetration of the retention portion.

3. A wall frame according to claim 1 or 2, wherein the stop has associated locating means such that the fastener can locate the rail in its operative position, the stop comprising a stop face at the end of the shank adjacent the retaining portion.

4. The wall frame according to any of the preceding claims, wherein the deflection guide runner is a cylindrical portion of the fastener and the stop surface is an annular shoulder from which the retaining portion projects, the retaining portion terminating adjacent the stop surface.

5. a wall frame according to any preceding claim, wherein the skewed guide runner extends from one end of the retaining portion to the head portion, with the effect that when the stop face abuts a surface, the head portion is a predetermined distance from the surface, which distance is substantially the same for all fasteners along the track.

6. A wall frame as claimed in any preceding claim, wherein the head has a flange adapted to be fixed in alignment with the track at a predetermined distance from the surface determined by the stop, and the shank provides a pin function such that the fastener can slide relative to the track, thereby taking into account the deflection of the surface relative to the track.

7. a heavy-duty wall track-spaced fastener is unitary or has two portions with a retaining portion, a head portion and a skew guide runner extending axially between the head portion and the retaining portion, and a transversely extending stop surface at the end of the retaining portion of the skew guide runner.

8. The heavy wall track space fastener of claim 7, wherein the skewed guide runner is a pin portion and the stop surface is an outer edge of an end of the pin portion at a junction between the pin portion and the retaining portion.

9. An in situ rigid wall assembly comprising an upper track, a lower track, a wall frame element extending between and secured to the upper and lower tracks by which the wall assembly is secured to a concrete surface, the upper track having axially spaced and axially extending slots and being spaced from adjacent said concrete surface and being in axially slidable engagement with spaced fasteners passing through each slot, each fastener having a deflection guide way passing through said track and a stop providing a gap between said track and concrete determined by the position of the stop, a filler or spacer arrangement secured to the wall frame element and track being employed in the gap and wall cladding.

10. a method of securing a wall track to a surface, comprising:

Preparing a wall frame guide rail with spaced apart guide channels through which the inclined guide runners can pass;

Providing a fastener having a retaining portion, a head, and a skewing guide track, the retaining portion typically being threaded;

Securing the rail with a retaining portion of the fastener such that the deflection guide runner is axially slidably engaged in the guide channel to account for deflection, the fastener automatically setting the spacing of the rail from the surface.

11. The method of claim 10, further comprising:

using a rail connector bracket between rail sections;

The rail connector bracket coincides in use with the vertical frame member at a certain position.

12. the method of claim 10 or 11, further comprising:

The vertical frame members are secured to the connected rail ends by gaps in the connector brackets.

13. The method of any of claims 10 to 12, further comprising:

first positioning the rail end over the connector bracket and securing the rail end and connector bracket to the concrete roof; and

Sliding an end of another rail over the already fastened rail portion and the carriage and securing the other rail along the other rail with the fastener in alignment with the rail portion and securing the other rail to the carriage as well.

14. The method of any one of claims 10 to 13, further comprising applying spaced apart guide channels to the wall frame rails through which the skewed guide runners can pass to the top or bottom of the wall frame.

15. A track for use according to any one of claims 1 to 6, 9 or 10 to 14 wherein the track has a width in the range 64mm to 150mm, a base metal thickness in the range 0.5mm to 1.5mm and the guide channel comprises axially spaced grooves having a groove length in the range 60mm to 310 mm.

16. A track for use in accordance with any one of claims 1-6, 9 or 10-14, and additionally a track for use in a wall according to any one of the rows in the following table:

17. The wall frame according to any of claims 1-6, wherein at least one stud has an end gap to accommodate a head of a fastener.

18. The method according to any one of claims 10 to 14, further comprising the step of: the fastener heads are placed in the gaps at the ends of the vertical frame members.

Technical Field

the present invention relates to fasteners and particularly, but not exclusively, to fasteners for use in deflected situations where the fastener is required to provide a deflection between a wall assembly and an associated floor or base to which the wall assembly is attached.

Background

known arrangements for placing wall frames utilize rails or the like, wherein the upper rail is fixed to the roof or ceiling of the head end and the lower rail is fixed to the floor with wall frame studs between them. This may be between concrete slabs, for example in a multi-storey building, where the upper track is positioned to take into account the vertical deflection of the slab relative to the wall. Although these arrangements have existed for many years, no attempt has been made to improve the structural integrity of the connection of the track to the slab across the wall plane of the head top, particularly in shear. The patent literature provides examples of various combinations with their own advantages and disadvantages, some of which, of course, have never actually been used. The following are examples and, although these documents are set forth, they are from a search of the invention and do not constitute an admission of the common general knowledge in australia or elsewhere.

Us patent application 2006/0032157(Baryla et al) describes a "seismic wall system" in which the top rail is loosely fixed for axial relative motion and the studs (stud) are free to move within the frame. The basic requirement of this system is relative vertical movement between the stud and the top rail, with the stud being positioned by notches in the top and bottom rails. The interface of the stud with the rail is inherently weak due to the lack of connection between the stud and the rail. Us patent applications 2016/0201319 and 2017/0032157 (both Pilz) describe a fire resistant head for a wall joint in which the insert or layered insert between the head rail and the ceiling expands when heated. The head rail is secured by standard concrete screws and is spaced from the ceiling above by the insert. US3,309,825(Zinn et al) is also similar. The present invention does not use an insert to set the gap. GB 461,706(Fisk) describes an acoustic partition wall which allows ventilation and addresses any vibration of the floor or ceiling. The walls are mounted at the top and bottom using "free-running" screws, with the spaces between the frames separated by felt pads.

It should be clear that walls have been in use for many years. The above is a non-limiting example, and it should also be understood that the technology of the inner wall and its construction is "fully developed" or "focused technology".

the present invention has been made in view of this background, and it was an idea of the inventors 'desire to provide a useful alternative to the prior art, and in response to the inventors' quite unexpected discovery, it was possible to both save material and reinforce existing walls by simply modifying the existing arrangement in the rail fixing and frame to which the rails are connected. This means that the present invention produces greater strength for any given BMT (base metal thickness).

All prior art arrangements have the disadvantage of being very complicated or structurally weak, or of not being able to be used effectively in an environmentally friendly manner for the materials used.

It is therefore desirable to provide a fastening device that improves the structural integrity of the track and thus the associated wall to cement panel connection, as well as simplifying the construction method and optimizing the materials used to save costs, and to achieve a sustainable and environmentally friendly system by obtaining structural benefits with less material.

Disclosure of Invention

Accordingly, in one aspect, there is provided a wall frame comprising: a top rail and a bottom rail secured to the top surface and the bottom surface; spaced apart studs extending between the channels in fixed spaced relation to form a rigid frame with the top and bottom rails; spaced apart fasteners for securing the top and bottom rails to the top and bottom surfaces to account for surface deflection; each fastener includes a retaining portion, a head and a deflection guide ramp in axial sliding engagement with the rail to account for surface deflection, the fastener having a stop for setting the distance of the head from the surface and thus the rail distance from the surface.

In another aspect, a fastener is provided for securing a rail to a surface in a fixed spaced relationship to account for surface deflection and installation of a wall in the rail, the fastener including a retaining portion (typically a threaded) head, and a deflection guide runner in axial sliding engagement with the rail to account for deflection. The skewing guide ramp is typically the shank portion (shank section) of the fastener and has a physical stop to limit penetration of the retaining portion. Preferably, the physical stop has an associated locating means such that the fastener is able to locate the track in its operative position. In one form, the physical stop and the positioning device have stop surfaces. Typically, the stop surface is the end of the shank adjacent the thread. In a preferred form, the skewing guide ramp is a cylindrical portion of the fastener and the stop surface is an annular shoulder emanating from the thread, wherein the thread terminates immediately adjacent the stop surface. The effect of the skew guide runner preferably extending from one end of the retaining portion to the head is that when the stop face abuts against a surface, the head is at a predetermined distance from the surface and the distance is substantially the same for all fasteners along the track. Preferably, the head has a flange adapted to be secured in alignment with the track at a predetermined distance from the surface, and the shank provides a pinning function such that the fastener can slide relative to the track, thereby taking into account deflection of the surface relative to the track. The invention is typically used on the top or bottom of a vertical wall. The fastener may be unitary or have two parts.

In a second aspect, there is provided a heavy-duty wall track-spaced fastener, which is unitary or has two portions, with a retaining portion, a head and a skew guide runner extending axially between the head and retaining portion, and a transversely extending stop surface at the end of the retaining portion of the skew guide runner. The deflection guide runner is typically a pin portion and the stop surface is an outer edge of one end of the pin portion at the junction between the pin portion and the retaining portion. The retention portion is typically a thread, the deflection guide runner is a cylinder, and the stop surface is an outer edge of an end of the cylinder adjacent a terminal end of the thread.

In another aspect, a wall assembly is provided comprising an upper track, a lower track, a wall frame element extending between the tracks, the upper track being spaced from an adjacent surface and in axially slidable engagement with spaced apart fasteners, each fastener having a skewed guide way passing through the tracks. Typically, each fastener has a spacer including a stop that sets the spacing between the tracks and then secures into the concrete, and a track portion according to the fastener described above that secures the track into the concrete at a distance determined by the shank length of the fastener. Typically, a gap is formed above the track and a filler or spacer arrangement is employed in the gap. The spacer arrangement may be any suitable filler and one example may be a fire/sound deadening single-sided adhesive layered expandable/compressible tape or foam. The tape may be adhesively applied to the upper outer surface of the channel and its other side pressed against the underside of the surface above the rail.

in yet another aspect, a wall frame rail is provided having spaced apart guide channels through which a skewed guide runner passes. These guide channels are typically spaced holes in the crown of the rail. The spaced apart holes may be elongated slots. The track preferably has at least one side wall and the cladding is secured to the side wall on its inner or outer side using suitable fasteners. Typically there is a top rail and a bottom rail supporting the walls, and these rails are each usually located in a channel having the side walls spaced apart and cladding secured to the side walls with spaced apart fasteners.

In another preferred form there is provided an in situ rigid wall assembly comprising an upper track, a lower track, wall frame elements extending between and secured to the upper and lower tracks, the wall assembly being secured to a concrete surface by the tracks, the upper track having axially spaced and axially extending slots and being spaced from adjacent said concrete surface and being in axially slidable engagement with spaced fasteners passing through each slot, each fastener having a deflecting guide way passing through the track and a stop providing a gap between the track and the concrete determined by the position of the stop, a filler or spacer arrangement secured to the wall frame elements and the track being employed in the gap and wall cladding. Where the frame member is aligned with the head of the fastener, it is preferred to have a gap to accommodate the head. In the case of channel studs, there is a U-shaped cut-out to accommodate the head.

In yet another aspect, there is provided a method of securing a wall track to a surface, comprising:

preparing a wall frame guide rail with spaced apart guide channels through which the inclined guide runners can pass;

Providing a fastener having a retaining portion, a head, and a skew guide runner, the retaining portion typically being threaded;

The rail is secured using a retaining portion of a fastener that automatically sets the spacing of the rail from the surface such that the deflection guide runners are axially slidably engaged in the guide channels to account for deflection.

the method may further comprise using a rail connector bracket between portions of the rail. Preferably, the rail connector bracket coincides at certain positions with or without positions of the vertical stud in use. Typically, the vertical stud is secured to the attached rail end through a gap in the bracket. Preferably the track first terminates on the carriage and the method comprises sliding the end of the other track over the already fastened track portion and carriage and then using the fastener to secure the other track also to the carriage.

Preferably the width of the rail is in the range 64mm to 150mm, the base metal thickness is in the range 0.5mm to 1.5mm and the guide channel comprises axially spaced grooves having a groove length in the range 60mm to 310 mm. The slots may be evenly spaced. More preferably, the height of the groove to the wall may be selected from the following table:

drawings

In order that the invention may be more readily understood and put into practice, reference will now be made to the accompanying drawings which show a preferred embodiment of the invention applied to the top of a vertical wall, but it will be understood that the top track may be located at the bottom of the wall, wherein:

FIG. 1 is a sectional view illustrating a wall assembly according to an aspect of the present invention;

FIG. 2 is an enlarged view of the top of a conventional wall assembly;

FIG. 3 is a diagram illustrating the application of the present invention to a curved wall;

FIG. 4 is a partial view showing a portion of a conventional assembly process;

FIG. 5 is a possible next step;

FIG. 6 is another possible next step following the view of FIG. 5;

Fig. 7 is a possible final view.

FIG. 8 is a view of a conventional fastener.

fig. 9 is a side view of the fastener of fig. 8.

Fig. 10 is a top view of the fastener of fig. 8.

FIGS. 11 and 12 are another embodiment similar to FIGS. 1 and 3, wherein spaced fasteners are used to secure cladding to the exterior of a conventional rail at any location along the rail;

FIG. 13 is a connector bracket that may be used to secure to a portion of a track;

FIG. 14 is a diagram showing the use of a connector bracket at the junction of two rail ends and a stud;

FIG. 15 is an exploded view of another fastener; and is

Fig. 16 is a graph that is an example of displacement under an applied load according to an otherwise existing stud rail interface.

Detailed Description

Referring to the drawings and initially to fig. 1, there is shown a wall assembly 10 which includes a top cover 11 and a bottom cover 12 which are generally U-shaped channels and which are secured to a floor 13 and a concrete slab ceiling 14 which in this case comprises the underside of the concrete floor of the next level in a multi-level building.

In these arrangements, the ceiling 14 must be arranged relative to the wall 15 for deflection of the ceiling 14, so that the rail 11 is spaced from the floor surface 16 by a distance of typically 20mm, and a suitable compressible spacer arrangement 17 is positioned between the upper surface 18 and the floor surface 16 of the rail 11. The spacer arrangement 17 may be any suitable filler and one example may be a fire/sound absorbing single sided adhesive layered expandable/compressible tape or foam. The tape may be adhesively applied to the upper outer surface of the trench with the other side pressed against the bottom surface of the concrete.

The lower track 12 is secured using concrete screws 19, which concrete screws 19 are positioned at spaced intervals along the track 12. In order that the track 11 may be secured in place, fasteners 20 according to the present invention secure the track in the concrete slab 14 at spaced intervals along the track.

referring now to fig. 2, the top of the wall assembly 10 is shown in an enlarged view, showing the studs 21 fitted inside the rail 11, and then the outer cladding 22, 23 is applied to complete the assembly. The fastener 20 in this case comprises a retaining portion in the form of a thread 24, a deflecting guide race in the form of a cylindrical shank 25, and a conventional hexagonal flanged head 26, the shank 25 having a stop face included in this example as an annular shoulder 27 which can be seen to act as a stop to set the spacing between the concrete slab underside 16 and the top 28 of the track 11.

Referring to fig. 3, there is shown the application of the invention to a curved wall assembly, in this case using a track 30, which track 30 is made up of separate sections 31, which sections 31 have flexible bridges 32 and are interconnected by flexible strips 33, so that a curved track can be formed. As shown, the studs 34 are secured in the track with the fasteners 20 located at the center of the studs as previously described to secure the track to concrete or other deflectable surface in a fixed spaced relationship depending on the length of the shank of the fasteners 20.

Due to the self-drilling capability of the threads on the shank 25 and fastener 20, it will be appreciated that it is a simple matter to apply the fastener 20 in the form of a heavy-duty fastener located at the center of the stud along the length of the track. This provides a very robust arrangement for simply and easily scoring the center and bore and then securing the rail in place while meeting the requirements of the shank to achieve the deflection margins specified for such assemblies.

Fig. 4 to 7 show a conventional assembly arrangement of the wall assembly according to the invention using fasteners 20. The track 36 has been fixed in place by the fastener 20, screwed into the plate 37, and the stud 38 has also been fixed. In this case, the studs 38 have repair holes 39, and these are aligned along the wall assembly. The fastener 20 acts as a deflector bolt that is inserted through the head rail and secured into the plate with the anchor point at the center of the stud. Screws 40 secure the track to the stud. After the top and bottom rails and studs are positioned, the plasterboard is secured as shown, and the sheet 41 is secured in place.

The plasterboard is fixed with screws 42. The open cell compressible support bar 42 is fixed and positioned in the 20mm gap 43 and then sealant 44 is applied to fill the gap between the top of the gypsum board and the bottom surface of the board. The gypsum board and sealant can be generally fire resistant. This step is repeated as shown in fig. 6 and 7. As further shown in fig. 7, other cladding layers may be used, and additional gypsum board sheets may be used at 45, depending on spacing requirements, as is conventional.

referring now to figures 8 to 10 there is shown a preferred form of fastener 20, in this case the overall length of the fastener is 75mm and most importantly the shank 25 is located 20mm from the flange 26 in this case so that the stop shoulder 27 can be operated to secure the track at this preset distance so that it is a simple matter to quickly and quickly place the track in position using common tools and equipment.

referring now to fig. 11, another embodiment 46 is shown. Like reference numerals refer to like features. As in the previous embodiment, it will be appreciated that the track 11 is fixed to the upper end of the stud 34 at 46 locations on opposite sides. In this case, the rail 47 differs from the rail 11 in that the holes 48 are elongated in the axial direction of the rail. This allows limited movement in the axial direction. This is particularly useful in the case of ground motion during an earthquake, for example. In all other respects, the tracks are identical. The fastener 20 is concentric with the stud. The fastener spacing may vary depending on the thickness of the rail material.

Fig. 12 shows a track arrangement 49 that may be used at the lower end of a ceiling partition or the like of the type that generally involves a frame. The upper end, not shown, may correspond to the previous figures in fig. 1-11. One frame member of the ceiling floor frame is shown at 50 to which gypsum board or other cladding may be secured in the usual manner. The track 49 has a strap (strap)51 passing through a flange portion 52, but there is no corresponding flange and strap on the inside. In all other respects this is the same track. It may have an elongated hole. As shown, it is fixed to the stud.

In each embodiment, the rail material may be made of less or thicker and stronger metal as desired by the application. In some cases it may be desirable to use thicker material to make the track self-supporting, an example being the use of 0.75mm zinc (a registered trademark of Bluescope Steel) or the like, and in such cases the tape 51 may be omitted entirely. In this case, the fastener pitch may be further apart, but of course the fastener pitch may be selected as desired.

To connect the track sections, the connector bracket shown in fig. 13 may be used in the arrangement of fig. 14. In fig. 14, only a portion of the bracket is shown in phantom to show its position with the ends of the various tracks and the ends of the studs. Referring to fig. 13 and 14, the connector bracket 53 fits within and is secured to the rail 54, the rail 54 being secured together to the roof 55 using spaced apart fasteners, shown at 56, passing through slots 57. This way of connecting the rails is in fact the arrangement of the previous embodiment, so that the roof can float above the rails. The vertical inner wall with the studs 58 is firmly attached back to the floor.

It will be appreciated that once the bracket 53 and track portion 54 are secured, the end 59 of the second track portion 60 may be manually positioned over the bracket 53 to abut the end of the track portion 54, and the track portion 60 may be secured at the distal end of the track portion 60 using the fastener 56 prior to securing the track portion 60 to the bracket 53. Other fasteners 56 may be added. The studs 58 may be added later. It will be appreciated that in this case the mounting of the track portion may be one-man. A bracket similar to bracket 53 may be used with curved track sections.

The bracket 53 has a crown 61, an angle flange 62 for securing the track portion and a stud opening 63 for securing the track directly to the stud 58. The bracket also has cutouts 64 therein and the stud 58 also has U-shaped cutouts 65 therein (shown in phantom in fig. 14) which are adapted to receive the heads 26 of the fasteners 56 to permit full length adjustment or movement of the slot 57. The gap 65 is used for repositioning of the stud and alignment with the fastener at these locations.

referring now to fig. 15, an alternative fastener 66 formed from an internally threaded head end 67 and a complementary nail end 68 is shown. In fig. 15, the respective ends are shown separated, but it will be understood that they are screwed together to form the fastener. The nail end is a standard threaded concrete nail used with nail guns so that the nail head can be driven into place and then the head end used to secure the rail in place. It should be understood that any equivalent form of concrete connection may be employed.