Metal frame for prefabricated drywall panels

Abstract

[Metal framework for prefabricated panel drywall, said metal framework comprising a metal profile (10) having a base (12) and two opposing flanges (14, 16) extending from said base (12) facing each other, said facing flanges being adapted to respectively receive prefabricated panels in support. Said base (12) of said metal profile (10) has at least a set of n cutouts (28, 30, 32, 34) each extending from a central point (36) and along n mean radii (R1, R2, R3, R4), to allow n tabs (44, 46, 48, 50) projecting from said base (12) around a duct passage opening (52), n being a natural number greater than 2.

Description

[0001] The present invention relates to a metal frame for prefabricated panel drywall.

[0002] One area of ​​application envisaged is, in particular, but not exclusively, that of dry partitions of prefabricated plaster panels, installed inside buildings.

[0003] Common metal framing systems consist of horizontal rails installed in the floor and ceiling walls, and vertically mounted U-shaped metal profiles that are anchored to the rails. These U-shaped metal profiles, or studs, have a bottom and two opposing flanges, and are progressively adjusted so that their bottoms are oriented perpendicular to the rails, while their flanges extend in planes parallel to the average plane defined by the rails. Thus, the opposing flanges of the metal profiles can support prefabricated panels, which are then secured to them by screws.

[0004] Between the prefabricated panels, which define the partition, insulating materials such as fiberglass or rock wool are generally inserted. In addition, cable trays are installed. To do this, the bottom of the metal profiles has pre-cut circular openings allowing the passage of standard corrugated conduits, the interior of which forms the cable channels.

[0005] These circular openings are generally oversized to accommodate all sizes of corrugated duct. Furthermore, they have a sharp inner edge that disrupts the deployment of corrugated ducts through the openings in the metal profiles, as the duct rings tend to straddle the sharp edge and become stuck during translation.

[0006] Reference may be made to documents US 4 235 054 A, US 2009 / 178369 A1 or US 3 800 489 A which describe such profiles.

[0007] Also, a problem that arises and that the present invention aims to solve is to provide a metal framework that facilitates the deployment of the ducts through the bottom of the metal profiles.

[0008] For this purpose, a metal framework for prefabricated panel drywall is proposed, according to claim 1.

[0009] Thus, a key feature of the invention lies in the implementation of four cutouts in the base of the profile during its manufacture. These cutouts allow the base wall to be pressed into the cutouts during installation, forming tabs that are then extended substantially perpendicularly to the base. Furthermore, the passage opening has a cross-section larger than that defined by the cutouts. Consequently, the corrugated ducts can be easily moved through these duct passages, as the surface area of ​​the tabs facilitates their sliding.

[0010] Therefore, if two cuts were made from a central point along non-collinear radii or segments, perpendicular to each other for example, a tab could be inserted, but the resulting opening would have two sharp edges that could obstruct the corrugated duct's movement. Consequently, by using three cuts extending along non-collinear radii, a roughly triangular duct opening is created, with three edges fitted with tabs that are themselves roughly triangular.

[0011] According to a particularly advantageous embodiment of the invention, the framework further comprises another metal profile having a different base and two opposing flanges extending from said other base opposite each other, said one profile and said other profile being adapted to be mounted against each other. Metal profiles usually have standard lengths and standard cross-sectional dimensions, while the height of drywall partitions can vary. Therefore, for example, two U-shaped profiles are joined in situ back to back, adjusted to the desired total height, and then secured together with self-tapping screws through their base.

[0012] Furthermore, the other base advantageously features at least one other set of four cutouts, each extending from a different central point along four other average radii, to allow for the bending of four additional protruding tabs in the other base around another duct passage slot. This creates additional duct passage slots in the other metal profile in the same way as in the first. In this manner, the formation of further duct passage slots in the other profile is also permitted, and consequently, the insertion of corrugated ducts through the other profile.

[0013] According to a particularly advantageous embodiment of the invention, the opposing wings are extended by means of two extensions folded in opposite directions against said wings, extending behind said base. In this way, using a single metal strip, an I-beam is obtained with significantly increased inertia. In other words, the metal I-beam has greater resistance to bending.

[0014] Furthermore, and preferably, the aforementioned other wings are extended by two additional extensions folded opposite each other against the aforementioned other wings, extending behind the other bottom. In this way, it is easy to join the two sliding metal profiles, one inside the other, as will be explained in more detail later in the description. The two bottoms rest back to back, while the extensions of the two profiles overlap. Thus, the length of the two profiles, inserted one inside the other, can be easily adjusted to the desired partition height and then secured with screws through the two back-to-back bottoms. It should be noted that the cutouts made in the bottom of the profiles do not hinder their sliding during the adjustment of the overall length.When they are screwed in, tabs can be deformed to create passageways in the non-overlapping background sections.

[0015] According to the invention, said at least one assembly comprises four cutouts extending from said central point along four successively perpendicular average radii. In this way, four tabs can be deformed to extend them outward from the bottom of the metal profile. Naturally, the four tabs are extended on the same side of the bottom to allow for better guidance of the corrugated sheaths in translation through the opening thus created.

[0016] According to a variant not conforming to the invention, said cutouts are slots. In this way, four triangular tabs are deformed and extended, creating a substantially square passageway. Thus, when a corrugated sheath is moved in translation through the passageway, it is driven by friction against the surface of the tabs and does not encounter any sharp edges or obstacles that could interrupt its movement.

[0017] According to the invention, each of said cutouts has, from said central point and along the corresponding average radius, a small square recess followed by a large square recess, the diagonals of said square recesses coinciding with said corresponding average radius. The four cutouts, successively orthogonal to one another, then form a central square recess centered on the central point and resulting from the cutouts of the small square recesses, and four corner square recesses resulting from the large square recesses. Preferably, said small square recess is substantially four times smaller than said large square recess, so as to allow for better exposure of the tabs. In this way, four tabs capable of being deformed are created on each of the four edges of the passageway thus exposed, as will be explained in more detail below.

[0018] Furthermore, the base of the metal profile advantageously features a plurality of sets of four cutouts spaced apart. For example, the sets of four cutouts are spaced 500 mm apart so as not to reduce the inertia of the metal profile.

[0019] According to another aspect, the present invention relates to a method according to claim 11.

[0020] Thus, a sheath is further provided and, advantageously, said sheath is driven in translation through said sheath passage light.

[0021] Other features and advantages of the invention will become apparent from the following description of particular embodiments of the invention, given by way of example but not limitation, with reference to the attached drawings in which: [ Fig. 1 ] is a partial schematic perspective view of the end of a structural element according to the invention; [ Fig. 2 ] is a partial schematic side view of the structural element according to the invention, in a first embodiment of the invention and in a first state; [ Fig. 3 ] is a schematic detail and front view of the object in the figure [ Fig. 2 ] ; ] Fig. 4 ] is a schematic perspective view of the object in the figure [ Fig. 2 ] according to a second state; [ Fig. 5 ] is a schematic detail view of the object in the figure [ Fig. 4 ] ; ] Fig. 6 ] is a partial schematic detail view showing the object in the figure [ Fig. 5 ] associated with a complementary element; [ Fig. 7 ] is a partial schematic detail view showing a variant not conforming to the invention, in a first state; [ Fig. 8 ] is a schematic view of the object in the figure [ Fig. 7 showing the object of the figure [ Fig. 7 ] in a second state; and, [ Fig. 9 ] is a schematic cross-sectional view showing two frame elements fitted one inside the other.

[0022] There Figure 1 This shows the free end of a first I-beam 10 used to form metal framing studs for prefabricated drywall panels. The first I-beam 10 has a first end 12 and two opposing flanges 14, 16 extending perpendicularly from the first end 12, facing each other and forming a U-shaped section. The first flanges 14, 16 are extended by two extensions 18, 20 folded in opposite directions against their respective first flanges 14, 16, so that they can extend parallel to each other behind the first end 12.

[0023] The first extensions 18, 20 are approximately twice as wide as the first wings 14, 16, so that they extend parallel to each other behind the first bottom 12 over a width approximately equivalent to that of the first wings 14, 16. For example, the first extensions 18, 20 are approximately 60 mm wide, while the first wings 14, 16 are approximately 30 mm wide. However, one of the first extensions, 18, extends over a width, for example 60 mm, which is approximately 57 mm, for practical reasons as will be explained below. Furthermore, the width of the first bottom 12 varies depending on the type of bulkhead, for example between 35 mm and 150 mm. In addition, the first extensions 18, 20 have free borders 22, 24 curved towards each other.As will be explained below, such I 10 metal profiles allow the formation of metal frame uprights, and preferably their original length is for example 1600 mm and they are matched and mounted sliding one into the other to be able to adjust the length of the upright to the wall height.

[0024] I-beam metal profiles are continuously formed in a forming plant from a single metal strip with a thickness, for example, between 0.4 mm and 1 mm. The forming plant also includes, downstream, cutting devices for sectioning the profile into sections of predetermined lengths, for example, 1600 mm. Upstream, the forming plant includes a punching device for continuously cutting the metal strip. Thus, Figure [ Fig. 2 ] partially illustrates the first metal profile 10, which has in the base 12, a first set of checkerboard cutouts 26 according to the invention and which will be described in detail from the front opposite the figure [ Fig. 3 ].

[0025] Thus, the first set of checkerboard cutouts 26 corresponds to four cutouts 28, 30, 32, 34 extending radially from a central point 36 along four average radii, or segments, R1, R2, R3, and R4, which are substantially identical and offset by 90° from each other. Each of the cutouts 28, 30, 32, 34 is further divided, from the central point 36, into a small proximal square recess 38 and a large distal square recess 40, which communicate at their corners. Each of the average radii R1, R2, R3, and R4 then coincides with the diagonals of the small proximal square recess 38 and the large distal square recess 40, which lie in line with each other. Also, the four small proximal square recesses 38 together form a single central square recess 42 having the central point 36 as its center.

[0026] Such a set of cuts 28, 30, 32, 34 thus makes it possible to delimit four tabs 44, 46, 48, 50 oriented towards the central point 36. When implementing the first metal profile 10 to form the upright of a frame, the four tabs 44, 46, 48 and 50 are then pushed in on the same side of the base 10 as illustrated in the figure [ Fig. 4 ], so as to release a first square passage light 52.

[0027] The square opening 52 thus defines four inner edges 54, 56, 58 and 60. The tabs 44, 46, 48 and 50 can easily be deformed and pressed in with the fingers, because the thickness of the metal, on the order of a few tenths of a millimeter, is thin enough that they can be deformed by hand. Also, the tabs 44, 46, 48 and 50 are bent to be positioned substantially perpendicular to the bottom 12 as illustrated in detail in the figure [ Fig. 5 ]. This figure shows the four tabs 44, 46, 48, and 50 protruding from the base 12 and around the first square opening 52, one for each of the edges 54, 56, 58, and 60. It will be observed that the tabs 44, 46, 48, and 50, when pressed in, do not fold precisely around the edges 54, 56, 58, and 60 respectively, but with a noticeable offset, thus creating a step relative to these edges 54, 56, 58, and 60. The significance of these step-ins will be fully appreciated by referring to the figure [ Fig. 6 presenting a portion of corrugated sheath 62 engaged through the square passage opening 52. Thus, the portion of sheath 62, whose diameter is of course smaller than the spacing between the opposing tabs 44, 48 and 46, 50, can be moved in translation through the square passage opening 52 by bearing against one or another of the tabs 44, 46, 48 and 50 bent parallel to each other. The portion of sheath 62 is driven by friction against the surface of the folded tabs 44, 46, 48 and 50 without being able to come into contact with any of the four inner edges 54, 56, 58 and 60, notably thanks to the notches described above.

[0028] Also, the present invention relates to a method of assembling a metal frame for prefabricated panel drywall.

[0029] According to this method, a metal frame comprising a plurality of metal profiles 10, as described above, is provided. Next, the four tabs 44, 46, 48, and 50 projecting from the base 12 are bent around the duct passage opening 52 for each of the metal profiles. Then, the duct 62 is provided and moved through the duct passage openings 52 in the metal profiles.

[0030] Thus, when the metal I-beams are installed vertically to form a framework, and before the space between prefabricated panels is closed, the sheath is stretched through the passageway without restraint due to the sharp edges of these openings.

[0031] The punching device described above also allows for the continuous creation of a second set of cross cuts 26' in the bottom 12' of the metal strip. See Figure [ Fig. 7 illustrating in detail this second variant which does not conform to the invention. Also, the functional elements identical to those of the first embodiment will have the same reference numerals marked with a prime sign: "'. Thus, this second set of cross cutouts 26' corresponds to four cutouts 28', 30', 32', 34' in the form of slots, extending radially from the central point 36' and along four average radii R1', R2', R3' and R4' that are substantially identical and offset by 90° from each other. Such a set of cutouts 28', 30', 32', 34' thus makes it possible to define four triangular tabs 44', 46', 48' and 50' oriented towards the central point 36'.

[0032] Also, as illustrated in the figure [ Fig. 8 ], the tabs 44', 46', 48' and 50' are folded to be positioned approximately perpendicularly to the bottom 12' on the same face of it. This figure shows [ Fig. 8 ] the four tabs 44', 46', 48' and 50' projecting from the bottom 12' and around a second square passage light 52'. In the same way, as in the variant embodiment according to the invention, illustrated in the figure [ Fig. 6 ], it is easy to drive in translation a corrugated sheath through the second square passage light 52' which then comes into friction on the triangular tabs 44', 46', 48' and 50'.

[0033] In this alternative embodiment of the invention, it will be observed that it is easy to create a set of six cutouts, each extending from a central point along six average radii, to allow six tabs projecting from the base to be bent around a conduit passage. Furthermore, again according to this alternative embodiment, it is easy to reduce the width of the slots to simply the width of the punch's cutting blade. In this way, when the tabs are not bent, the metal profile retains high inertia.

[0034] Furthermore, and particularly advantageously, multiple sets of cutouts, as described above, are made in the bottom of the I-beam; these sets of cutouts are spaced a predetermined distance apart, for example, 500 mm. This allows for the installation of several cable trays within the thickness of the partition and also enables the selection of the desired extension height for a single tray.

[0035] It will be noted that the cuts thus described, at the right of the variant according to the invention or at the right of the variant not in accordance with the invention, can also be made in a C profile, which also make it possible to form uprights to make metal frames for drywall partitions.

[0036] The advantage of implementing I-beams of the type of the first metal I-beam 10, illustrated in the figures [ Fig. 1] et [Fig. 2 The advantage is that they can be matched and mounted telescopically inside one another to accommodate high partitions. Furthermore, as long as the tabs of the cutouts are not bent, the sliding of the profiles inside one another is not hindered.

[0037] We will therefore refer to the figure [ Fig. 9 [showing in cross-section the first I-beam 10 mounted to slide inside a second I-beam 10'. The first bottom 12 is shown with its two opposing flanges 14 and 16, which extend perpendicularly from the first bottom 12, facing each other. Also shown are the first two extensions 18 and 20, which extend from the first flanges 14 and 16, folded back against them opposite each other so that they can extend parallel to each other behind the first bottom 12.]

[0038] The second metal profile 10' is paired head-to-tail with the first 10. Thus it includes, a second bottom 12' resting flat against the first bottom 12, and it is matched with its two second opposite wings 14', 16' which extend perpendicularly from the first bottom 12' facing each other. Furthermore, the second wings 14', 16' are extended respectively by two second extensions 18', 20', which are folded against the second wings 14', 16', one of the second extensions 20' interlocking between one of the first wings 14 and one of the first extensions 18, while the other second extension 18' is pressed against the other first extension 20, which is itself interlocked between the second wing 14' and the other second extension 18' that extends it. In this way, a single doubled profile is obtained, the two profiles 10, 10' of which constitute it are able to slide within each other.

[0039] The second 10' I-beam also features multiple sets of cutouts in its 12' end, spaced apart from each other. Therefore, when the two 10' and 10' profiles are slid to the desired length, they are held in a fixed position by self-tapping screws through their two supporting ends; the exposed, non-overlapping portions of the 12' and 12' ends then reveal, in the upper and lower parts of the resulting upright, the sets of cutouts which can thus be used for the passage of conduits.

Claims

1. Metal framework for a prefabricated drywall panel, the said metal framework comprising a metal profile (10) with a base (12) and two opposite flanges (14, 16) extending from said base (12) and facing each other, the opposite flanges being configured to respectively receive and support prefabricated panels. characterised in that said base (12) of said metal profile (10) has at least one set of four cut-outs (28, 30, 32, 34) each extending from a central point (36) and along four mean radii (R1, R2, R3, R4) that are successively perpendicular to each other, so as to be able to bend four tabs (44, 46, 48, 50) protruding from said base (12) around a duct passage opening (52); and in that each of said cut-outs (28, 30, 32, 34) has, starting from said central point (36) and along the corresponding mean radius (R1, R2, R3, R4), a small square recess (38) followed by a large square recess (40), with the diagonals of said square recesses (38, 40) being aligned with the corresponding mean radius.

2. Metal framework according to claim 1, characterised in that it further comprises another metal profile (10') having a different base (12') and two other opposite flanges (14', 16') extending from said other base (12') facing each other, with said profile (10) and said other profile (10') being configured to be mounted against one another.

3. Metal framework according to claim 2, characterised in that the other base (12') has at least one additional set of four cut-outs (28', 30', 32', 34') each extending from a different central point (36') and along four other mean radii (R1', R2', R3', R4'), to allow for the bending of four additional tabs (44', 46', 48', 50') protruding from the said other base (12') around another duct passage opening (52').

4. Metal framework according to any one of claims 1 to 3, characterised in that said opposite flanges (14, 16) are extended respectively by two extensions (18, 20) folded in opposite directions against said flanges (14, 16) to extend behind said base (12).

5. Metal framework according to claims 2 or 3 and 4, characterised in that said other opposite flanges (14', 16') are extended respectively by two other extensions (18', 20') folded in opposite directions against said other flanges (14', 16') to extend behind said other base (12').

6. Metal framework according to any one of claims 1 to 5, characterised in that the four small square recesses (38) together form a single central square recess (42) with the central point (36) at its centre.

7. Metal framework according to any one of claims 1 to 6, characterised in that the four mean radii (R1, R2, R3, R4) are essentially identical.

8. Metal framework according to any one of claims 1 to 7, characterised in that the said small square recesses (38) are substantially four times smaller than said large square recess (40).

9. Metal framework according to any one of claims 1 to 8, characterised in that the base (12; 12') of said metal profile (10; 10') has a plurality of sets of four cut-outs that are spaced apart from one another.

10. Method for assembling a metal framework for a prefabricated drywall panel, comprising the following steps: - a metal framework is provided according to any one of claims 1 to 9, the said metal framework comprising a metal profile (10) with a base (12) and two opposite flanges (14, 16) extending from said base (12) and facing each other, said opposite flanges being capable of respectively receiving and supporting prefabricated panels, the base (12) of said metal profile (10) having at least one set of four cut-outs (28, 30, 32, 34), each extending from a central point (36) and along four mean radii (R1, R2, R3, R4) that are successively perpendicular to one another, each of said cut-outs (28, 30, 32, 34) having, from said central point (36) and along the corresponding mean radius (R1, R2, R3, R4), a small square recess (38) followed by a large square recess (40), the diagonals of said square recesses (38, 40) being aligned with the corresponding mean radius; and, - the four tabs (44, 46, 48, 50) protruding from said base (12) are folded around a duct passage opening (52).

11. Assembly method according to claim 10, characterised in that a duct (62) is additionally provided and in that said duct (62) is driven in translation through said duct passage opening (52).

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