Wall stud

Abstract

A cross-shape wall stud (10) made from first and second stud members (12, 14), which are releasably secured to one another. The cross-shape stud has longitudinally- extending contact surfaces (20, 22, 24, 26) for receiving a wall construction board to be secured thereto in use. The contact surfaces include a first primary contact surface (20) at an extremity of the cross-shape, a second primary contact surface (22) at an opposing extremity of the cross-shape, and first and second secondary contact surfaces (24, 26) located either side of and recessed from the or each first and second primary contact surface (20, 22).

Description

[0001] WALL STUD

[0002] This invention relates to a stud for use in constructing a wall and to a wall assembly including at least two such studs.

[0003] It is known to construct a wall by building a frame using wooden or metal studs (uprights) which are secured to the floor and ceiling. The studs are often positioned in a U-shaped track along the floor and / or ceiling to ensure the studs are positioned in line with one another along the wall plane. The frame is then covered with plasterboard which is secured to the studs so as to create a wall. Insulation is also normally placed between studs with the plasterboard fitted over the insulation.

[0004] According to a first aspect of the invention there is provided a stud for use in constructing a wall, the stud comprising: first and second longitudinally extruded stud members each having mutually engageable attachment formations configured to releasably secure the first and second stud members to one another, engagement of the first and second stud members creating a cross-shape cross-sectional profile stud, the cross-shape stud having longitudinally-extending contact surfaces for receiving a wall construction board to be secured thereto in use, the contact surfaces including a first primary contact surface at an extremity of the cross-shape, and first and second secondary contact surfaces located either side of and recessed from the first primary contact surface.

[0005] Such an arrangement of stud means that the acoustic and fire performance of the wall in which it is situated is improved without the need for the wall thickness to be increased. This is because the stud is made from two extruded stud members which are secured to one another, thus resulting in a hollow stud into which insulation material could be placed. This could remove the need for resilient bars in certain situations.

[0006] The stud members being releasably secured to one another means that they are easily stored and transported onto site, and then easily assembled and disassembled when needed.

[0007] The cross-shape cross-sectional profile of the stud provides the primary contact surface for securing a wall construction board (such as plasterboard) thereto, and additionally secondary contact surfaces which further wall construction boards can be secured. The further wall construction boards could be plasterboard, which increases the sound and fire rating of the wall, or they could be wooden or ply pattresses which are required between studs in certain circumstances. Therefore, further wall construction boards can be added to the stud without the need for additional components such as brackets or lengths of angle linear grooves within wooden pattresses. Not only does this reduce the number of components needed (thus reducing cost and complexity), it also makes wall construction quicker.

[0008] The cross-shape of the stud also increases the stability of the stud because it is geometrically stable due to the shape and will reduce the risk of the stud twisting under pressure.

[0009] It will be understood that "wall construction board" could be any type of board or member that would be used when constructing a wall, such as plasterboard, ply / wooden pattress, letter box or other transom, a baffle box, acoustic socket box or an access hatch. It will also be understood that plasterboard may also be referred to as gypsum or drywall. It will be understood that in the context of this application, a pattress is a board (typically plywood or timber) which is fixed within a wall to which equipment can be secured, such as ceiling roses, power outlets, etc.

[0010] Preferably, at least one of the first and second stud members is configured to resiliently deform to permit securing of the mutually engageable attachment formations.

[0011] Such an arrangement means that the or each stud member can be pressed or pulled so as to change shape and allow securing of the stud members to one another, without permanently deforming the shape of the stud member. It will be understood that the resiliently deformable nature means that the stud member (or portion thereof that is deformable) springs back to its original shape when the deforming pressure being exerted is stopped.

[0012] Optionally, the or each first and second stud member is configured to resiliently deform inwards to permit engagement of the mutually engageable attachment formations.

[0013] By being able to resiliently deform inwards, the or each stud member can be deformed by a pinching or squeezing pressure exerted onto the stud member - which can readily be done by hand. The or each first and second stud member may include a longitudinally-extending resiliently deformable portion to permit engagement of the mutually engageable attachment formations.

[0014] Such an arrangement means that the resiliently deformable portion extends along the entire length of the or each stud member so that the resiliently deformable portion can be accessed anywhere along the length of the stud member.

[0015] Optionally, the resiliently deformable portion is located at a corresponding mutually engageable attachment formation.

[0016] Positioning the resiliently deformable portion at an attachment formation makes the joining of the stud members easier because the deforming and the securing is occurring at the same place on the stud member.

[0017] Preferably only one of the first and second stud members includes the resiliently deformable portion, the deformable portion being located at opposing extremities of the cross-shape.

[0018] Only one of the stud members having the resiliently deformable portion means that the structural integrity of the stud is maintained. Moreover, by locating a deformable portion at opposing extremities of the cross-shape means that the part of the crossshape which is not being used as a contact surface for a wall construction board is being utilised for another means. Moreover, in embodiments where the resiliently deformable portion is configured to deform inwards, the opposing position of the portions makes it easier for a user to pinch / squeeze the portions so as to achieve the necessary deformation.

[0019] Optionally the mutually engageable attachment formations include an arm portion and a channel portion, the arm portion being configured to be received by the channel portion.

[0020] Such an arrangement provides a robust and simple means of securing the stud members to one another.

[0021] The mutually engageable attachment formations may be longitudinally-extending attachment formations. Such an arrangement means that the attachment formations are available along the entire length of the stud members, thus making it easier to secure the stud members together and resulting in a robust attachment of the stud members.

[0022] Optionally the mutually engageable attachment formations are formed from the crosssection of the first and second stud members.

[0023] Therefore, the attachment formations are integral to the stud members. This results in fewer components needed in the stud.

[0024] The stud may further include a second primary contact surface located at an opposing extremity of the cross-shape to that of the first primary contact surface.

[0025] Such an arrangement provides another surface to which wall construction boards can be secured to form the other side of a wall.

[0026] Optionally, the first and second secondary contact surfaces are located either side of and recessed from each of the first and second primary contact surfaces.

[0027] Preferably the cross-section of the primary and secondary contact surfaces of the first stud member and the cross-section of the primary and secondary contact surfaces of the second stud member are symmetrical along a central axis of the cross-shape stud.

[0028] Such an arrangement provides ease of manufacturing (due to symmetrical nature) and ease of installation (due to the surfaces being sized and positioned the same).

[0029] According to a second aspect of the invention there is provided a wall assembly comprising: two studs as defined hereinabove wherein the first and second stud members of each stud are secured to one another to form the cross-shape cross-sectional profile stud, the studs being arranged in an upright position, and in-plane and spaced from one another so that the primary contact surfaces of each stud are facing perpendicular to said plane; a first wall construction board secured to the first primary contact surfaces of the studs, and a second wall construction board secured to adjacent secondary contact surfaces of the studs. Advantages in accordance with the first aspect of the invention apply mutatis mutandis to the second aspect of the invention.

[0030] Preferably, the distance between the primary contact surface and the secondary contact surfaces on the or each stud member is larger than the depth of the second wall construction board.

[0031] Such an arrangement means that a gap is created between the wall construction boards located on the primary and secondary contact surfaces, which can be useful for acoustic performance for example.

[0032] Optionally, the wall assembly further includes an insulation material located between the first and second wall construction boards.

[0033] Such an arrangement improves the fire and / or sound rating of the wall without increasing the wall thickness.

[0034] The wall assembly may further include an insulation material located in the hollow cavity created between the first and second stud members.

[0035] Such an arrangement improves the fire and / or sound rating of the wall without increasing the wall thickness.

[0036] A preferred embodiment of the invention will now be described, by way of a nonlimiting example, with reference to the accompanying drawings in which:

[0037] Figure 1 shows a stud according to a first embodiment of the invention;

[0038] Figure 2 shows a plan view of the cross-sectional profile of the stud shown in Figure 1;

[0039] Figure 3 shows a cross-sectional plan view of the stud in-situ in a wall construction; and

[0040] Figure 4 shows an enlarged view of the portion of the in-situ stud shown circled in Figure 3.

[0041] A stud according to the invention is shown in Figures 1 to 4 and is designated generally by reference numeral 10. The stud 10 includes first and second longitudinally extruded stud members 12, 14. Each of the first and second stud members 12, 14 includes mutually engageable attachment formations 16, 18 which secure the stud members 12, 14 to one another.

[0042] When the stud members 12, 14 are so secured, they create a stud 10 with a crossshape cross-sectional profile. The stud 10 therefore has a hollow cavity 13. The crossshape stud has longitudinally-extending contact surfaces, as explained in more detail below, which are for receiving wall construction boards to be secured thereto. In other words, the contact surfaces are substantially flat and have a sufficient area which permits securing (e.g. screwing) of a wall construction board to the surface. This is explained in more detail later in relation to Figures 3 and 4.

[0043] The cross-shape stud 10 includes a first primary contact surface 20 at an extremity of the cross-shape and a second primary contact surface 22 at an opposing extremity of the cross-shape. In other words, the primary contact surfaces 20, 22 are located at either end of what would be one of the intersection bars that make up a cross shape.

[0044] The cross-shape stud 10 also includes first and second secondary contact surfaces 24, 26 which are located at either side of and recessed from each of the first and second primary contact surfaces 20, 22. In other words, the cut out or rebated sections that are created by the cross shape define secondary contact surfaces 24, 26 at either side of each of the primary contact surfaces 20, 22. In other embodiments, there may only be one set of secondary contact surfaces (i.e. on only one side of the cross-shape stud 10).

[0045] In this embodiment, what would be the intersecting bars of the cross-shape cross each other at a central point so that the cross-shape is essentially symmetrical (i.e. it is a cross as opposed to a crucifix). In other embodiments, the cross shape may not be symmetrical.

[0046] Moreover, the primary and secondary contact surfaces on either side of the crossshape stud 10 are a mirror image of one another (i.e. they have the same dimensions) as can be more clearly seen in Figure 2.

[0047] As can also be seen more clearly in Figure 2, the attachment formations 16, 18 are located at the other opposing extremities of the cross-shape. In this way, the primary contact surfaces 20, 22 are located at opposing extremities of what would be a first intersecting bar of the cross shape, while the attachment formations 16, 18 are located at opposing extremities of what would be a second intersection bar of the cross shape.

[0048] In this embodiment, the attachment formations 16, 18 include an arm portion 16a and a channel portion 18a. The arm portion 16a is located within the channel portion 18a to secure the stud members 12, 14 together.

[0049] As can be seen in Figure 1, the arm and channel portions 16a, 18a extend along the length of the respective stud member 12, 14. Indeed, the arm and channel portions 16a, 18a are part of the cross-sectional extrusion of the stud members 12, 14. The arm and / or channel portions 16a, 18b may be formed from the extrusion itself and / or by bending part of the extrusion.

[0050] Although not shown in the figures, a push-over gasket may be secured over (and thus cover) the channel portion 18a when to the arm and channel portions 16a, 18a are secured to one another.

[0051] The cross-shape stud 10 further includes a resiliently deformable portion 25. In this embodiment, only the first stud member 12 includes a resiliently deformable portion 25 but in other embodiments both stud members may include such portions.

[0052] The first stud member 12 includes two resiliently deformable portions 25. The resiliently deformable portions 25 are located on the same opposing extremities of the cross-shape to that of the attachment formations 16, 18. Indeed, the resiliently deformable portion 25 on each side of the first stud member 12 extends into the arm portion 16a.

[0053] The resiliently deformable portions 25 are configured to be deformed inwards, i.e. towards the inside cavity 13 of the cross-shape stud 10. In this way, the resiliently deformably portions 25 are able to be pinched or squeezed in order to deform these portions 25 inwards. The resiliently deformable portions 25 are such that they are biased back to their original shape once the inwards force is ceased.

[0054] The resiliently deformable portions 25 in this embodiment are formed by a concave curved portion of stud which curves from the arm portion 16a to a spacer portion 27. The spacer portion 27 spaces the end of the curved deformable portion 25 from the corresponding secondary contact surface 24, 26. Returning to Figure 1, the stud 10 further includes one or more openings 28 formed through the or each stud member 12, 14. The openings 28 are configured to permit the passing of cables therethrough.

[0055] In this embodiment the cross-shape stud 10 is made from metal, in particular sheet metal. The stud 10 may be made from any other suitable material such as from plastics material.

[0056] The stud 10 is shown in-situ in a wall assembly 50 in Figures 3 and 4. There are three studs 10 shown in Figure 3 but it is understood at any number of studs 10 can be used depending on the size of the wall being constructed.

[0057] The wall assembly 50 includes first wall construction boards 52 that are secured, via screws 54, to the primary contact surfaces 20, 22 of adjacent studs 10. In this way, the first wall construction boards 52 are outward facing in the wall assembly 50. First wall construction boards 52 are secured side by side at a mid-way point on the primary contact surfaces 20, 22, as is common place in wall construction.

[0058] The wall assembly 50 further includes second wall construction boards 56 that are secured, via screws 54, to adjacent secondary contact surfaces 24, 26 of the studs 10. In this way, the second wall construction boards 56 are located behind the first wall construction boards 52 and are therefore hidden from view when the wall assembly 50 is constructed. The second wall construction boards 56 therefore sit in the cut outs (or rebates) formed by the cross-shape stud 10.

[0059] The first wall construction boards 52 are typically plasterboard since these are outward facing in the wall assembly 50. The second wall construction boards 56 may also be plasterboard or may instead be wooden or ply pattress board.

[0060] The distance between the primary contact surface 20, 22 and the secondary contact surface 24, 26 on each side of each stud member 12, 14 is larger than the depth of the second wall construction board 56. In this way, a gap 58 is created between the first and second construction boards 52, 56 (see Figure 4).

[0061] Although not shown in this embodiment, the wall assembly 50 may further include an insulation material located in the gap 58. Although also not shown, an insulation material may be included in the cavity 13 of the stud 10. In use, the resiliently deformable portions 25 are squeezed together (e.g. by hand) to allow the arm portions 16a of the first stud member 12 to be inserted into the channel portions 18a of the second stud member 14. The resiliently deformable portions 25 are then released and they spring back to their original shape to thus capture the arm portions 16a within the channel portions 18a - this secures the first and second stud members 12, 14 to one another.

[0062] The stud 10 is then positioned vertically as required for constructing a wall with the primary contact surfaces 20, 22 facing outwards to create a plan where the wall will be. Appropriate second wall construction boards 54 are then secured to the secondary contact surfaces 24, 26, followed by first wall construction boards 56 being secured to the primary contact surfaces 20, 22 (over the second wall construction boards 54) so as to create a wall assembly 50.

Claims

CLAIMS:

1. A stud for use in constructing a wall, the stud comprising: first and second longitudinally extruded stud members each having mutually engageable attachment formations configured to releasably secure the first and second stud members to one another, engagement of the first and second stud members creating a cross-shape cross-sectional profile stud, the cross-shape stud having longitudinally-extending contact surfaces for receiving a wall construction board to be secured thereto in use, the contact surfaces including a first primary contact surface at an extremity of the cross-shape, and first and second secondary contact surfaces located either side of and recessed from the first primary contact surface.

2. A stud according to Claim 1 wherein at least one of the first and second stud members is configured to resiliently deform to permit securing of the mutually engageable attachment formations.

3. A stud according to Claim 2 wherein the or each first and second stud member is configured to resiliently deform inwards to permit engagement of the mutually engageable attachment formations.

4. A stud according to Claim 2 or Claim 3 wherein the or each first and second stud member includes a longitudinally-extending resiliently deformable portion to permit engagement of the mutually engageable attachment formations.

5. A stud according to Claim 4 wherein the resiliently deformable portion is located at a corresponding mutually engageable attachment formation.

6. A stud according to Claim 4 or Claim 5 wherein only one of the first and second stud members includes the resiliently deformable portion, the deformable portion being located at opposing extremities of the cross-shape.

7. A stud according to any one of the preceding claims wherein the mutually engageable attachment formations include an arm portion and a channel portion, the arm portion being configured to be received by the channel portion.

8. A stud according to any one of the preceding claims wherein the mutually engageable attachment formations are longitudinally-extending attachment formations9. A stud according to any one of the preceding claims wherein the mutually engageable attachment formations are formed from the cross-section of the first and second stud members.

10. A stud according to any one of the preceding claims further including a second primary contact surface located at an opposing extremity of the cross-shape to that of the first primary contact surface.

11. A stud according to Claim 10 wherein the first and second secondary contact surfaces are located either side of and recessed from each of the first and second primary contact surfaces.

12. A stud according to Claim 11 wherein the cross-section of the primary and secondary contact surfaces of the first stud member and the cross-section of the primary and secondary contact surfaces of the second stud member are symmetrical along a central axis of the cross-shape stud.

13. A wall assembly comprising: two studs according to any preceding claim wherein the first and second stud members of each stud are secured to one another to form the cross-shape cross- sectional profile stud, the studs being arranged in an upright position, and in-plane and spaced from one another so that the primary contact surfaces of each stud are facing perpendicular to said plane; a first wall construction board secured to the first primary contact surfaces of the studs, and a second wall construction board secured to adjacent secondary contact surfaces of the studs.

14. A wall assembly according to Claim 13 wherein the distance between the primary contact surface and the secondary contact surfaces on the or each stud member is larger than the depth of the second wall construction board.

15. A wall assembly according to Claim 14 further including an insulation material located between the first and second wall construction boards.

16. A wall assembly according to any one of Claims 13 to 15 further including an insulation material located in the hollow cavity created between the first and second stud members.

17. A kit of parts comprising: two or more studs according to any one of Claims 1 to 12; and a plurality of wall construction boards.

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