GB2350850A

GB2350850A - Bendable metal channel for securing studs for wall panels

Info

Publication number: GB2350850A
Application number: GB0020247A
Authority: GB
Inventors: Jonathan Cherry; Roy Humpage
Original assignee: BPB Ltd
Current assignee: BPB Ltd
Priority date: 2000-08-17
Filing date: 2000-08-17
Publication date: 2000-12-13
Anticipated expiration: 2020-08-17
Also published as: HUP0103351A2; EP1182304A2; US20020043040A1; ZA200106765B; EP1182304A3; GB2350850B; GB0020247D0; CA2354493A1

Abstract

A metal channel for securing to a floor or ceiling for retaining metal studding for partition walls comprises a central web 1 with retaining flange portions 2,3, along its opposite sides. The web is segmented by division along its length by slots 5, one of the flanges 2 being similarly divided by slots aligned with slots 5. Adjacent segments 9 of this flange 2 are connected together by expansible bridges 10, and optionally also by frangible bridges 12 (Fig 8, not shown). The other flange 3 has a flexure zone aligned with slots 5, e.g. in the form of perforations 11. The channel is formed straight but is easily bent by expansion of the expandible bridges 10, so that curved walls may be constructed.

Description

2350850 TITLE Metal Channel for Wall Panels

DESCRIPTION Field of the Invention

The invention relates to metal channels for positioning and retaining partition wall systems, and provides a novel channel member for use as a head or base channel for straight or curved partition wall systems.

Background Art

Partition panels for the creation of dividing walls in office and industrial premises has made it possible for architects to design buildings with completely open-plan interiors which can then be internally divided in virtually any format according to the working practices of the end user. Furthermore, the partition panels once installed can be modified or removed and replaced as a user's demands change or whenever the building is occupied by another user with different requirements.

Typically the partition systems comprise double-skinned wall panels which are supported at the sides by metal studding and above and below in metal channels. One metal channel, the base channel, is secured fast to the internal f loor of the building, and another metal channel, the head channel, is secured to the ceiling vertically above the first channel. Vertical metal stud rails are then f itted between the head and base channels, and partition wall panels are then secured to the studs and form the partition extending between the head and base channels. It should be' understood that in the context of such partition systems it is the mounting channels and studding that are essentially metal, and not the wall panels. The wall panels themselves may be made of metal, or from any other. wall-boarding material, such as plasterboard.

The construction of the head and base channels is perfectly simple for straight wall sections. The channels are generally U-shaped, with a central longitudinal web from opposite edges of which are formed upstanding or depending flanges. The central web is secured to the floor or ceiling, and the wall panels held in place between the two flanges.

A more labour- intensive system of assembly is needed for the construction of curved walls. Typically curved timber head and sole plates are prepared, cut to the precise radius of the intended curve. The sole and head plates are first secured to the floor and ceiling of the interior of the building that is to be partitioned and then the vertical metal stud rails are secured directly to the head and sole plates. There are no continuous metal head and base channels extending around the curve of the head and sole plates. The process is labour- intensive, and there is a need for a simpler and cheaper method for the positioning and anchorage of curved partition walls.

It is an object of the invention to provide a channel system for such a simpler and cheaper anchorage system, which can be used for either straight or curved partition wall anchorage.

THE INVENTION The invention provides a metal channel for the positioning and retention of metal studding and wall panels to form straight, angled or curved partition walls, comprising a straight longitudinal web for anchorage to a floor or ceiling of a building and first and second flange portions upstanding or depending (as appropriate to floor or ceiling mounting respectively) from opposite longitudinal edges of the web for abutting opposite sides of metal studding supporting a partition wall panel, characterized in that the web is divided along its length into discrete segments spaced each from the next by a transverse slot, and the first flange portion on one side of the web is similarly divided along its length into discrete segments spaced each from the next by a transverse slot, with each pair of adjacent segments being connected together by an expansible bridge of metal, and the second flange portion on the other side of the web has a flexure zone aligned with the transverse slots in the web and in the f irst f lange portion, so that bending the channel around any of the flexure zones causes widening of the associated transverse slots in the web and in the first flange portion, with associated expansion of the bridge of metal across the widened transverse slot in the first flange portion.

The expansible bridge of metal may be created by a suitable pattern of stamping apertures in the sheet metal from which the channel is formed, before bending it into channel section. For example a plurality of slots stamped out of the metal of the first flange portion, each having a length slightly less than the height of the first flange portion and each overlapping appreciably in transverse extent and location from the immediately adjacent slot or slots can leave a sinusoidal bridae of metal connecting together the segments of the flange on opposite sides of the bridge. Or the bridge may have the form of a circular or oval or rectangular or diamond-shaped annulus of metal connected at opposite sides to the adjacent segments, and capable of distortion as the segments are moved apart.

The expansible bridges preferably have a modulus of expansion which increases with increasing expansion. Such a modulus ensures that if a length of channel is bent into a curve, each bridge will expand by approximately the same amount so that the curve naturally conforms, approximately, to the arc of a circle. It will be understood of course that the actual shape will be a series of interconnected straight channel sections, but it has been found that the overall shape is visually indistinguishable from a true circle if the transverse slots and bridges in the web and first flange are about 75mm apart.

Advantageously the expansible bridges have a limit of expansion which defines the radius of the smallest curve to which the associated metal wall partition panels can conform.- For example with all bridges expanded to their ultimate limit the channel could desirable have a Goomm radius.

The flexure zone in the second flange portion could simply be a straight and unperforated transverse portion of the second flange portion aligned with the slots in the web and first flange portion. Advantageously however a line of weakness across the second flange portion defines each flexure zone. For example a line of perforations across the height of the second flange portion would define a clear and accurate flexure line. Such a line of perforations would also create a clear guide for cutting the channel to length in situ.

In one modification of the invention the segments of the first flange portion may be temporarily attached to one another at, or near, their edges distal to the web by frangible bridges of metal. Such a channel would retain its straight configuration until the frangible bridges were severed, for example by a hacksaw or other cutting tool. Such a channel could be used as supplied for straight partition walls. For curved walls a number of the frangible bridges could be severed corresponding to the length of the arc of the curve, and the resulting wall would then run smoothly from straight to curved and again to straight. or for a single obtuse angle in the wall, only one of the frangible bridges would be cut.

For curved walls, always the first flange portion of the channel, with its expansible bridges, lies on the outside of the curve. A sinusoidal wall can therefore be created by securing to the floor and ceiling of the building lengths of channel in end-to-end abutment, each length being inverted relative to the next so that the expansible bridges always lie on the outside of the curve. if sinusoidal walls form a significant use of the channel, however, it may be desirable to form identical slots and expansible bridges in both flange portions, preferably both accompanied by the frangible bridges described above. Cutting the frangible bridges on one flange portion therefore permits the expansion of the expansible bridges on that flange portion, permitting that flange portion to lie on the outside of the curved wall, while the associated expansible bridges and uncut frangible bridges on the other flange portion define the flexure zones and permit that other flange portion to lie on the inside of the curved wall. By a judicious pattern of severing the frangible bridges along the length of the channel the functions of first and second flange portions can thus alternate along the channel to create from a single channel length a support for a sinuous wall.

DRAWINGS Figure 1 is a perspective view of a short length of a first embodiment of a channel according to the invention; Figure 2 is a plan view of the channel of Figure 1, with the flange portions beneath the plane of the paper; Figure 3 is a side elevation of the first flange portion of the channel of Figure 1; Figure 4 is a side elevation of a second f lange portion of the channel of Figure 1; Figure 5 is a transverse section through the channel of Figure 1; Figure 6 is a side elevation of an expansible bridge formation of a second embodiment of a channel according to the invention; Figure 7 is a side elevation of an expansible bridge formation of a third embodiment of a channel according to the invention; and Figure 8 is a side elevation of an expansible bridge formation and associated frangible bridge of a fourth embodiment of a channel according to the invention.

Referring first to Figures 1 to 5, a channel according to the invention is illustrated in an orientation suitable for floor fixing, to create the base channel locating and retaining metal studding to support a partition wall. The same channel section can be inverted to form the head channel for the same wall. The channel comprises a central web 1 bounded on its opposite sides by first and second f lange portions 2 and 3. The web 1 is divided into discrete segments 4 longitudinally of the channel by transverse slots 5 spaced apart by equal distances of 75mm. The web 1 is longitudinally profiled (see Figures 1 and 5) for added rigidity, and has preformed holes 6 for fastening the channel to the floor or ceiling of a building.

The first flange portion 2 is similarly divided into discrete segments by transverse slots 7 aligned with the slots 5, the significant difference between the slots 5 and 7 being that the slots 7 do not extend completely through the first flange portion 2 whereas the slots 5 do extend completely through the web 1. The slots 7 leave two short anchorage portions 8 of the first flange portion 2 connecting adjacent segments 9 of the first flange portion 2 to an expansible metal bridge 10. The expansible bridge 10 is in the form of an oval-shaped annulus of metal joined to the segments 9 by the anchorage portions 8 across its short axis. Expansion of the bridge, as described below, causes extension of that short axis and defornation of the oval annulus until ultimately the oval is reformed with its long axis connecting together the anchorage porzions 8.

The second flange portion 3 has a line of perforations 11 defining a flexure line or flexure zone aligned with each of the slots 5 and 7.

The channel is formed by first punching the -appropriate apertures from a straight strip of metal and then forming the metal into the channel shape shown.

The metal of the channel is preferably made by the ULTRASTEEL (Trade Mark) process which is a process protected by, inter alia, Patents GB-B- 2063735 and GB-B-2095595 in the name of Hadley Industries p1c.

In use, the channel may be kept straight as it is secured to the floor and ceiling, and used to position and retain metal studding and partition panels to form straight walls. or it may be bent into curves, each bending being accompanied by flexure of the second flange portions 3 along the flexure zones and expansion of the expansible bridges 10 as the slots 5 and 7 widen.

Figure 6 shows another possible shape for the expansible metal bridge 10. Figure 7 shows a further possible shape, illustrating how the adjacent segments 9 of the first flange portion 2 may be connected together by more than one expansible bridge 10.

Figure 8 illustrates how a temporary and frangible bridge 12 may be left in the manufacturing process, connecting together the adjacent segments 9 of the first flange portion 2 at its end remote from the web 1. If the frangible bridges 12 are left intact, the channel is straight and can be used for the positioning and retention of straight walls where the majority of partition walls are expected to be straight. Whenever a curved wall section is desired, however, the frangible bridges 12 can be severed by a hacksaw or by tinsnips, and the channel -a- formed into an appropriate cu--ve. The slot 7, frangible bridge 12 and expansible bridge 10 formation of Figure 8 can advantageously be repeated on the second flange portion 3 to create the flexure zones of the second flance portion, so that the functions of first flange portion (supporting the outer curve of a curved wall) and the second flange portion (supporting the inner curve) can alternate along the length of the channel to support an undulating wall.

Claims

1. A metal channel for the positioning and retention of metal studding and wall panels to form straight, angled or curved partition walls, comprising a straight longitudinal web for anchorage to a floor or ceiling of a building and first and second flange portions upstanding or depending (as appropriate to floor or ceiling mounting respectively) from opposite longitudinal edges of the web for abutting opposite sides of metal studding for supporting a partition wall panel, characterized in that the web is divided along its length into discrete segments spaced each from the next by a transverse slot, and the first flange portion on one side of the web is similarly divided along its length into discrete segments spaced each from the next by a transverse slot, with each pair of adjacent segments being connected together by an expansible bridge of metal, and the second flange portion on the other side of the web has a flexure zone aligned with the transverse slots in the web and in the f irst f lange portion, so that bending the channel around any of the f lexure zones causes widening of the associated transverse slots in the web and in the first flange portion, with associated expansion of the bridge of metal across the widened transverse slot in the first flange portion.

2. A channel according to claim 1, wherein the expansible bridges of metal are formed by a suitable pattern of stamping apertures in the sheet metal from which the channel is formed, before bending the sheet into a channel section.

3. A channel according to claim I or claim 2, wherein the expansible bridges have a modulus of expansion which increases with increasing expansion.

4. A channel according to any preceding claim, wherein the expansible bridges have a limit of expansion which defines the radius of the smallest curve to which the associated metal wall partition panels can conform.

5. A channel according to any preceding claim, wherein adjacent segments of the first flange portion are attached to one another at or near their edges distal to the web by frangible bridges of metal.

6. A channel according to any preceding claim, wherein each flexure zone is defined by a line of perforations through the second flange portion.

7. A channel according to claim 6, wherein each flexure zone is defined by a transverse slot dividing the second flange portion into adjacent segments, the segments being attached to one another at or near their edges distal to the web by frangible bridges of metal and at intermediate portions by an expansible bridge of metal.

8. A metal channel for the positioning and retention of straight, angled or curved partition wall panels, substantially as described herein with reference to the drawings.