BACKGROUND TO THE INVENTION In conventional timber framing, nails are the preferred fastening means for joints between stud and plate members. Such a fastening means must be introduced at the specific locations of studs relative to the plate.

Manufacturing systems for fabricating timber wall frames have typically revolved around either the wall plates or the fastener delivery system moving relative to the other, stopping at each specific stud location, installing the fastening means then moving to position the next stud location and so on. The location system of fixing studs into wall frames is linked to positioning plates relative to a known datum. Management of plate position by encoders or pulse generators, or by notching or marking stud locations on the plate is the conventional means for manufacturing wall frames. Therefore the controlling systems are referenced to a fixed means of forming the connections, which is typically nail guns fixed at top and bottom of the frame. In these systems the plates are cut to length. These systems have a fabrication rate that is dependant upon the number and frequency of studs in the frame such that the closer the stud spacing the slower the production rate, and the other controlling influence is the speed by which the plates are indexed to the next fastening position. To affect all joints in one wall panel at the same time multiple fastener delivery systems would need to be individually aligned with each stud. This process would have a high capital cost, since as many as 22 fastener delivery systems would be required for a 6m wall panel, and would not significantly improve the fabrication rate due to the requirement to align each fastener delivery system to each stud.

OBJECT OF THE INVENTION It is an object of the present invention to provide a framing system including the types of components used and the method of their assembly, which substantially overcomes or ameliorates the disadvantages with known systems. At the very least the object of the present invention is to provide an alternative to known systems.

DISCLOSURE OF THE INVENTION The typical embodiment of the cold-formed steel sections of the wall framing form of this invention are unlipped or lipped Nominal Cee section studs of 70 x 30 mm and 90 x 30 mm with longitudinally recessed web portions, longitudinally web stiffened, or locally recessed at each end, of the web elements, in gauges ranging from 0.35 to 4.0 mm and the typical embodiment of the structural plate members are 70 x 35 mm and 90 x 35 mm, typically timber, however this by no means limits the ability of these structural members to

perform in a similar way in other sizes, section geometry and/or materials or in other applications aside from wall framing.

Some examples of other applications of this invention apart from wall framing are framing systems such as beds, fences, balustrades, pergolas, shelving, pallets, furniture, cupboards, partitioning, site fencing. Broadly, the scope of this invention is concerned with joints between one or a plurality of members, one end or both ends of which butt into another or other members, and which can be effected by pressing together in a direc- tion substantially perpendicular to the former member or members.

The present invention provides framework connections which are formed by forming one or a plurality of tags or spikes which can have gripping deformations such as barbs, serrations, knurls, raised annular threads and the like in one or both ends of a framing member.

In the preferred form of a wall frame, said spikes are in each end of the web element of a channel or lipped channel stud member. In the case of a lipped channel member there can also be such a tag or spike in the lip elements. In one preferred form of the present invention the spikes are formed integral with the longitudinal web stiffeners or stiffener, where the web element and stiffener remain substantially in the form of a conventional cee shape. In another preferred form, a web portion is recessed towards the ends of the flanges so that the bends in the recess are used to form the spikes. The recessed web portion in this embodiment extends the length of the stud member. In another form the recessed web portion is locally formed or pressed into the web adjacent the ends of the member. In all these examples, the spikes are stiffened by the deformation in the web element. In an embodiment where the spikes are in an offset web element, joints at the ends of wall frame plates and at door openings can be made without reversing the orientation of the stud.

The fastening means used to secure the joints of the present invention are integral to the stud member and as such no external fastening means is required. The tags or spikes have forms or features that provide integrity of the tag or spike during insertion into timber, allow resistance against withdrawal from the timber fibres and lateral restraint of the stud out of plane of the wall frame. The profile and form of the tag or spike can be any form that is functional within the context of this invention.

The web material between and/or adjacent to the formed tags or spikes is preferably folded at substantially right angles to the web element of the stud member to provide improved bearing capacity of the stud against the plate.

It is within the scope of this invention to have joints formed between plate members specially formed by longitudinally milling, routering or the like to suit specific forms of abutting stud members, but also having tags or spikes as disclosed herein.

It is also within the scope of this invention to have any form of stud with protruding fastening means, whether integral or introduced. For example, nails installed through timber studs such that they protrude through the ends, thus allowing a plate member to be pressed onto the stud or a purpose made connector plate, nail plate

or knuckle plate used in a way to cause a connection to be made between the stud and the plate by pressing in a direction substantially parallel to the axis of the stud.

It is further within the scope of this invention to use any other suitable material forms such as plastic, foam and the like in the place of timber where mentioned and any other suitable material forms in the place of steel where mentioned.

In another form of the invention, there is disclosed a single slot formed in a plate web element that is offset from its base web elements such that a tongue formed within a mating stud member causes a nominal joint to be made. The base web elements abut the end of the mating stud member with the slot being formed substantially perpendicular to the longitudinal axis of the plate member. There is also a preferable feature of a plurality of slots and/or offset web elements and corresponding stud tongues and to have other integral means of locking via barbs, tangs and the like formed at the edges or in the face of the tongue, singly or in plurality.

In another form, a formed bearing plate with pre-punched holes can provide location for installation of fasteners.

BRIEF DESCRIPTION OF THE DRAWINGS The preferred embodiments of the present invention will now be described with reference to the drawings in which: Fig. I is a perspective view of the end of a stud member of a preferred form of the present invention showing the spikes formed at the corners of the offset web portion ; Fig. 2 is an exploded perspective view of a stud and plate member joint of a preferred form; Fig. 3 is a perspective view of the end of a stud member of another preferred form; Fig. 4 is a perspective view of the end of a bed slat member of a preferred form; Fig. 5 is a perspective view of the end of a shelf of a preferred form; Fig. 6 is an elevation view of another form of the present invention, being fencing; Fig. 7 is a perspective view of a nail plate of a preferred form; Fig. 8 is a perspective view of a nail plate of another preferred form; Fig. 9 is a perspective view of the end of a stud member of another preferred form showing the spike formed from longitudinal stiffeners ;

Fig. 10 is a perspective view of a stud member to plate member joint of a preferred form showing a formed bearing plate and installed fastening means; Fig. I 1 is a longitudinal sectional view of Fig. 10 showing the profile of the formed bearing plate and installed fastening means ; Fig. 12 is a perspective view of a stud member to plate member joint of another preferred form, showing the flanges of the stud member overlapping the sides of the plate member ; Fig. 13 is a perspective view of a stud member of a preferred form with depressed slits in the flanges ; Fig. 14 is a transverse cross section view of the flange of Fig. 13; Fig. 15 is a perspective view of the end of the stud member of the preferred form; Fig. 16 is an end view of the tag or spike of Fig. 15 ; Fig. 17 is a perspective view of the end of a stud of the preferred form with timber blocking inserted; Fig. 18 is a perspective view of a stud to plate member joint of a preferred form showing the tags or spikes embedded into the timber; Fig. 19 is a perspective view of the stud and plate member of a preferred form; Fig. 20 is an end view of the stud to plate member joint of the preferred form of Fig. 19 ; Fig. 21 is a detail view of adjacent studs of a preferred form in a wall frame with nogging members of a preferred form across them; Fig. 22 is an end view of the stud of Fig. 21 showing the connection of the nogging member ; Fig. 23 is a plan view of a semi-automated fabrication plant of a preferred; Fig. 24 is a plan view of a preferred form of the manufacturing ; and Fig. 25 is a perspective detail view showing a mechanical triggering system for a fastener delivery system of Fig. 24 ; Fig. 26 is a perspective view of a preferred embodiment of a stud showing a formed tongue; Fig. 27 is a section view of the stud member of Fig. 26 showing the preferred opposing deformation ofthe edges of the tongue ;

Fig. 28 is a perspective view of a joint of a preferred form with the stud tongue folded out and hold-down fastening device installed through the tongue and offset web ; Fig. 29 is a perspective view of a stud member with another preferred form of the tongue ; Fig. 30 is a perspective view of a stud member with another preferred form of the tongue ; and Fig. 31 is an exploded perspective view of a joint of another preferred form showing a slot in an offset web element and sides thereof. and notched end of the mating stud member.

BEST MODE OF CARRYING OUT THE INVENTION A stud member 11 of a preferred form of the present invention as seen in Figs. I and 2 is adapted to be fixed to a timber plate member 12. The stud member 11 has a lipped Cee section profile with a web element 13 having an offset portion 13a and non-offset portions 13b, flange elements 14 with lip stiffeners 15. The ends of the stud member 11 of this preferred form have formed tags or spikes 16. In this embodiment there are two spikes 16 formed in the corners of the offset web element 13 and one formed in each lip stiffener 15. The material adjacent to or between the tags or spikes 16 is formed into bearing plates 17 to improve the bearing capacity of the stud member 11 against the timber plate member 12.

The tags or spikes 16 have barbs 18 that lock into the fibres of the timber plate member 12 to improve the withdrawal capacity of the stud member 11 from the plate member 12. The spikes 16 formed at the corners of the offset web element 13 allow the stud 11 to be joined to the end of a plate 12 with the non-offset web portions 13b flush with the end of the plate member 12. such as for ends of wall panels or at doorways.

In another form of the present invention, as seen in Fig. 3, the offset web portion 13a of the stud member 11 is formed at the ends of the stud member 11, not along its entire length. This embossed or pressed end 19 is shown in figure 3 and is preferably formed by pressing or stamping in the same action of forming the spikes 16. In this form, a joint at the end of a plate member 12 can be made so that the web element 13 of the stud 11 is flush with the end of the plate 22 along the major part of its length.

Other types of framing system or joints using this method are within the scope of the present invention. A few examples are given in Figs. 4 to 7 which how an application of this technology to bed frame slats 20, shelves 21, posts or palings 22 which have spikes 16 which may or may not have barbs 18.

Figs. 7 and 8 show connector plates of preferred forms which are employed to fix studs (or slats, shelves, palings, etc depending on the type of frame) of similar material form to the plate members, preferably timber. using the same single action to complete the frame. In Fig. 7 a connector plate 23 is shown that is formed from a flat sheet of steel 20. Tangs or spikes 24 are formed so as to act through the plate 23 in one direction and tangs 25 formed so as to act in the opposite direction. In this way, when the connector plate 23 is inserted between abutting frame members and pressed together, the connections between the nail connector plate 23 and both members to form the frame joint are made in the same action. Fig. 8 shows a connector

plate 26 having spikes 16 with barbs 18, with some formed upward from the plate 26 and some formed downward from the plate 26 Another preferred form of the stud member 11 is illustrated in Fig. 9, which shows a lipped Cee-section profile with web 13, flanges 14 which have lip stiffeners 15 and longitudinal web stiffeners 27. The spikes 16 with the barbs 18 are formed from the web stiffeners 27 to provide rigidity to the spikes 16.

A stud member 31 of another preferred form of the present invention for joining to a plate member 32, is illustrated in Figs. 10 to 14 and has a lipped Cee section profile with web element 33 that has stiffeners 34. and flange elements 35 with lip stiffeners 36. The ends of the stud member of the preferred form have a formed bearing plate 37 with web recess 38. Stiffeners 39 in the recess 38 continue through the corner into the formed bearing plate 37. The end of the formed bearing plate 37 is flush with the flange elements 35 of the stud member 31 to allow it to be joined to the end of a plate member 32, such as for ends of wall panels or at doorways.

The formed bearing plate 37 has pre-punched holes 40 that provide location for installation of fasteners 41.

In another preferred form of the present invention the flange elements 35 of the stud member 31 extend over the sides of the plate member 32 to form side plates 42 respectively, which in turn have pre-punched holes 40 for location of fasteners 41.

The flange elements 35 of the stud member 41 of another variation of this embodiment has a plurality of depressed slits 43 formed partially across the width of the flange 35, but preferably close to the bend at the web element 33 to facilitate installation of fasteners or clips, as seen in Figs. 13 and 14.

A stud member 51 of another preferred form of the present invention for joining to a plate member 52, is illustrated in Figs. 15 to 18 and has a lipped Cee section profile with web element 53, flange elements 54 with lip stiffeners 55. The ends of the stud member 51 of have a plurality of formed tags or spikes 56. In this embodiment there are three formed in the web element 53 and one formed in each lip stiffener 55. The material adjacent to or between the tags or spikes 56 is formed into bearing plates 57 to improve the bearing capacity of the stud member 51 against the timber plate member 52. The tags or spikes 56 have barbs 58 that lock into the fibres of the timber plate member to improve the withdrawal capacity of the stud member from the plate member 52.

A stud member 61 of another preferred form of the present invention for joining to a plate member 62, is illustrated in Figs. 19 and 20. The stud member 61 of this form has notched flanges 63 and the remaining web element 64 that protrudes is folded into a base plate 65 that abuts the trench 66 formed transversely in the mating plate member 62, as is conventional practice in timber framing. The folded base plate 65 can be stiffened by ribs 67 that are formed around the bend into the web element 64 of the stud member 61. The folded base plate 65 also preferably has an edge stiffener 68 at its extremity. The stiffeners 68 serve to improve the bearing capacity of the stud member 61 against the plate member 62 and provide integrity of the steel material during installation of fasteners 69, which is preferably nailing, as shown in Fig. 20. The plate

member 62 can in other forms have formed profiles whereby the folded base plate 65 corresponds to any profile, such as arcuate etc.

A nogging member 71 of the preferred form as seen in Figs. 21 to 23 is formed from sheet steel into a typical angle section with preferably one long leg 72 and one short leg 73. Stiffeners 74 are formed in the legs 72 and 73 and are continuous around the bend 75 to maximise the rigidity of the section. In the preferred form the ends of the nogging member 71 are flat.

The nogging members 71 are showed installed on studs 76 of a frame of the preferred form of the present invention, with the short leg 73 against either the web 77 or the lips 78 (and can be nested or locked in with the lip 78 by appropriate means) of the stud members 76 and the long leg 72 on the top surface of the frame defined by the flange 79. Adjacent noggings 71 are staggered, but can be lapped. A fastener 80, preferably a nail is installed through the long leg 72 of the nogging member 71 such that it is supported by a recessed web portion 81 of the stud member 76. This arrangement is not dependent upon the spacing of the studs 76 in the frame, with the length of the long leg 72 of the nogging member 71 being nominally the largest stud spacing plus the width of the stud member 76.

A wall fabrication plant 82 as seen in Fig. 23 principally has an assembly table 83 and frame press 84. The assembly table 83 has an operator controlled variable speed feed with studs placed in position by an operator 84. Cut to length plate members at 85 can be placed in position by either the operator 84 or an automatic feed mechanism. Alternatively, a continuous plate feed can be used with cutting process after the feed table 83.

The studs 76 are taken from a pack 86 located in front of the operator on a roller bed 87. When the pack 86 is empty, or when different studs are required, another pack is pushed in from the side. The assembly table 83 moves along sliders 88 and studs 76 are positioned visually over strips 89 of diodes or similar devices that are lit certain colours to indicate the location, type and orientation of the stud. Squareness of the studs is maintained by the stud locator guides 90 which move independently of the assembly table has a variable speed feed with studs placed in position by an operator. Cut to length plate members can be placed in position by either the operator or an automatic feed mechanism. In the frame press 83, hydraulic rams 98 push the timber plates 99 onto the studs 76 to produce a wall panel.

In another embodiment as illustrated in Figs. 24 and 25, stud members 91 are clamped between plate members 92 by spring loaded and driven rollers 93 located before and after a fastener installation system 94.

A wall frame assembly 95 moves continuously in the direction of the arrow. As the stud members 91 reach the fastener installation system, they come into contact with flag 96 of arm 97 of a mechanical triggering system that activates the fastener installation system 94 affecting the joint between stud 91 and plate 92. The foregoing description applies to both top and bottom of the frame assembly. The triggering device is shown as a mechanical system but it is within the scope of the present invention to have any other system that can trigger the fastener installation means, examples of which might be motion detection, light sensitive or laser systems.

The wall frame members are timber in this representation and the fastener installation system, nail guns, are oriented in a conventional manner for timber frame fabrication. It is within the scope of this invention to employ framing members of other material forms such as cold formed steel, and any combinations thereof, and other orientations and types of fastener installation systems that are applicable to such framing systems.

Other forms of the invention are illustrated with respect to Figs. 26 to 31 of the drawings where joints of a partially illustrated framework system 110 are illustrated. The framework system generally referenced as 110 includes studs 111 and mating plates 112 in nominal joints 113 and high strength joints 114. The studs I I I are formed as a lipped Cee-section with a web 115 and two lipped flanges 116. The plates 112 are formed as a double U section with a web 117 and two flanges 118, the web 117 having a centrally located offset element l l 9 and two spaced apart base elements 120 adjacent the flanges 118. The offset element 119 has a rectangular profile and corresponds and mates with a cutout portion 121 in the web 115 at ends 122 of the studs 111 when the ends 122 of the studs 111 abut against the plates 112 in the perpendicular manner shown in the drawings.

Each stud I I I has a tongue 123 protruding into the cutout portion 121 while the plates 112 have a number of slots 124 located in the offset element 119 of the web 117. To form the nominal joints 113, the tongue 123 is fitted through one of the slots 124 such that the ends 122 of the studs 111 abut against webs 117 of the plates 112 with the flanges 116 and 118 also abutting. It is seen that the studs 111 nest in the plates 112 when the tongues 123 are inserted into the slots 124 as the distance G across the cutout portion 121 is substantially the same as the distance H across the offset element 119, while the length I of the tongue 123 is less than the depth J of the offset element 119.

The tongues 121 of this embodiment have deformed edges 125 which lock under the offset web element 119 after insertion through the slots 124. The deformed edges 125 are flexible and are preferably offset such that they deform either side of the slot 124 when inserted to form the nominai joints.

To form the high strength joints 114, the deformed edges 125 are bent further under the offset element 119 by a suitable hand tool (not illustrated).

Hold-down of the stud 112 into concrete, timber or the like as shown in Fig. 28 can be effected with masonry anchors 126 through holes 127 in the tongues 123 whereby the tongues 123 are bent at right angles to abut against the offset element 119. This method of hold-down can be applied to all forms.

In the embodiment illustrated in Fig. 29, which is basically the same as described with respect to Figs. 26 to 28, the tongue 123 formed in the cutout portion 121 which in this embodiment is non-rectangular, has a pair of barbs 128 which lock into side slots 129 formed in the sides 130 of the offset element 119 of the web 117 of the plate 112. In this embodiment the slot 124 extends into the sides 130 and the slots 129 are formed lower in the sides 130. In forming the nominal joint 113, the tongue 123 is inserted through the slot 124 and the barbs 128 then fit through and lock behind the slots 129.

Similarly, in the embodiment illustrated in Fig. 30, which is similar to the other embodiments, the slot 124 is deformed and barbs 128 on the tongue 123 interact to form the locking mechanism. Once again the nominal joints 113 and high strength joints 114 are formed in a similar manner to the other embodiments.

In the embodiment shown in Fig. 31, the slot 124 extends around the offset element 119 and the tongue 123 which are inserted therethrough consist of a pair of tongues extending from the side of the cutout portion 121 which in this embodiment is seen to take the form of a T-shaped slot. The pair of tongues are the deformed edges 125 which lock under the offset element 119. To form the nominal joint 113 of this form the tongues or tags 23 are inserted into the slot 124 in the offset web element 119 of the mating plate 112. The deformed edges 125 of the tags 123 lock under the offset web element 119 of the plate 112. To form a high strength joint 114 of this form, the deformed edges 125 of the tags 123 are bent around further under the offset web element 119 by suitable means and can be folded flat against the sides of the offset web portion. This description applies to each end of the stud member in a framework. The maximum depth of the tags 123 corresponds to the depth of the offset web element 119 of the plate 112.

The foregoing describes only some embodiments of the present invention, and modifications obvious to those skilled in the art can be made thereto without departing from the scope of the present invention.