Patent Application
20170138046
The present invention relates to a fastening system for attaching a structural element to a profile rail by means of a nailed joint, said fastening system comprising said profile rail, which comprises:
The present invention also relates to method for attaching a structural element to a profile rail by means of a nailed joint, comprising:
The present invention especially relates to a fastening system and a method for such a system for attaching a board-shaped structural element in the form of a building board or wall panel to a profile member by means of a nailed joint. For example, the building board or wall panel may be a building board of wood fibers, chips, OSB, plywood or fiber/gypsym. Alternatively, the building board or wall panel may be a magnesium oxide board, a silicate board or a plasterboard.
The present invention also especially relates to a fastening system and a method for such a system for attaching a first profile rail to a second profile rail by means of a nailed joint, e.g. for attaching a lying or horizontal profile rail to an upright or horizontal profile rail.
As used herein, profile rail refers to an elongated rail or member, usually of metal, e.g. steel, which is designed with a uniform cross-section along its length. The cross-section is usually C or U-shaped. Such profile rails are used e.g. for forming a truss structure or a framework in so-called lightweight construction, wherein said framework is subsequently covered with board-shaped structural elements (see also
When a structural element is attached to a profile rail by means of a nailed joint, the profile rail has to be dimensioned so that the nails of the joint hold in the profile rail. This means that there is a lower limit for how thin the material thickness of the profile rail can be designed. Accordingly, if the structural element is to be attached to the profile rail by means of a nailed joint, at least the flange portion facing toward the structural element has to be designed with a material thickness that is sufficient to allow the nails of the nailed joint to hold.
This is a problem, since it makes the continuous ambition to reduce the material consumption in profile rails more difficult.
An additional problem may arise when a first, vertical profile rail is to be attached to a horizontal profile rail to form a truss structure or a framework according to the foregoing. During such mounting, the stud is inserted into the rail so that the flange portions of the stud abut against the flange portions of the rail, whereupon a nail is driven through the respective flange portions of the rail and into the respective flange portions of the stud behind. When nailing in such a way, the flange portions of the stud run the risk of being folded inwards before the nail penetrates therethrough. Thereby, there a risk of unwanted gaps forming between the flange portions of the rail and the stud, which is not acceptable in load-bearing structures.
In document US2004159071, it has been attempted to solve this problem by placing a yoke on the nailing tool used when forming the nailed joints attaching the studs to the rails, wherein said yoke serves the function of maintaining the flange portions of the rails and the studs in contact with each other during the nailing. This solution, however, makes the nailing tool heavier and more bulky, which makes the work slower and puts more pressure on the installers. Furthermore, the yoke will be in the way if the tool is to be used for other nailing.
A further problem may arise when structural elements mounted on the framework are subjected to a dynamic load, e.g. a wind load. The vertical studs, which receive the load, are then pushed inwardly and tend to bend. The resulting load is then transferred by the nailed joints between the studs and rails. In each nailed joint, the force becomes a tensile force loading along the axial attachment of the nailed joint. Furthermore, this force increases if light-gauge studs are used, i.e. studs having a relatively thin material thickness, such as, for example, 0.7-1.5 mm, since the studs then also bend in shape, i.e. do not maintain their shape, which further increases the demand on the holding ability of the nailed joint.
To solve this problem, it has been attempted in the same document US2004159071 to develop nails or fastening devices which are supposed to increase the holding ability of the nailed joint in different ways. However, these design measures on the fastening devices are strongly limited by the fact that there is a risk of crack formation occurring in the flange portions of the studs when heavy-gauge fastening devices displacing a lot of material are used. Yet another problem is that the strength of the nailed joint is dependent on a combination of the friction of the surface of the fastening device and the buckling strength of the body of the nail, which are both jeopardized by the technologies described in the above document, which is why they may be regarded as suitable only for non-load-bearing structures.
In the Technical Handbook for Construction sheeting, Materials and Design (Teknikhandboken för byggnadsplåt, material och utförande (www.teknikhandboken.se)), it is stated that:
“When using penetrating screws, crack formation has been observed in the sheet material. Furthermore, in dynamic loading, penetrating screws with high thread pitch have a tendency to become unscrewed from the support.
The risk of crack formation is also a problem when nailing profile rails. Tests have shown that the design features of the screw for achieving hold are in opposition to its dimensioning for efficient shooting. If the diameter of the nail is limited to enable it to penetrate the flange portions without crack formation therein, the hold of the nail in the flange portions will become dependent on the design of its surface. If the surface is designed with grooves or furrows, the hold of the nail increases, but its strength decreases.
Another problem is that electric and pneumatic nailing tools have a limited penetration force and thereby limits the steel thickness of the profile rails. Electric nailing tools today are capable of penetrating profile rails having a thickness of approx. 1.5-2 mm, and pneumatic ones approx. 3.5-4 mm. If profile rails of greater steel thickness are to be joined, gas powered or powder-actuated nailing tools, which are substantially more expensive than electric and pneumatic nailing tools, have to be used.
Another problem is that the nail can rotate when loads are applied to the profile rails, which implies that it is mainly the axial locking mechanism of the nail that holds the profile rails together.
Yet another problem is that many of the present facade structures cannot withstand the movements arising in the structure. In a structure where studs are arranged vertically in a horizontal rail, a transverse load, e.g. a wind load, is transferred from the studs to the rail attachment to the joists via the flange portion of the rail. The transition between the flange portion of the rail and the web portion thereof then forms a natural, sagging “hinge”. For instance, it is common that plaster facades exhibit cracks after a very short time, wherein said cracks are least partially caused by this phenomenon.
Accordingly, there is need for a fastening system and a method which allow the formation of a strong and reliable nailed joint, and which allow the formation of nailed joints in thin profile rails to which nails normally will not hold.
The object of the present invention is to at least partially solve the above-mentioned problems and to produce a fastening system and a method which allow the formation of a strong and reliable nailed joint substantially independently of the characteristics of the profile rail.
One object of the invention is to transform the holding force of the nails from a tensile force, which is axial to the nails, into a buckling load, which is perpendicular to the longitudinal direction of the nails.
Another object is to increase the strength of the nailed joint by obtaining a buckling load instead of an axial tensile load in the nailed joint.
An additional object is to prevent the flange portion of the profile rail from being folded when the nail is driven into the flange portion.
A further object is to reduce the risk of cracks forming in the flange portion when the nail penetrates it.
Another object is to enable the use of electric or pneumatic nailing tools also when nailing heavy-gauge profile rails.
One object is to reduce movements between studs and rails in a nailed light construction frame, which otherwise are at risk arising e.g. in case of wind loading on the structure.
Another object is to prevent the nail in the nailed joint from rotating when the profile rail is loaded.
Another object is to achieve an efficient load transfer from the profile rail, via the nailed joint and to the joists supporting the profile rail.
The fastening system according to the invention is characterized in that it comprises at least one fastening means comprising a first fastening means portion, a second fastening means portion and at least one connecting portion supporting and connecting the fastening means portions to each other, wherein said fastening means is disposable in the profile rail so that the first fastening means portion abuts against, or is at least disposed in close proximity to, the internal surface of the first flange portion, and so that the second fastening means portion abuts against, or is at least disposed in close proximity to, the internal surface of the second flange portion, wherein said first fastening means portion forms a fastener for a nail which passes through the structural element, the first flange portion and holds in the first fastening means portion to form the nailed joint.
The method according to the invention comprises the steps of:
Accordingly, according to the invention, the first flange portion of the profile rail is secured between the structural element and the first fastening means portion of the fastening means before the nail is driven through the structural element, the profile rail and into the fastening means. This prevents the first flange portion of the profile rail from being folded backwards/inwards when the nail is driven in, which ensures the formation of a stable joint. Furthermore, the fastening means prevents the flange portion of the profile rail from separating or moving away from the structural element after the formation of the joint. For example, the fastening means prevents the structural element from separating from the profile rail when the profile rail is loaded, e.g. by a wind load.
The structural element can be constituted by a building board or by an adjoining, second profile rail to which the first profile rail is to be connected.
Accordingly, the first fastening means portion forms an attachment point for the nail of the nailed joint, which allows a nailed joint to be formed between the structural element and the profile rail substantially independently of the characteristics of the profile rail. If the profile rail is made of folded or bent sheet metal, the invention allows the profile rail to be designed with a reduced material thickness, which is an advantage from environmental, ergonomic and cost point of view.
Furthermore, the invention allows profile rails to be designed from materials which normally do not allow nailed joints, e.g. profile rails formed from polymeric materials or laminated profile rails formed from layers of fibrous materials, e.g. cellulose fibers.
Furthermore, the first fastening means portion supports the first flange portion of the profile rail and resists folding of the flange portion inwards when the nail penetrates it. This supporting function is enhanced since the connecting portion of the fastening means that extends between the fastening means portions of the fastening means conveys forces from the flange portion of the profile rail through which the nail is driven to the opposite flange portion thereof.
It may be advantageous to design the fastening system so that it comprises a plurality of fastening means, which are adapted to be mounted in the profile rail at predetermined positions along the length of the profile rail.
It may also be advantageous to design the fastening means so that they extend between the flange portions of the profile rail, in which case the fastening means also contribute to reinforcing the profile rail, both in its longitudinal direction as well as in its transverse direction.
It may be advantageous to arrange the fastening system so that the profile rail exhibits a plurality of recesses for receiving said at least one supporting means.
It may be advantageous to arrange the fastening system so that the recesses are disposed in sets, which are positioned at regular intervals along the length of the profile rail.
It may be advantageous to arrange the fastening system so that the profile rail, at a free edge of the first flange portion, comprises a first reinforcement portion extending back toward the second flange portion, and that the profile rail, at a free edge of the second flange portion, comprises a second reinforcement portion extending back toward the first flange portion, and that each set of recesses comprises a first recess disposed in the web portion in close connection or at least close proximity to the first flange portion, a second recess disposed in the first reinforcement portion in close connection or close proximity to the first flange portion, a third recess disposed in the web portion in close connection or close proximity to the second flange portion, and a fourth recess disposed in the second reinforcement portion in close connection or close proximity to the second flange portion.
It may be advantageous to arrange the fastening system so that said at least fastening means comprises a first flange portion, a second flange portion and web portion interconnecting the flange portions, said flange portions of the fastening means being substantially planar and substantially mutually parallel, and that said web portion of the fastening means is substantially planar and extends substantially orthogonally between the flange portions of the fastening means portions so that the fastening means exhibits substantially a U-shape, wherein said at least one fastening means is intended to be mounted in the profile rail by being inserted into said recesses.
Preferably, the fastening means is formed from folded or bent steel plate having a thickness in the range of 0.7-1.5 mm.
If a first, vertical profile rail is to be connected to a second, horizontal profile rail, as is the case in a framework designed using lightweight construction technology, it may be advantageous to position the fastening means inside the first profile rail at the lower end thereof, so that the fastening means is caused to support the inside of the flange portions of the first profile rail, whereupon the first profile rail, with mounted fastening means, is positioned in the second profile rail so that the outsides of the flange portions of the first profile rail are caused to abut against the inside of the flange portions of the second profile rail. When the profile rails are subsequently connected to each other by driving nails through the flange portions of the profile rails and into the fastening means, the fastening means portions of the fastening means will prevent the flange portions of the first profile rail from being folded backwards when the nails penetrate them.
Furthermore, the fastening means portions will prevent the profile rails from separating when they are loaded. The fastening of the flange portions of the first profile rail between the flange portions of the second profile rail and the supporting means portions of the supporting means implies that the adjacent flange portions can only slide against each other, which implies that the nail will be subjected mainly to a transverse buckling force when the profile rails are loaded.
If the profile rails are formed from a relatively thin sheet metal material, e.g. 0.7-1.5 mm, the supporting means furthermore prevents the nail from rotating when the profile rails are loaded, since the profile rail being loaded, i.e. the vertical, first profile rail, is fixed between the second, horizontal profile rail and the fastening means.
In order to further prevent rotation of the nail, it may be advantageous to design the fastening means with a connecting portion that abuts against the web portion of the horizontal profile rail. The fastening means can then be attached to the joists upon which the horizontal profile rail rests by driving one or several nails through the connecting portion, the web portion of the horizontal profile rail and into the joists. The fastening means will then also serve as a pressure-equalizing washer for the attachment to the joists while simultaneously securing the horizontal profile rail to the joists.
When nailing a profile rail of a heavy-gauge material, it may be advantageous to minimize the material that the nail has to penetrate by designing the fastening means portion supporting the flange portion of the profile rail with a through opening, and to realize the nailed joint with two nails, wherein a first nail is applied at the position of the opening so that the first nail is caused to penetrate the flange portion of the horizontal profile rail and the flange portion of the vertical profile rail, but not into the material of the fastening means. The second nail is driven through the flange portion of the vertical profile rail and into the fastening means portion of the fastening means, but not through the flange portion of the horizontal profile rail. The two nails will then together form a nailed joint connecting the profile rails to each other, and the fastening means will still support the flange portion of the vertical profile rail and prevent this portion from folding when the first nail penetrates it. In this case, the application of the second nail should be made at a position where the flange portion of the horizontal profile rail does not overlap the flange portion of the vertical profile rail, but where the fastening means portion of the fastening means is disposed behind the flange portion of the vertical profile rail.
In the following, the invention will be described more closely with reference to accompanying patent drawings.
The profile rails 1-3 form a frame system 4, or framework, for the mounting of board-shaped structural elements 5, e.g. in the form of building boards or wall panels. In some contexts, profile rails having a U-shaped cross-section, which are normally intended for horizontal mounting, are called rails, whereas profile rails having a C-shaped cross-section, which are normally intended for vertical mounting, are called studs.
In the following, a fastening system for mounting the board-shaped structural elements 5 in
The fastening system comprises the profile rail 3, which is elongated and extends between a first, upper end 6 and a second, lower end 7, wherein said ends 6, 7 are adapted to interact with said horizontal profile rails 1 and 2, as shown in
The profile rail 3 exhibits a plurality of sets or arrays of recesses 13-16, which are disposed at predetermined positions along the profile rail 3. The recesses in each set of recesses 13-16 are arranged on a level with each other as viewed in the longitudinal direction of the profile rail 3. The sets of recesses 13-16 are preferably placed at regular intervals along the length of the profile rail 3, e.g. with a spacing in the range of 10-100 cm.
Each set of recesses 13-16 comprises four through recesses 17-20 in the material forming the profile rail 3. Each recess 17-20 is elongated and extends in the longitudinal direction of the profile rail 3. The length of the recess 17-20 may, for example, be in the range of 10-20 mm and its width in the range of 1-3 mm. The recess 17 is disposed in the web portion 10 in close connection or close proximity to the first flange portion 8, and the recess 18 is disposed in the reinforcement portion 11 in close connection or close proximity to the first flange portion 8. In the same way, the recess 19 is arranged in the web portion 10 in close connection or close proximity to the second flange portion 9, and the recess 20 is arranged in the reinforcement portion 12 in close connection or close proximity to the second flange portion 9. Accordingly, the recesses 17 and 18 form a pair of recesses, where the recesses are facing each other, and, in a corresponding way, the recesses 19 and 20 form a pair of recesses, where the recesses 19 and 20 are facing each other.
The fastening system further comprises a plurality of fastening means 21 in the form of a flange reinforcer, which are adapted to interact with the profile rail 3 in a manner that will be described more closely below. Each fastening means 21 comprises a first fastening means portion 22 in the form of a flange portion, a second fastening means portion 23 in the form of a flange portion and web portion 24 interconnecting the fastening means portions 22, 23. The fastening means portions 22, 23 are substantially planar and are substantially mutually parallel. The web portion 24 is substantially planar and extends substantially orthogonally between the fastening means portions 22, 23 so that the fastening means exhibits a U-shape. The web portion 24 has a length corresponding to the distance between the recesses 17 and 19, i.e. a length that is slightly smaller than the distance between the flange portions 8 and 9 of the profile rail 3. The fastening means portions 22 and 23 have a length that is slightly longer than the width of the flange portions 8 and 9. The fastening means portions 22 and 23 further have a width that is slightly smaller than the length of the recesses 17-20. Furthermore, the fastening means portions 22 and 24 have a thickness that is slightly smaller than the width of the recesses 17-20. These dimensions enables the fastening means 21 to be inserted into the recesses 17-20, either from the side of the web portion 10, as shown at the top of
Before mounting a wall panel to the profile rail 3, a desired number of fastening means 21 are inserted into the recesses 17-20 at desired positions along the profile rail 3. If the fastening means 21 is inserted from the web side of the profile rail 3, as shown in
When the fastening means 21 has been inserted into the recesses 17-20, the fastening means portions 22 and 23 thereof will abut against, or at least be in close proximity to, the flange portions 8 and 9, respectively, of the profile rail 3. More precisely, the first fastening means portion 22 of the fastening means 21 will abut against, or at least be in close proximity to, the internal surface 26 of the flange portion 8 of the profile rail 3, and the second fastening means portion 23 of the fastening means 21 will, in a corresponding manner, abut against, or at least be in close proximity to, the internal surface 26 of the flange portion 9 of the profile rail 3, as shown in
When the desired number of fastening means 21 have been mounted in the profile rail 3, the wall panel 5 is brought into a desired position against the profile rail 3, as shown in
The fastening means 21 makes it possible to design the profile rail 3, or at least the flange portion 8, with a relatively thin material thickness. If the profile rail 3 is formed from a steel plate, this constitutes a considerable advantage, since it enables the profile rail 3 to be formed from a steel plate which by itself cannot form a joint with a nail. This enables a considerable saving, since the material consumption, i.e. weight of steel per meter length of profile rail, can be drastically reduced. Furthermore, this enables an improvement from a purely ergonomic point of view, since the profile rail will be lighter and therefore easier to handle.
Accordingly, the fastening means portion 22 of the fastening means 21 forms a fastener for the nail 27, wherein said fastener enables the formation of a nailed joint between a structural element and a profile rail which by itself cannot provide a sufficient hold for the nails.
The fastening means portion 22 also prevents the flange portion 8 from being folded inwards, i.e. away from the structural element 5, when the nail 27 is applied, which ensures the formation of a reliable nailed joint. Furthermore, the fastening means portion 22 prevents the flange portion from separating from the structural element 5 when the structural element 5 and the profile rail 3 are loaded, e.g. by a wind load.
It may be advantageous to form fastening means 21 from a steel plate having a material thickness in the range of 0.7-2.5 mm, e.g. 0.7-1.5 mm, but other dimensions and materials, e.g. fiber-reinforced material, for example fiber-reinforced hard plastic, are possible as long as the fastening means provides a good hold for the nail.
Preferably, said nails 27 are so-called ballistic nails, which are driven through the wall panel 5, the flange portion 8 of the profile rail 3 and the fastening means portion 22 of the fastening means 21 with a tool designed for the purpose, e.g. a nail gun.
It can be appreciated that the quality of the nailed joint is dependent on the number of fastening means 21 and their mutual position in the profile rail 3. The number of fastening means 21 and their positions are advantageously adapted to the board-shaped structural element which is to be attached to the profile rail 3. A heavy structural element may e.g. require a larger number of attachment points than a light one, and accordingly, it may be advantageous to use relatively many and closely spaced fastening means for such a structural element.
It is appreciated that the second fastening means portion 23 of the fastening means 21 may constitute a fastener during the formation of a corresponding nailed joint with a structural element at the second flange portion 9 of the profile rail, wherein said structural element may, for example, be constituted by the support upon which the wall structure formed by the wall panel 5 is to be mounted.
It is appreciated that the fastening means 21, in addition to forming fasteners for the nails, also contribute to increasing the bending resistance of the profile rail 3, both in its longitudinal direction and in its transverse direction. The web portions 24 of the fastening means 21 especially contribute to reducing the buckling or bending tendency of the web portion 10 of the profile rail 3, whereas the fastening means portions 22 and 23 of the fastening means 21 contribute to reducing the buckling or bending tendency of the flange portions 8 and 9 of the profile rail 3.
The fastening means 28 is mounted in the profile rail 3 in substantially the same manner as the above-described fastening means 21, but with the addition that the fastening means portions 22 and 23 are pressed against each other before the mounting so that the free edges of the supporting sections 29 can be brought into the recesses 17 and 19 of the profile rail 3.
In this embodiment, the profile rail 3 comprises an adhesive 31, which is applied in a thin layer on the external surface 25 of the flange portion 8. The adhesive layer can, for example, be constituted by a glue layer or a double stick tape.
Accordingly, the fastening means 28 is elastically deformable to an extent sufficient, on the one hand, to allow mounting in the profile rail 3, and, on the other hand, to allow the installer to push the supporting sections backwards, but sufficiently rigid to enable the supporting sections 29 to provide a sufficient support during the positioning of the structural element 5.
When the structural element 5 has adhered to the adhesive, which can extend along all or portions of the length of the profile rail 3, a nail 27 is driven through the structural element 5, the flange portion 8 of the profile rail 3 and the fastening means portion 22 of the fastening means 21, as described previously and shown in
The fastening means 32 generally has a rectangular shape, and has a length and width enabling it to be mounted with an exact fit in a profile rail 3 by being inserted into the end of the profile rail 3, as shown in
In conjunction with driving the nail through wall panel, flange portion 8 and the fastening means portion 33, the supporting portion 37, and also the side wall portion 35 and bottom portion 36, contribute to the fastening means portion 33 being maintained in its position and not being pushed or folded backwards by the force from the penetrating nail.
The bottom portion 36 allows the fastening means 32 to be attached, by means of a nailed joint or screw joint, to the support on which the profile rail 3 rests.
As mentioned above, the fastening system according to the invention can also be used for attaching two profile rails to each other. This may be of interest when a vertical profile rail is to be connected to a horizontal profile rail, e.g. to form the type of frame system 4 or framework shown in
In the following, a method for attaching a vertical profile rail 3, or stud, to a horizontal profile rail 2, or rail, to each other with the aid of the above-described fastening means 32 will be described more closely with reference to
The method comprises the step of inserting the fastening means 32 into the profile rail 3 so that the fastening means portions 33 and 34 thereof are caused to abut against, or at least be in close proximity to, the flange portions 8 and 9, respectively, of the profile rail 3, as shown in
Thereafter, the vertical profile rail 3 with the mounted fastening means 32 is placed in the horizontal profile rail 2 so that the flange portions 8, 9 of the profile rail 3 are caused to abut against corresponding flange portions 38, 39 of the profile rail 2, as shown in
In this connection it may be noted that, while the vertical profile rail 3 has a C-shaped cross-section in order to increase the ability of the profile rail 3 to resist transverse forces, e.g. caused by a wind load acting on the frame system 4, the horizontal profile rail 2 has a U-shaped cross-section in order to enable the insertion of the profile rail 3 into the profile rail 2, as shown in
After placing the vertical profile rail 3 with mounted fastening means 32 in the desired position in the horizontal profile rail 2, nails 27 are driven through the flange portion 38 of the horizontal profile rail 2 and the flange portion 8 of the vertical profile rail 3, as well as through the flange portion 39 of the horizontal profile rail 2 and the flange portion 9 of the vertical profile rail 3, and are caused to hold to the fastening means portion 33 and 34, respectively, of the fastening means 32, as shown in
In this case, the profile rail 50 exhibits a first flange portion 51 and a first fastening means portion 52, which connects to the flange portion 51 and extends behind and in parallel therewith. The profile rail 50 further exhibits a web portion 53, which connects to the first fastening means portion 52 and forms a substantially right angle therewith. The profile rail 50 furthermore exhibits a second flange portion 54 and a second fastening means portion 55, which connects to the flange portion 54 and extends behind and in parallel therewith.
The fastening means portion 55 connects to the web portion 53 and forms a substantially right angle therewith.
The profile rail 50 furthermore exhibits reinforcement portions 56, 57, which connect to the flange portions 51, 54 and extend in parallel to the web portion 53.
As is evident from
The profile rail 50 is mounted in the horizontal profile rail 2 in the same manner as has been described above, but with the difference that the fastening means in this case is integrated into the profile rail and thus does not need to be inserted into the profile rail 50 before it is mounted in the horizontal profile rail 2.
The profile rail 50 is attached to the profile rail 2 in the same manner as has been described above, i.e. in that nails 27 are applied through the flange portions 38, 38 of the profile rail 2 and through the flange portions 51, 55 of the profile rail 50 and are caused to hold to the fastening means portions 52, 54 of the profile rail 50, as shown in
In the foregoing, the invention has been described starting from a number of embodiments. However, the skilled person will appreciate that other embodiment examples, or variations thereof, are possible within the scope of the following claims.
| Number | Date | Country | Kind |
|---|---|---|---|
| 1430100-6 | Jul 2014 | SE | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/SE2015/050773 | 7/1/2015 | WO | 00 |
