ADJUSTABLE NOGGINGS

This invention relates to noggings and in particular to a method of making an adjustable wood nogging which may be used between other members to maintain the separation thereof and also to an adjustable wood nogging, per se. In this specification, the terms "timber", "wood" and "wooden" are used to refer to real wood as such, together with manufactured materials having the same or closely similar characteristics to real wood and which are used in similar applications. Such materials should be capable of being machined, nailed, screwed and glued, in much the same way as is real wood. When constructing a timber structure, such as a frame for a building, a floor, a studwork wall or a roof, it is common practice to stabilise the members of the structure by employing elements extending between the principal timber members. Such elements are usually referred to as noggings. In addition to their stabilising function, noggings may be employed for the mounting of other components to the structure, such as electrical fittings, as well as giving support for edges of various kinds of cladding which may be attached to the structure, such as wall and ceiling boards.

Given the variability of the spacing between the timber members, such noggings must be cut during construction to the exact required length. This involves measuring the spacing between the two members, transferring that dimension to the timber from which the nogging is to be cut, and then trial-fitting the nogging before securing it in position, and possibly finally trimming the length of the nogging or maybe even discarding it, if it had been inadvertently cut too short. The nogging must then be secured in position and this is usually done by means of nails hammered in on the skew.

The process of installing noggings is therefore time consuming and the resulting joint utilising skew nails is mechanically weak and can lead to a less than wholly satisfactory connection.

In order to reduce the costs associated with the construction of a building there is an increasing emphasis on speed of construction of the building, and a reduction in the labour required.

In an attempt to address these difficulties, there has been a proposal for a pre-manufactured adjustable metal nogging in AU-A-75375/96. This describes a telescopic nogging having end tabs which allow it to be firmly secured in the required position, the length of the nogging being set and then locked by means of self-tapping screws. Though easier to use onsite than the manufacture of a timber nogging, this has the disadvantage that nails cannot be employed to secure for example cladding to the nogging.

This invention aims at providing an adjustable nogging which may be used in conjunction with a metallic connector for securing the nogging between a pair of spaced members, in order to address the various problems discussed above in providing a nogging of the required length onsite, and with minimum wastage of both material and time.

According to this invention, there is provided a method of making an adjustable wood nogging, comprising the steps of:

- selecting an elongate length of timber for the nogging;

- dividing the length of timber into two elongate pieces by way of a diagonal cut extending from one side of the length at one end region thereof to the other side of the length at the other end region thereof; - adjusting the total length of the divided length by relatively sliding the two pieces with the cut faces thereof in sliding engagement; and

- securing together the two pieces when the total length of the resultant nogging is that required for installation.

It will be appreciated that with the method of this invention, it is no longer necessary accurately to measure the spacing of a pair of members between which the nogging is to extend, and then cut a length of timber to the precise measured length. Rather, a length of timber is selected which is approximately equal in length to the spacing and which is then divided into two pieces by way of a diagonal cut whereafter the total length of the nogging assembled from the two pieces is adjusted by relatively sliding the two pieces with the cut faces in engagement with each other. For instance, if the length of timber is longer than the spacing a greater overlap between the two pieces may be effected to reduce that length. Alternatively, if the length of timber is shorter than the spacing the overlap between the two pieces may be reduced to increase the overall length. By selecting a length of timber roughly as long as the required finished length of the nogging and providing a diagonal cut as defined herein, the nogging will have a greater thickness even when adjusted to the required length than would be the case were a cut to be provided extending parallel to the length of the selected timber. Thus, the nogging will have a greater strength when finished than would be the case were two simple rectangular pieces of timber secured together for example by way of screws, to have the required finished length. An advantage of a diagonal cut is that it need not intersect the end faces of the timber whereas a parallel cut would intersect the end faces of the timber. Thus the end faces of two pieces formed from a diagonal cut are not reduced in size by the cutting action and therefore can be used with a larger

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connector. Also the connector may be secured to the end face prior to providing the diagonal cut.

The two pieces are preferably secured together by way of an adhesive and advantageously a hot-melt adhesive is used for this purpose. Such an adhesive is easy to dispense from a portable hand-tool and remains tacky until the mass of adhesive reaches room temperature. When applied to wood, the adhesive will be tacky for long enough to allow final adjustment of the overall length, before setting and then holding the two pieces at the required length. Other possibilities for securing the two pieces together include the use of double-sided adhesive tape with an aggressive adhesive, or the use of essentially rigid fixings extending transversely of and engaged with the two pieces. Such fixings may be selected from screws and screw-derivatives, nails and nail-derivatives, and bolts with nuts engaged with the threads thereof.

It is preferred for a metallic connector to be secured to at least one end, but preferably both ends, of the length of timber before that length is divided into two pieces. Such a connector may facilitate the connection of the nogging to the two timber members between which the nogging is to extend. The end regions of the length of timber may be profiled to suit the connector, before the connector is divided into the two pieces by way of a diagonal cut. In one method of this invention, the cutting step is performed to furnish a rib on one cut face and a complementary groove on the other cut face, whereby the rib and groove interengage whereby the two pieces are constrained against relative lateral movement by the interengagement of the rib and groove during relative sliding movement. This method may be modified such that the rib is formed along one side face of the length of timber and the groove is formed along the opposed side face of the length of timber, in each case before the

length of timber is divided into two pieces, and then after the division of the length into two pieces, the pieces are turned so that the side face having the rib bears on the side face having the groove, with the rib received in the groove. Then, when the total length of the nogging is adjusted by relative sliding movement of the two pieces the interengaged rib and groove restrain lateral movement of the two pieces until the two pieces have been secured together at the required total length for installation.

Either of the above methods may be modified to provide a plurality of ribs and corresponding grooves formed along the faces of the first and second pieces.

By way of example only, two specific embodiments of adjustable noggings of this invention will now be described in detail, reference being made to the accompanying drawings, in which:-

Figure 1 is an isometric view of a length of timber profiled for use in a method of this invention and carrying metallic connectors at its two ends;

Figure 2 shows the length of timber of Figure 1 , following division thereof into two pieces;

Figures 3 and 4 show the adjustment of the two pieces of the length of timber to form a nogging of the required length; Figure 5 shows a length of timber for use in a method of this invention and about to have metallic connectors secured to its two ends;

Figure 6 shows the division of the length of timber of Figure 5 into two pieces;

Figure 7 illustrates the two pieces reversed to give a sliding connection therebetween;

Figure 8 shows the two pieces slidably interconnected and adjusted to a required length, ready for nailing together; and

Figure 9 shows a complete assembly of an adjustable nogging with end connectors installed between a pair of ceiling joists for supporting adjacent edges of two ceiling boards.

Figure 1 shows a length of timber ready for forming into a nogging and provided with metallic connectors at its two ends, the finished nogging being suitable for installation between a pair of other timber members such as timber stud work, joists, rafters or the like, in the construction of a building. The length of timber 10 is of generally rectangular cross-section though the end regions have been cut away on opposed sides, as shown at 1 1 and 12. The remaining part of the timber has opposed side faces 13,14, a top face 15 and a bottom face 16. Square-cut end faces 17,18 are formed at the two ends of the timber and the corners between the side faces 13,14 and the top face 15 are cut away as shown, to form two tapering flutes 19 extending for a short distance along the length of the timber.

Each end of the timber carries a metallic connector 20 the details of which form no part of this invention. The connector is however described in detail in my co-pending International Patent Application No. PCT/GB2008/050808, being filed concurrently with this application and the content of which is imported into this specification by virtue of this reference thereto. The connector will not be described in any further detail here.

Following the profiling of the length of timber and the securing of the connectors to the ends thereof, as shown in Figure 1 , the length of timber is divided into two pieces 22,23 by means of a diagonal cut extending from one side of the timber adjacent one end to the other side of the timber adjacent the

other end, the cut being aligned with the profiled and cut away regions 1 1 and 12 of the timber. In this way, the two pieces are of similar form, each of a tapering width along its length, as shown in Figure 2. Further, each of the two pieces is of reducing height towards its end remote from the attached connector.

Subsequent to the separation of the length of timber into the two pieces 22,23, the cut faces 24,25 are offered one to the other (Figure 3) and then the overall length of the nogging is adjusted by relative sliding movement of the two pieces. Once the overall length is adjusted as required, typically a mark such as a pencil line may be drawn across the aligned top faces 15 of the two pieces and then the two pieces separated once more to allow the application of hot- melt adhesive from the tapered end of each piece back towards the other end. The two pieces are then pressed together with the pencil line extending continuously across the top faces 15 and final adjustment of the length then performed, before the adhesive sets. The two pieces may be clamped together for example by means of quick-release clamps or G-clamps until the adhesive sets sufficiently. In addition, screws or nails (not shown) may be used to assist the securing of the two pieces together.

Once adjusted, the nogging may be fitted to the two members, using the connectors 20 at the ends of the nogging, with nails extending through the holes 26 in the connectors and the teeth 27 of the connectors penetrating those members to enhance the strength of connection. In an alternative method, the two connectors may be secured to the members as described but before the adhesive has set and so before final adjustment such that the act of securing the connectors to the members performs the final adjustment. Then, when

secured, the two members may be clamped together and then possibly also secured by means of screws or nails.

Referring now to Figure 5, there is shown a modified method of forming an adjustable nogging. In this method, a length of timber is machined to have the profile shown. Thus, the timber has a pair of side faces 47,48, a top face 49 and a bottom face 50, as well as a pair of end faces 51 ,52. Those end faces are cut at a non-perpendicular angle to the length of the timber so that the finished nogging will have those end faces perpendicular to the length of the nogging, as will be described below. One side face 47 of the nogging is machined to leave an upstanding rib 53 and the opposed side face has a groove 54 machined therein (see Figures 6 and 8). In this embodiment, there is one rib 53 and one groove 54, both of rectangular complementary form. Other numbers of ribs and grooves could be provided as required, and different interfitting profiles for those ribs and grooves could be employed - for example, they could be of triangular or saw-tooth cross-sectional shape. The end portions 55 and 56 of the timber are machined to have a slightly reduced cross- sectional area; along the corners between the side faces 47 and 48 and top face 49 there are formed tapering flutes 57.

Also shown in Figure 5 are two metallic connectors 59 each of which is as described in my co-pending international patent application referred to above. As those connectors form no part of this invention they will not be described in further detail here.

The length of timber is then cut into two pieces 61 ,62 by means of a cut extending diagonally along the length of the timber, from one end portion 55 to the other. Piece 62 is then placed on the opposed side of piece 61 (Figure 7) so that the diagonally-cut faces are outermost and the rib 53 can be received in

the groove 54 (Figure 8). When the two elements are interfitted as described, the end faces 51 ,52 now lie perpendicularly to the length of the nogging.

Adjustment of the nogging is achieved by simply sliding one piece 61 relative to the other 62, while keeping the rib 53 and groove 54 in engagement. Once the length has been set as required, the two pieces of the nogging are secured together for example by means of nails 63 as shown in Figure 8. As an alternative to nails, woodscrews, bolts or an adhesive such as a hot-melt adhesive may be employed.

Figure 9 shows the adjustable nogging of Figure 8 fitted between two ceiling joists 64,65. The connectors 59 of the adjustable nogging are secured to the two joists 64 as is described in my co-pending international application, using nails (not shown) hammered into the joists 64, through holes in the connectors. The location of the adjustable nogging should be selected so as to support adjoining edges 65,66 of a pair of ceiling boards 67,68 secured to the joists 64, the edge margins of the boards being nailed as required to the nogging.

Though Figure 9 shows the adjustable nogging installed in a ceiling, it may of course be used in other circumstances such as in the construction of walls, floors, roofs or other timber structures.