CA1305843C - Integral wallboard and stud - Google Patents

Integral wallboard and stud

Info

Publication number
CA1305843C
CA1305843C CA000575588A CA575588A CA1305843C CA 1305843 C CA1305843 C CA 1305843C CA 000575588 A CA000575588 A CA 000575588A CA 575588 A CA575588 A CA 575588A CA 1305843 C CA1305843 C CA 1305843C
Authority
CA
Canada
Prior art keywords
wallboard
stud
elongate
web portion
web
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Lifetime
Application number
CA000575588A
Other languages
French (fr)
Inventor
Robert J. Menchetti
Richard P. Weir
Robert M. Chapman
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
National Gypsum Co
Original Assignee
National Gypsum Co
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from US07/202,298 external-priority patent/US4843784A/en
Application filed by National Gypsum Co filed Critical National Gypsum Co
Application granted granted Critical
Publication of CA1305843C publication Critical patent/CA1305843C/en
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

Links

Abstract

ABSTRACT OF THE DISCLOSURE

A wallboard and stud unit formed of an elongate strip of foldable steel affixed to the wallboard back face, adapted to be folded outwardly away from the wallboard to function as a wall stud, in a hollow wall having a plurality of such units in back-to-back relationship.

Description

~13Q5lS1~3 BACKGROUND OF THE INVENTION

This invention relates to a novel wallboard and stud combination particularly adapted for compact storage and shipment and for easy transformation into perpendicu-larly disposed wallboard and stud elements for use in constructing interior walls and partitions.
Prior wall constructions ha~e included combina-tions includinq gypsum board facing elements with elements which are foldably affixed for compact storage and shipment, to be unfolded to a perpendicular disposi-tion to function as the wall supporting studs. U.S.
Patent 3,112,532 discloses a wall panel of two parallel wallboards with a foldable cardboard core, of corrugated configuration, foldable from a flat compact condition in which all elements are in substantially parallel planes, to an open condition in which the cardboard ribs are perpendicular to the wallboards, forming a hollow panel.
U.S. Patent 3,188,773 discloses a gypsum wallboard which has been cut into a plurality of alternating wide and narrow sections, which are foldable from a flat compact condition in which all elements are in substantially parallel planes, to an open condition in which the narrow sections are perpendicular to the wide sections, forming a hollow panel.

.~

1305~343 SUMMARY OF THE TNVENTION

The present invention is directed to a combina-tion of gypsum wallboard with an attached foldable sheet metal stud element which is adhered along the edge of the wallboardO The sheet metal foldable stud is af a contin-uous elongate form having a narrow elongate inner edge portion firmly adhered to the wallboard back face, inward from, but parallel to and near the wallboard side edge, a relatively wider elongate central web portion definitely not adhered to the wallboard, foldable from a position extending out over the wallboard side edge to a position perpendicular to the wallboard back face, and a third narrow elongate outer edge flange portion, extending perpendicular to the web portion, in a direction from the web portion opposite to the direction the inner edge portion extends when the web is folded perpendicular to the wallboard.
It is an object of the invention to provide an improved structure for forming both wallboard and stud, in a wall construction.
It is a Eurther object to provide a novel foldable steel sheet for compact placement for storage and shipment and foldable to provide a strong, rigid wall stud, when adhered to a wallboard.
It is a still further object to provide a novel hollow wall having a metal stud factory affixed to a wallboard.

~305843 BRIEF DESCRIPTION OF THE_DRAWINGS
These and other objects and advantages will be more readily apparent when considered in relation to the preferred embodiments of the invention as set forth in the specification and shown in the drawings in which:
Fig. l is an isometric end view of a sheet of gypsum wallboard with a foldable sheet metal stud element affixed along each side edge of the wallboard, in accor-dance with the invention.
Fig. 2 is an enlarged isometric end view of one corner of the wallboard of Fig. 1, with the metal stud element shown in phantom in a folded out disposition, for use as a wall stud.
Fig. 3 is an isometric sectional plan view of a hollow partition wall constructed of the wallboards with stud elements of Fig. 2.
Fiy. 4 is a view similar to Fig. 2 further including a stud element bending tool, in accordance with the invention.
Fig. 5 is an enlarged isometric end view of one corner of a modified form oE the wallboard of Figs. 1-4, with the metal stud shown in phantom in a folded out disposition, for use as a wall stud.
"
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to Figs. 1 and 2, there is shown a factory laminated wallboard and stud wall unit 10, consisting of a paper covered bevelled edge gypsum wallboard 12 adhesively affixed to two roll-formed sheet metal stud elements 19, 14, which extend almost the full length of the wallboard 12.

~305~4~

Each stud element 14 is an elongate strip of .015 inch thick steel which includes an attachment portion 16 of about two inch width along the inner edge of the stud element 14, a web portion 18 of about two-and-a-half-inch width adjoined to and coplanar with the attachment portion 16, and a downwardly extending flange portion 20 adjoined to and perpendicular to the web portion 18. Flange portion 20 preferably also includes a reversely bent upwardly extending edge portion 22.
The attachment portion 16 is the only part of stud element 14 that is adhesively affixed to the back face 24 of the wallboard 12, and is affixed along a strip 26 on the back face 24, which is spaced inwardly from the side edge 28 of the wallboard 12, a distance of almost two-and-a-half inches, whereby web portion 18 lies against the edge portion 30 of back face 24 and flange portion 20 extends downwardly closely adjacent wallboard side edge 28. The width o flange portion 20 is e~ual to or slightly less than the thickness of wallboard 12, which is preferably between about 3/8 to 5/8 inch.
A fold line 32 is formed along the ~unction of the attachment portion 16 and web portion 18, preferably in the form of a s].ight elongate depression in the metal and preferably a plurality of small diamond shaped holes 34 are located along fold line 32, spaced apart about every two to six inches.
Slightly raised reinforcing ribs 36 extend perpendicular to the fold line 32 in the web portion 18, spaced evenly apart about every four to twelve inches.

~ - 4 -13()~843 Ribs 36 can be formed with a slit 38 through the sheet metal at both ends 40, 90', leaving an opening completely through ribs 36 for a reason to be discussed below.
Alternatively, the slits 3~ can be eliminated and a triangular or diamond shaped hole, such as holes 39, can be formed along the fold line 32, at the one end of each rib 36.
Eig. 2 shows how the stud element is Eolded from a flat original storage form to a right-angled Z-shaped functional form, in phantom lines.
Fig. 4 shows a novel tool 92 for folding the stud element 14 to its functional form. The tool 42 includes a rigid elongate body 49, which has a length approximately the length of the longest units 10 available, which will be about eight to twelve feet.
Projecting forwardly from body 49 are a plurality of pegs 46, spaced evenly apart about every four to twelve inches, depending on the spacing of ribs 36. Pegs 46 have a length and diameter suitable for firmly fitting through the ribs 36 and extending slightly out of the remote end 90', terminating at or short of fold line 32.
At least one handle 48 extends rearwardly from body 44, preferably two or more, for raising the web portion 18 in a folding motion around fold line 32.
Fig. 3 shows a hollow wall 50 formed of a ; plurality of units 10. With the web portion 18 and flange portion 20 on each of the two stud ele~ents 14 on the two side edges 28, 28 of each unit 10 in the functional form, the stud elements 14 each provide the normal functions of prior wall studs, holding the :

~3(15~343 wallboard in place and providing suitable rigidity to the wall.
In forming the wall 50, one set of wallboard and stud units 10 is arranged with wallboard edges 28 abutting one another to form a front side 52 of wall 50, with stud web portions 18 projecting rearwardly. A
second set of units 10 is arranged, also with their wallboard edges 28 abutting one another, forming a rear side 54 of wall 50, with their stud web portions 18 projecting forwardly. The wall 50 is constructed by placing one unit 10 against the outside of a floor track 56 and the outside of a ceiling track (not shown), and the two ends of the wallboard 12 are screwed to a flange 58 of floor track 56 and a flange of the ceiling track (not shown). Each end of each stud element 14 is enough short of the end of the wallboard 12 to allow room for the wallboard ends to extend down along the outside of the track flanges. The web 60 of the floor track 56 and the web of the ceiling track tnot shown) are both equal in width to the width of the web portion 18 of each stud element 14.
A plurality of additional wall units 10 can then be afflxed to the floor and ceiling tracks, on the same side, with the same procedure. Subsequently, a plurality of similar wall units lO are mounted on the opposite side of the floor and ceiling tracks and screwed to the flange 58 of floor track 56 and an opposite flange of the ceiling track (not shown). Because the floor track and ceiling track webs are equal in width to the width of the web portions 18 of the stud elements 1~, the ~1 305843 flange portions 20 of each unit 10 abut the ~ac~ face 24 of wallboard on the opposite side of wall 50.
In the embodiment shown in Fig. 3, the adjacent units 10 on each respective side of wall 50 are also adjoined one to another by the use of preferred, but optional, clips 62. Clips 62 are narrow, prefolded strips of spring steel having a central web 64 disposed firmly against the back of the wallboard edges 28, bridging the edges 28 or the two abutting wallboards 12, maintaining the abutting wallboards in coplanar relation-ship. Angled upwardly and outwardly from each side of web 64 is a short angled leg 66, followed by a perpendic-ular leg 68. At the outer end of each perpendicular leg 68 and extending perpendicularly outwardly therefrom, is an opposite side web 70, disposed against the outer face 72 of a flange portion 20.
Each opposite side web 70 is slightly wider than the width of a flange portion 20, and has along its opposite edge a hook-type flange 74 extending downwardly around the remote side web portion 18. An inwardly depressed hump 76 on flange 74 engages an outwardly depressed hump 78 on web portion 18, locking the two together. With one such interlocking of humps 76 and 78 on each of the two adjacent stud elements, the clip 62 tends to hold the two abutting side edges 28, 28 in tight abutment.
The wallboard side edge 28 is shown to have a bevelled edge, however, tapered edge board, for use with a ioint concealing drywall treatment, or square edge board may also be used in accordance with the invention.

~3~5843 With the bevelled edye board or the square edge board, a decorative vinyl film or cloth facing may be used on the board face and side edges. One reason for providing a small space between the side edge 28 of the board and the flange portion 20 of the clip is to permit the use o a subsequently added film of decorative vinyl or cloth on the wallboard face and side edges.
Referring to Fig. 5, there is shown a modified form of factory laminated wallboard and stud unit 80, consisting of a paper covered bevelled edge gypsum wallboard 82 adhesively affixed to two roll-formed sheet metal stud elements 84 (one not shown), which extend almost the full length of the wallboard 82, along each side edge 86 (one not shown) thereof.
Each stud element 84 is an elongate strip of .015 inch thick steel which includes an attachment portion 88 of about two inch width, a 180 fold 90 disposed remotely from edge 86, a narrow elongate flat section 92 overlying attachrnent portion 88, a relatively wide web portion 94, of about two-and-a-half-inch width adjoined to and coplanar with the flat section 92, and a downwardly extending flange portion 96 adjoined to and perpendicular to the web portion 94. Flange port.ion 96 preferably also includes a reversely bent upwardly extending edge portion 98.
The attachment portion 88 is adhesively affixed to the back face 100 of the wallboard 82, and is affixed along a strip 102 on the back face 100 which is prefera-bly spaced inwardly from the side edge 86 a short distance, whereby web portion 94 overlies part of ~3~:)S~43 attachment portion 88 and also an edge portion 104 of back face 100 and flange portion 96 extends downwardly closely adjacent wallboard side edge 86. The width of flange portion 96 is equal to or slightly less than the thickness of wallboard 82, which is preferably between about 3J8 to 5/8 inch.
A fold ].ine 106 is formed along the junction of the flat section 92 and web portion 94, preferably in the form of a slight elongate depression in the metal and preferably a plurality of small diamond shaped holes 108 are located along fold line 106, spaced apart about every two to six inches.
Slightly raised reinforcing ribs 110 extend perpendicular to the fold line 106 in web portion 94, spaced evenly apart about every four to twelve inches.
Fig. 5 also shows, in phantom lines, how the stud element 84 is folded from a flat original storage form to a right angled Z shaped functional form. The wallboard and stud wall unit 80, in its Z-shaped functional form is then in suitable condition to be used in forming a hollow wall, in a manner similar to the way units 10 are used to form hollow wall 50.
Having completed a detailed disclosure of the preferred embodiments of our invention, so that others may practice the same, we contemplate that variations may be made without departing from the essence of the invention.

-- g _

Claims (9)

The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows:
1. A wallboard and stud unit comprising a wallboard and an elongate sheet metal strip affixed to the back face of said wallboard adjacent to each side edge of said wallboard, said metal strips each having (1) a continuous elongate attachment portion affixed to said wallboard, said metal strips each also having a (2) 180° fold along an edge of said attachment portion which is remote from said wallboard side edge, (3) a narrow elongate flat section overlying said attachment portion and adjoined thereto by said fold and (4) a continuous elongate web portion which is formed and suitably disposed for bending, along an elongate fold line parallel to said side edge of said wallboard, from a storage form, in which said flat section and said web portion are substantially coplanar, to a functional form, in which said web portion extends substantially perpen-dicularly to said wallboard back face and to said attachment portion and said flat section.
2. A wallboard and stud unit as defined in claim 1 wherein said attachment portion is adhesively affixed to said wallboard.
3. A wallboard and stud unit as defined in claim 1 wherein said metal strip further includes a flange portion extending perpendicularly from the outer edge of said web portion.
4. A wallboard and stud unit as defined in claim 3 wherein said flange portion is disposed along and closely spaced from the side edge of said wallboard, when said web portion is in a storage form, and said flange portion is substantially equal in width to the thickness of said wallboard.
5. A wallboard and stud unit as defined in claim l wherein said fold line is formed with a slightly indented elongate depression in the metal.
6. A wallboard and stud unit as defined in claim 1 wherein slightly raised reinforcing ribs extend perpendicular to said fold line, in said web portion, spaced evenly apart at about every four to twelve inches.
7. A wallboard and stud unit as defined in claim 6 wherein said raised ribs have openings at each end suitable for reception of a bending tool.
8. A method of forming a combination of a wallboard and a stud comprising the steps of affixing an attachment portion of an elongate strip of metal to the back face of a wallboard and parallel to a side edge of said wallboard, leaving an elongate web portion of said elongate strip of metal free and suitably disposed to be bent along a fold line away from said wallboard, said fold line adjoining said web portion to a coplanar flat section which is adjoined to said attachment portion along an inwardly disposed 180° fold, and bending said web portion to a position substantially perpendicular to said back face of said wallboard.
9. A hollow wall comprising a plurality of wallboard and stud units as defined in claim 1 wherein said wallboards of some of said units are positioned vertically to form one side of a hollow wall and said wallboards of others of said units are positioned verti-cally to form a spaced parallel opposite side of said wall, said web elements being disposed in a functional form extending substantially perpendicular to said wallboard back face, said web portion providing rigidity to the wallboards of said wall.
CA000575588A 1988-06-06 1988-08-24 Integral wallboard and stud Expired - Lifetime CA1305843C (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US07/202,298 US4843784A (en) 1987-08-10 1988-06-06 Integral wallboard and stud
US07/202,298 1988-06-06

Publications (1)

Publication Number Publication Date
CA1305843C true CA1305843C (en) 1992-08-04

Family

ID=22749295

Family Applications (1)

Application Number Title Priority Date Filing Date
CA000575588A Expired - Lifetime CA1305843C (en) 1988-06-06 1988-08-24 Integral wallboard and stud

Country Status (1)

Country Link
CA (1) CA1305843C (en)

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Effective date: 20050804