GB1570761A

GB1570761A - Building a construction member

Info

Publication number: GB1570761A
Application number: GB313/77A
Authority: GB
Original assignee: Individual
Current assignee: Individual
Priority date: 1977-01-06
Filing date: 1977-01-06
Publication date: 1980-07-09

Description

(54) BUILDING CONSTRUCTION MEMBER (71) I, JAMES DOUGLAS KIRK, Jr., a citizen of the United States Of America, residing at 40 North Tower Road, Oak Brook, Illinois 60521, United States of America do hereby declare the invention for which I pray that a Patent may be granted to me and the nttthed by which it is to be perforted to be particularly described in and by the following statement: Much of the current construction of buildings for industrial, commercial and residential purposes utilize gypsum board construction which has become commonly known as "dry wall" construction. Gypsum board cons:- tion has become especially desirable due to its fire resistant properties.Further, the provision of gypsum board with various finish surface lniinatlons and in forms which have even higher fire resistance than the conventional gypsum board, have made gypsum boards popular, especially for interior partitions. In the past, such walls have been erected by attaching gypsum board to a framework of sheet metal studs and other framing members by use of mechanical fastening means such as sheet metal screws. In such construction, the joints and the heads of mechanical fastening means must be finished by taping and filling.

The prior construction requires substantial manual labor in the erection of the wail framing, in the attachment of the gypsum boards and in the necessary touch up. Further, such partition walls cannot be disassembled without severe damage to the gypsum board which renders the wall system largely unsalvageable in the event that new erection of the wall is required.

This invention provides a construction member and erection technique which greatly simplifies the erection of gypsum board walls.

Use of the construction member of this invention renders construction utilizing such members moveable and reusable in new locations as well as materially reducing the erection time. A basic characteristic of the construction member of this invention is that when used as a wall member it provides its own studs, and when used as a ceiling member, it provides its own joists.

The present invention utilizes the consruction member in embodiments of interior wall systems, exterior wall systems, perimeter panel systems, and provides solid columns, column covers, ducts, duct covers and soffits. The present invention also provides simpliiied and more readily moveable wall systems utilizing panel clips and carrier clips according to this invention Certain preferred emodments of the in invention are shown in the drawings wherein;; Fig. 1 is a twofpart isometnc view of the construction member of the invention showing the member first in its "blank" form, notched for the folding up of its flanges, and secondly in the flanged or folded form, ready for erection;; Fig. 2 is a fragmentary isometric view of a wall made by assEling a plurality of the construction members of Figure 1 back-toback, and sidekby-side, with the juraposed flanges of adjacent construction members on one side of the wall interspersed with those of the other for the mutual support of each construction member at the midpoint of its panel; Fig. 3 is a fragmentary assembly of the construction members of Figure 1 modified somewhat in dimension, and slightly in the end treatment of the flanges, to facilitate their use as ceiling panels;; Fig. 4 is a twoupart fragmentary sectional view of a folded comer at the joint between flange and panel of the construction member of Fig. 1, utilizing one form of adhesive bond at the corner joint, whereas; Fig. 5 is a similar twoXpart fragmentary sectional view of a modified corner joint which is particularly suited for field erection of the self-studding flange; Fig. 6 is a horizontal cross-sectional view of an exterior wall employing the assembly technique of Figure 2, but in which the component materials of the exterior panels, and those as well of the interior panels, are especially chosen for exterior wall application;; Fig. 7 is a vertical cross section of an interior partition wall fabricated of the con struction members of the invention, assembled as in Figure 2, and illustrating the de countable connection of such a wall to the floor and ceiling; Fig. 8 is a fragmentary horizontal cross section of a wall assembled as in Figure 2, illustrating the start of such a wall where it corners with a pre-existing wall; Fig. 9 is a similar fragmentary horizontal sectional view illustrating the framing of an interior doorway located randomly with respect to the joints between abutted construction memibers of the invention when assembled as a wall;; Fig. 10 is a similar fragmentary horizontal sectional view illustrating an exposed corner between walls fabricated as indicated in Fig ure 2; and Fig. 11 is a fragmentary sectional elevation of a wall-ceiling joint illustrating the support of the construction member of the invention when employed as a ceiling member.

Fig. 12 is a perspective view of one embodiment of a panel dip used with a construction member according to this invention; Fig. 13 is a cross-sectional view of one embodiment of a wall according to this invention utilizing the dip shown in Fig. 12; Fig. 14 is a cross sectional perspective view of the comer detail of a wall system of one etriboditetit of this invention utilizing the panel clip shown in Fig. 12; Fig. 15 is a perspective view of a bottom channel having carrier clips for bottom or top support of the wall structure; Fig. 16 is a cross-sectional view of a wall according to this invention suitable for interior or exterior use; Fig. 17 is a cross-sectional view of a wall according to this invention suitable for interior or exterior use;; Fig. 18 is a cross-sectional view of a wall according to this invention suitable for interior or exterior use; Fig. 19 is a cross-sectional view of a construction member according to this invention for insulation on the inside of a masonry wall; Fig. 20 is the cross-sectional view of a wall according to this invention utilizing multiple layers of gypsum board for greater fire resistance; Fig. 21 is a cross-sectional view of one embodiment of a column or beam cover according to this invention; Fig. 22 is a cross-sectional view of a foursided duct, column cover or hollow column or beam according to this invention; Fig. 23 is a cross-sectional view of another embodiment of the comer between sides 301 and 304 of the structure shown in Fig. 10;; Fig. 24 is a cross sectional view of a solid gypsum board post according to this invention; Fig. 25 is a cross-sectional view of a threesided duct, duct cover, or soffit according to this invention; and Fig. 26 is a cross-sectional view of a twosided soffit, duct or duct cover according to this invention.

The construction member of the invention is essentially a panel having perpendicular flanges along a pair of opposed parallel edges, usually the longer edges of the panel. When ready for installation, the member is thus a wide, shallow channel, which may be assembled with other like or similar panels to form the walls or ceiling of a building structure. In the wall arrangement, the studs so formed by the flanges of the construction members on one side of the wall are interspersed medially of those formed by the construction members of the opposite side of the wall so that rhe panel portion of each construction member may be supported at its midpoint, or as near rhereto as may be feasible, as well as at its end.

For interior partition wall construction, the construction members may be of gypsum board, which is available readily in panels 4 feet wide. In conventional dry wall construction, normal interior spacing of the panels between opposite sides of a wall is either 2-1/2 inches or 3-3/8 inches.Thus, taking gypsum board in standard width as the basic component for interior construction, and grooving the panels from one side to fold up a mitered flange using the intact opposite face lamina as a binge, the width of each construction member for wall erection purposes would be approximately 42 inches, or 3essy depending upon the thickness of the board, and the desired thickness of the ttnished wall.The overall width of the construction member, when used to build a wall following the assembly pattern indicated by Fig. 2, also becomes the center line distance of the "studs" formed by the assembly for one side of the wall. Assuming equidistant interspersal with the studs of the opposite side, the center line distance from one stud to next adjacent stud would be 211 inches.

When the meter is intended for ceiling use in which unsupported spans of the order of six feet are contemplated, the width of the panel is reduced to provide appropriate spacing of the ceiling "joists" formed by each pair of jiuctaposed construction member flanges. In this instance, a two-foot wide gypsum board panel is contemplated as the base material with flanges having an outside depth of three inches to provide an overall width of 18 inches, which then also becomes the center-line distance between adjacent joists.

As shown in Figs. 2 and 3, construction member 20 of the invention is basically a shallow, channel-shaped member which may be assembled vertically with others to form a wall, as in Fig. 2, or assembled horizontally with others to form a ceiling, as in Fig. 3.

Fig. 1 shows flat board member 20 which could Ibe a fourufoot wide or a two-foot wide gypsum board sheet, having two V-shaped grooves 22, the sides of which are perpendicular to each other and the vertex of which is parallel to the long edge of the sheet The grooves are spaced inwardly from the edges of the board a distance approximately equal to the desired depth of the flanges 24 to be formed by bending up the narrow side portions of the sheet along the vertices of the Vgrooves, and define between them the panel portion 26 of the board.

The V-shaped grooves may either be milled in a panel or otherwise conventional fabrication, formed by cutting tools, or may be formed as part of the board in its initial fabrication.

The V-grooves leave intact a sufficient thickness of the paper skin or other lanainate on the side of the board 20 opposite the groove to serve as a hinge about which to form the construction member 28 by bending up the flanges 24 as indicated by the transition between the upper and lower portions of Figure 1 of the drawings. An adhesive applied to the V-groove at or before the time of the bending up of the flanges, secures the flanges to the panel portion 26 of the construction member 28 in the perpendicular arrangement indicated in the lower portion of Figure 1 and in subsequent drawings, the bond being sufficient to enable the flanges to materially stiffen, i.e., to enhance the longitudinal bending strength of, the member.

Any gypsum wallboard is suitable for use in this invention. Gypsum wailboards having fire resistant additives are suitable for use in this invention. Also, gypsum wallboards having any desired plastic or metallic coating are suitable. Gypsum lath boards are suitable for use in the structures of this invention and may be plastered over to provide a conventional plastered surface.

Fig. 4 shows the gypsum board blank 20 grooved to the depth of the gypsum filler 30 between the customary paper lamina 32 and 34 on opposite sides thereof. In addition, and by way of example only, I have shown on the notched side of the sheet which becomes the interior in contemplated wall construction assembly an optional additional lamina 36, which may, for example, be a metal foil where a vapor barrier is desired, as in the exterior wall construction shown in cross section in Figure 6. The paper skin 34 on the lower side of the sheet, which becomes the outside, or the "dress" side, when the flanges 24 are folded up, is left intact by the grooving, and may also have an optional layer 38 of a prefinishing material such as vinyl.

To fabricate the construction member 28 from the grooved blank of Figure 4, a viscous liquid adhesive, such as STA-STUCK S S-2000A, manufactured by Speciality Chemicals Company of Elk Grove Village, Illinois, U.S.A., is deposited in the V-grooves in sufficient quantity to provide a slight exuded fillet 40 when the flanges 24 are folded up, as indicated in the lower portion of Fig. 4, and a sufficient waiting period allowed, of the order of 15 minutes, for the adhesive to set up before further handling. If desired for greater strength when using sheet of lighter gauge, e.g., 1/2 inch, the mitered joint may be reinforced at intervals with glue blocks on the inside of the corner.

Fig. 5 illustrates a form of treatment d a gypsum board blank 20' to provide V-grooves during the process of manufacture of the board. In this instance, the upper paper layer 32 of the board is formed into a V-shaped grove 22' penetrating the gypsum filler 30' while the gypsum is still in a fluid state, with suitable provision for the retention of the penetration until the gypsum filler has set up. The Figure 5 arrangement contemplates the application of a contact adhesive 42 to both walls of the V-grooves 22' and to the upper surface of the board 20' along a narrow margin flanking the grooves, all covered by a releas- able protective "peel" tape 44.The arrange merit of Figure 5 would greatly increase the handleability of the construction member and greatly facilitate the erection of the flanges 24' into stable bracing arrangement with the panel portion 26 of the construction member on the job site. Fig. 5 also shows an optional interior laminate 36' of a vapor barrier such as foil, and the optional exterior laminate 38' such as a decorative vinyl.

Comparing the two corner treatments of Figs. 4 and 5, it will be noted that the paperlined groove of the Fig. 5 modification produces a slightly larger outside radius at the comer of the construction member when the flange is bent into place. To compensate for the additional paper material packed into the joint, particularly at or near the folding axis, the V-groove is preferably made slightly larger than 90" so that when the flange 24' is folded up, and the two walls of the groove brought into contact, the flange wall 24' will be perpendicular to the panel portion 26' of the construction member.

For exterior wall construction the sheet material of the outside members is preferably one of greater structural strength, such as wood. In Figure 6, the construction members 46 which constitute the outside of the wall are shown as formed from plywood sheet 48, but for this application particle board is also suitable. In this instance, I show the exterior construction members as sheathed with an outer lamina 50 of metal which may be either steel or aluminium, and preferably prefinished.

Adjacent exterior members 46 are abutted in line preferably with an application of caulking material at the joints, and then fastened together, as indicated, by hardened wood screws driven through the abutting flanges 52.

The construction members 28 for the inside of the exterior wall are of gypsum board and placed in abutting aligned relation with the studs formed by their adjacent flanges 24 interspersed between those of the outer panels.

They are screwed top and bottom to plate members, not shown, in the manner later to be described in connection with interior wall construction.

Gypsum board used as the inner face of an exterior wall, will preferably have an inner layer 36 of a vapor barrier material, and the void between the interior and exterior construction members filled with insulation 54.

The synthetic polymer foam for use in the structures of this invention may be substantially rigid organic polymer foam having good insulating properties and preferably a high temperature at which thermal decomposition occurs. Suitable foams include polystyrene, styrene-maleIc anhydride, phenolic, such as phenol formaldehyde, polyurethane, vinyl, such as polyvinyl chloride and copolymers of polyvinyl chloride and polyvinyl acetate, epoxy, polyethylene, urea formaldehyde, acrylic, polyisocyanurate and the like. Preferred foams are selected from the group consisting of poly- styrene and polyuethane. Particularly suitable foams are closed cell foams which provide high insulating properties and low permeability to moisture.Such organic polymer foams are substantially rigid bodies of foam and are well known in the art. For its utility as a bonding material as well as in providing highly efficient thermal insulation, foamed-inplace polyurethane may be used with suitable provision in the top plates of the wall for the pouring of the material from portable equipment in the field, and with fixtures as necessary to preent the "oil canning" of the panels as the polyurethane expands and sets up as is known from well known feam-invplace techniques.

As in typical dry-wall construction in com metal buildings, an interior wall (Fig 7) is positioned by locating a channel-shaped floor track 60 along the intended axis of the wall.

Such channels are usually roll4ormed sheet steel in light gauge, easily penetrated by selfdrilling, self-tapping screws, and are secured in place, openside up, by power-driven nails 62, or by tempered concrete nails, driven through the web of the channel or 'floor track' into the floor 64.

A hemmed ceiling track 66 of similar but wider channel shape and having smooth, hemmed, rounded edges on its flanges, is plumbed with the floor track 60 and secured by screws to the ceiling 68, with the track open down wardly. The flanges 24 of the gypsum board conuction members 28 are cut off at their lower ends 70 sufficiently to clear the floor track and to permit use of the track as raceway for electrical conduit. One side of the wall is then assembled by inserting the construction members 28 into the ceiling track, and abutting them to the floor track, to which they are secured with screws 72 driven through the panel portion 26 of the construction member along its bottom edge, as indicated in Fig. 7.

With one side of the wall, or a substantial portion thereof, assembled, the opposite side is then applied, and secured in place in the same manner. The flanges of the ceiling track 66 provides the upper trim of the wall, and the power-driven screws 72 by means of which the construction members are secured to the floor track are concealed by the application of a base molding 74, usually molded vinyl, after the erection of the wall.

The starting of a wall, where it adjoins another wall with an inside comer on both sides, is illustrated in Fig. 8. In such case, and in addition to the laying of floor and ceiling track as described in connection with Figure 7, a hemmed track 76 is secured vertically to the existing wall 78 on the desired axis of the new partition wall and lightly secured in place in any convenient manner, as for example by a pair of spaced self-tapping screws.A flanged gypsum board construction member 28 is then set into place within the hemmed wall track 76 and a sheet metal stud 80 is placed against the inside surface of the flange 24 of the gyp sum board construction member 28, and screwed to the existing wall 78 at several levels by pairs of power driven screws 82 as indicated in Figure 8, leaving sufficient space, however, for the subsequent insertion of the cut edge 84 of the panel portion 26 of the consruction member 28 on the opposite side of the wall.

Fig. 9 illustrates doorway framing occurring randomly with respect to the joints between adjacent construction members. The doorway is cut at the desired location which will have been predetermined by a gap in the floor track 60 of width to accommodate the door jamb 90. A sheet metal stud 92 is then inserted between the panel portions 26 of the gypsum board on opposite sides of the wall, and the cut ends 94 thereof are secured to the stud by screws 96. The sheet-metal door jamb 90 may be of wall-gripping press-on type, with integral doorstop 98, outer trim 100, and retum anchor portions 102.

The detailing of an exposed corner of an interior partitioning is illustrated in Figure 10, which is also a fragmentary horizontal section.

The construction member 108 on the inside of the corner is secured to a sheet metal stud 110 having a corner molding 112 riveted to one of its flanges, by means of screws driven 114 through the panel of the interior construction member 108 and into the stud. The end panel 116 of the outside od the existing wall has its cut edge seated in the channel of the corner molding 112, which is secured to the stud.The cornering wall 118 is then started by abutting the flange 24 of the construction member 122 on the inside of the new wall against the construction member 108 on the inside d the existing wall, with their edges flush, and securing the beginning construction panel 122 of the new wall to the end stud of the existing wall by means of self-tapping screws 124, driven through the double thickness of the gypsum board and into the flange of the stud 1110. The outside side of the cornering wall is then started by the insertion of the cut edge of the cornering outer construction member 126 into the space between the corner molding 112 and the end of the existing wall 106.

Ceiling installation is indicated by Figure 11, a particularly suitable application being relatively long and narrow ceilings such as in corridors and the like. In such applications, the long dimension of the construction member 28 is placed transversely of the passageway, with the construction member unsupported between its ends, which rest upon sheet metal angles 130 secured to the adjacent wall 132 by means of screws. Hallway ceilings are quite typically lower than those of the adjacent spaces for the accommodation of duct wok for utilities supplied to the privately occupied adjacent spaces, and the construction member 28 of the invention is especially suited to use in so-called "dropped" ceilings, of which corridors and passageways are a typical occrtence.

In such cases, as indicated in Figure 11, the ends 134 of the upstanding flanges 24 of the individual construction members are relieved at an angle to permit the insertion of the member diagonally into the space above its intended level, the resting of one of its ends upon the supporting angle or other sup port while still positioned diagonally, and teen the rotation of the opposite end of the panel down onto its support. In ceiling application, the construction members are preferably connected together for mutual support, this being accomplished by the driving of screws 136 through abutted upstanding flanges of adjacent members, with the omission of such screws at intervals where desired for access to the overlying space.

One of the advantages of the wall structure of my invention is the ease of erection and the capability to dismantle the walls and reassemble them using the same materials. Such flexibility is very desirable in modem commercial buildings which may be utilized for different purposes at different times but where a permanent appearing, fire resistant and soundproof or insulated structure is desired.

The panel clip shown in Figs. 12 through 14 aid in the ease of erection and in the mobility of the wall system.

As best seen in Fig. 12, panel clip 150 comprises a generally U-shaped sheet metal or plastic shape having wall 156 which joins opposing legs 153 and 154 at one end. Legs 153 and 154 having outwardly extending flanges 1511 and 152 at their other end. Legs 153 and 154 are separated by a distance so that spring action is obtained when clip 150 is in position holding the building construction member. Legs 153 and 154 may have indentations or barbs 1518 to maintain clip 150 firmly in position. Wall 156 may have barbs 159 to impale the clip upon the building construction member flanges. It is preferred that panel clip 150 have means, such as the aforesaid barbs, to maintain the dip firmly in desired position during erection while fastened to only one building construction member flange.The panel clips are desirably utilized every 2 to 4 feet in the wall construction of this invention.

The panel clip may have resilient pad 157 attached to the outer portion of wall 156 to provide sound deadening to wall structures according to this invention.

Fig. 13 shows the use of panel clip 150 in a typical wall construction wherein building construction member 170 has central panel portion 171 and flange 174 extending from one face, adhesive means in V-groove joint 17-5 maintaining flange 174 in perpendicular relation to central panel portion 171. Panel 180 is the central panel portion of a similar building construction member enclosing the opposite side of the wall from building con struction member 170. As seen in Fig. 13, clip 150 in addition to holding adjacent building construction members together by spring action against adjacent flanges, also acts as a spacer between the opposing panels of the wall.The action of clip 150 as a spacer results from flanges 151 and 152 being in the same planar relation and the distance from the plane through flanges 151 and 152 and the plane through wall 156 being substantially parallel and the same distance on all panel clips. Thus, the length of the flange 174 on building construction member 170 is not a critical feature and the end surface of the flange 174 is not important. Further, continuity between the opposing wall panels is eliminated except through resilient pad 157, which provides a superior sound barrier.

Fig. 14 illustrates utilization of clip 150 at an inside wall corner joint detail.

Fig. 15 shows the use of carrier clips 190 in one embodiment of the wall structure of this invention. Carrier clip 190 hangs on one of upstanding legs 202 and 203 of floor channel 200 and carries the load of the building construction member of this invention without the necessity of mechanical fastening.

Carrier clip 190 has inverted U-shaped portion with legs 193 and 194 to hold clip 190 snugly in position against channel leg 202. Clip 190 has U-shaped portion bounded by legs 191 and 193 of suitable width to snugly hold the thick ness of the wall panels of the building construction member of this invention. The building wall panel assemblies are simply set into carrier clip 190 which holds them snugly at the bottom, the wall assembly being mechanically fastened or snap fastened at the top by an inverted U similar to that shown in Fig.

7. Such construction provides interior partitions which may be readily disassembled and reassembled in a different location utilizing the same materials, the only marks remaining being the holes necessary to secure floor channel 200 to the floor.

Fig. 16 shows the construction detail of a wall structure according to this invention which may be used in either interior or exterior con striation. Building construction members are shown as 170 having central panel portion 171 and flanges 174 and 17i6 extending equally and perpendicularly in the same direction from one face thereof. The building construction mem bers are assembled in juxtaposed planar array with flanges of adjacent members abutting each otter as showa in Fig. 16.The core post tion of the wall comprNseVngid synthetic poly- newer foam slabs 210 having a central slot 21,1 for receiving flanges of adjacent building con snuiction members. The other side of the building wall may be faced with any suitable surfacing material. Foam slabs 210 may be faced with a vinyl covering or any rigid panel may be fastened to the foam slabs, such as wood layer 220 sin in Fig. 16. Foam slab 210 may be adhesively fastened to building construction members 170 and wood sheets 220 may be adhesively fastened to foam slabs 210 thereby providing a rigid, composite and insulated wall structure.

Fig. 17 shows another embodiment of a wall system according to this invention wherein building construction members 170 are assem bled in the same fashion as previously described for Fig. 16 utilizing foam slabs 230 similar to foam slabs 210 and having slot 231 coriesponding to slot 2111 previously described.

Foam slab 230 has precast concrete panel 232 affixed to its outer surface. The wall structure is assembled in the same fashion as described for the wall structure shown in Fig. 16 except that the outer wall layer of concrete is affixed to the foam slab and requires grouting between adjacent concrete joints at the edges.

Fig. 18 shows yet another embodiment of a wall system of this invention using building construction members 170 and 270. In this embodiment the opposing building construction members are the same and have between their flanges synthetic polymeric foam having slots 242 and 252 for receiving adjacent flanges of the opposing building construction members. Opposing building construction meters 170 and 270, together with the foam insulation attached may be readily ad hered together to form a utilized construction by gluing the faces of foam board 240 and 250 together upon assembly. The embodiment shown in Fig. 18 is particularly well suited to the builder with minimum equipment at the job site since slots 242 and 252 can be formed by using two narrower pieces of foam.

Fig. 19 shows use of the building construction members 170 in an embodiment of this invention providing perimeter interior finishing of masonry walls. Building construction members 170 have synthetic polymeric foam sheet 275 filling the space between their flanges. The wall panel assembly made up of construction member 170 and foam 275 may be adhered to the masonry wall for permanent installation or may be securely mounted into channels at top and bottom for removeable installation.

Fig. 20 shows a wall system according to this invention similar to that shown in Fig. 2 except that building construction member 170 has a similar but smaller building construction member 280 adhesively mounted within the shallow channel of construction member 170 to provide a double thickness gypsum board wall on one or both sides of the wall system.

The double thickness of the gypsum board provides enhanced fire protection and as is readily apparent may be used in the structures described above. The double thickness gypsum board may be produced by adhering the flat pieces of gypsum board together and then Vgrooving through the two pieces of gypsum board to the outer lamina or they may be produced by making construction member 170 separate from construction member 280 and then adhering them together.

Panel clips as shown in Fig. 12, may be used in any of the wall and ceiling systems described above. Likewise, the carrier clip 190 as shown in Fig. 15 may be used in any of the wall and ceiling construction shown. While many of the structures have been described with respect to walls, it is apparent the structures are suitable for use as ceilings.

Fig. 21 illustrates use of building construction members of this invention as beam covers, column covers and fireproofing assemblies.

Fig. 21 shows I beam 290 encased in a fire resistant gypsum board protective covering.

Construction members 292 and 294 are similar to building construction members 170 described earlier. End coverings 293 and 295 are similar to side coverings 292 and 294 with the addition of a second inwardly extending flange 296 and 297 formed in the same fashion utilizing the V-groove-glue adhesive technique previously described. The entire covering assembly may be held with panel clips 150 as shown. Side panels 292 and 294 may be completely prefabricated while the second flange on end panels 293 and 295 may be folded without gluing at the time of installation to provide easy installation around the beam.

Additional fire protection to the web of the I beam may be afforded by gypsum boards 291 and 298 on each side of the I beam web which are securely held in place by the action of panel clips 150.

Hollow columns, column covers, ducts and duct covers may be constructed using the principles of this invention as shown in Fig.

22. A four-sided structure which may be used as a duct, duct cover, hollow column or column cover is shown as 300 having sides 301, 302, 303 and 304 formed by the V-groove-adhesive technique of this invention utilizing conventional or high fire resistant gypsum board.

Fig. 23 shows an embodiment Of the comer junction between sides 301 and 304 of the structure shown in Fig. 22. The corner as shown in Fig. 23 is also formed by the same V-groove-adhesive technique.

Solid columns may be provided from a flat sheet by using the principles of this invention as shown in Fig. 24. For example, a fiat sheet of gypsum board starting with one edge portion 341 may be V-grooved and folded at right angles to form joint 351 and panel portion 342 which may be V-grooved to form joint 352 and panel portion 343 which may be V-grooved to form joint 353 and panel portion 344 which may be V-grooved to form joint 354 and panel portion 345 which may be Vgrooved to form joint 355 and panel portion 346 which may be V-grooved to form joint 356 another end panel tion 347. Of nBrse, it is apparent that the process may be continued to form solid columns Of any desired shape or size to meet specific loadRearing qualities. The solid columns or beans, such as illustrated by Fig. 24, may be utilized by use of any suitable adhesive or adhesive taught to be suitable for the V-groove corners. Thus, both hollow and solid gypsum board struc- tures may be provided according to this invention.

Fig. 25 shows a threeffided duct, duct cover, soffit, beam cover or ceiling panel according to this invention which may be fabricated from gypsum board to provide a fire resistant structure. When used as ceiling panels, the structure as shown in Fig. 3 may be used or the panel clips described above may be used.

Fig. 26 shows a twosided duct, duct cover, soffit or been cover according to this invention which may be readily fabricated from gypsum board to provide a structure having desired finished facing and to provide fire resistant structures.

The V-groove-adhesive gypsum board structures of my invention may utilize any suitable adhesive wbich sets sufficiently rapidly for field assembly and which secures the cementious gypsum. While the construction members may be fabricated at the construction site, it is obvious they may also be fabricated at a central facility.

While in the foregoing specification this invention has been described in relation to certain preferred embodiments thereof, and many details have been set forth for purpose of illustration, it will be apparent to those skilled in the art that the invention is susceptible to additional embodiments and that certain of the details described herein can be varied considerably without departing from the basic principles of the invention.

WHAT I CLAIM IS: 1. A building construction member which may be shipped to the jobsite in fiat condition and formed at the jobsite into a wide, shallow, channel-shaped member with a central panel portion and having flanges extending equally and perpendicularly in the same direction from one face of the panel at opposite long edges thereof, comprising a rectangular panel of gypsum board having face laminate and a core layer of gypsum therebetween, said board having on one face thereof two V-grooves con sizing of one V-groove set inwardly from each long edge for the full length of the gypsum board which penetrate the gypsum core substantially for the entire tepth of said core leaving intact a sufficient thickness of the lamina of the face opposite the grooved face to act as a hinge, said grooves having adhesive means Xein and defining between them a central panel portion with flanking flanges outwardly of said grooves when said flanges are hinged peipen & iiariy to said central panel portion and retained in that position by the adhesive means in said grooves, the adhesive means being present only in the grooves.

2. The consttstion member of Claim 1 having a contintious, unbroken outer lamina wpanning said panel from flange to opposite flange on the face thereof opposite said one face, and extending at least around the outsides of the corners formed by the juncture of said panel and flanges.

3. The construction member of Claim 2 in which the unbroken lamina is a paper skin of the gypsum board.

4. The construction member of Claim 3 having additional prefinished lamina on at least one side.

5. The construction member of Claim 2 wherein said panel is formed by a bonded miter joint 6. The construction member of Claim 5 in which the unbroken lamina is a paper skin of the gypsum board.

7. The building construction member of Claim 1 in which the grooves are lined with a lamina secured to the gypsum area.

8. The building construction member of Claim 7 in which rhe lamina lining rhe groove is an integral part of the lamina covering the grooved face of the board.

9. The building construction member of Claim 7 in which the lamina lining the grooves is coated with a contact adhesive covered by a peelable protective strip.

10. An interior building wall having two faces, each of said faces comprising multiple

**WARNING** end of DESC field may overlap start of CLMS **.

Claims

**WARNING** start of CLMS field may overlap end of DESC **. which are securely held in place by the action of panel clips 150. Hollow columns, column covers, ducts and duct covers may be constructed using the principles of this invention as shown in Fig. 22. A four-sided structure which may be used as a duct, duct cover, hollow column or column cover is shown as 300 having sides 301, 302, 303 and 304 formed by the V-groove-adhesive technique of this invention utilizing conventional or high fire resistant gypsum board. Fig. 23 shows an embodiment Of the comer junction between sides 301 and 304 of the structure shown in Fig. 22. The corner as shown in Fig. 23 is also formed by the same V-groove-adhesive technique. Solid columns may be provided from a flat sheet by using the principles of this invention as shown in Fig. 24. For example, a fiat sheet of gypsum board starting with one edge portion 341 may be V-grooved and folded at right angles to form joint 351 and panel portion 342 which may be V-grooved to form joint 352 and panel portion 343 which may be V-grooved to form joint 353 and panel portion 344 which may be V-grooved to form joint 354 and panel portion 345 which may be Vgrooved to form joint 355 and panel portion 346 which may be V-grooved to form joint 356 another end panel tion 347. Of nBrse, it is apparent that the process may be continued to form solid columns Of any desired shape or size to meet specific loadRearing qualities. The solid columns or beans, such as illustrated by Fig. 24, may be utilized by use of any suitable adhesive or adhesive taught to be suitable for the V-groove corners. Thus, both hollow and solid gypsum board struc- tures may be provided according to this invention. Fig. 25 shows a threeffided duct, duct cover, soffit, beam cover or ceiling panel according to this invention which may be fabricated from gypsum board to provide a fire resistant structure. When used as ceiling panels, the structure as shown in Fig. 3 may be used or the panel clips described above may be used. Fig. 26 shows a twosided duct, duct cover, soffit or been cover according to this invention which may be readily fabricated from gypsum board to provide a structure having desired finished facing and to provide fire resistant structures. The V-groove-adhesive gypsum board structures of my invention may utilize any suitable adhesive wbich sets sufficiently rapidly for field assembly and which secures the cementious gypsum. While the construction members may be fabricated at the construction site, it is obvious they may also be fabricated at a central facility. While in the foregoing specification this invention has been described in relation to certain preferred embodiments thereof, and many details have been set forth for purpose of illustration, it will be apparent to those skilled in the art that the invention is susceptible to additional embodiments and that certain of the details described herein can be varied considerably without departing from the basic principles of the invention. WHAT I CLAIM IS:

1. A building construction member which may be shipped to the jobsite in fiat condition and formed at the jobsite into a wide, shallow, channel-shaped member with a central panel portion and having flanges extending equally and perpendicularly in the same direction from one face of the panel at opposite long edges thereof, comprising a rectangular panel of gypsum board having face laminate and a core layer of gypsum therebetween, said board having on one face thereof two V-grooves con sizing of one V-groove set inwardly from each long edge for the full length of the gypsum board which penetrate the gypsum core substantially for the entire tepth of said core leaving intact a sufficient thickness of the lamina of the face opposite the grooved face to act as a hinge, said grooves having adhesive means Xein and defining between them a central panel portion with flanking flanges outwardly of said grooves when said flanges are hinged peipen & iiariy to said central panel portion and retained in that position by the adhesive means in said grooves, the adhesive means being present only in the grooves.

5. The construction member of Claim 2 wherein said panel is formed by a bonded miter joint

6. The construction member of Claim 5 in which the unbroken lamina is a paper skin of the gypsum board.

juxtaposed construction members as defined by Claim 1 in planar array with flanges of adjacent members vertically abutting each other, the abutted flanges of those members comprising one face of the wall being medially intesspersed in touching bracing contact with the opposite panel and forming studs between the studs so formed by the adjacent flanges of the members of the opposite face.

11. The wall of Claim 10 in which said interposed studs formed by the members of one face of the wall engage the panel portion of the members of the opposite face.

12. An interior partition wall in accordance with Claim n 10 wherein the assembly is main- tained by connection of said members top and bottom to ceiling and floor.

13. An exterior building wall having two faces, the inner of said faces comprising multiple juxtaposed construction members as deiined by Claim 1 in planar array with flanges of adjacent members vertically abutting each other, the outer of said faces comprising a rectangular panel of wood having integral flanges extending equally and perpendicularly in the same direction from one face of the panel at opposite long edges thereof, the abut ted flanges of the members of one face of the wall being medially interspersed in touching bracing contact with the opposite panel and foaming studs between the studs so formed by the adjacent flanges of the members of the opposite face.

14. The exterior building wall of Claim 13 having additional prhinished lamina on the extesior of the outer face.

15. The exterior building wall of Claim 14 wherein said additional prefinished laming is selected from the group consisting of steel and aluminium.

16. The exterior building wall of Claim 15 having insulation between said faces.

17. A building wall or ceiling having one face comprising multiple juxtaposed building construction members as defined by Claim 1 in planar array with flanges of adjacent members abutting each other.

18. The building wall or ceiling of Claim 17 wherein the said abutted flanges of adjacent members are held by a panel clip comprising a generally U < haped sheet metal shape having opposing legs and outwardly extending flanges at the end of each leg so that legs hold flanges of adjacent members securely together by spring action and said outwardly extending flanges are adjacent the central panel portion of each adjacent building construction member

19.A building wall having two faces, each of said faces comprising multiple juxtaposed construction members and panel clips as defined in Claim 18, the abutted flanges of those members comprising one face of the wall being medially inteppersed with the opposing panel and forming studs between the studs so formed by the adjacent flanges of the members of the opposite face, the wall of said panel clip joining opposing legs of the U-lshaped clip having a resilient pad in touting bracing contact with the opposite panel providing accurate spacing and providing sound deadening to the wall.

20. The building wall of Claim 19 additionally having carrier clips holding said building construction member snugly against a floor chrinel, said carrier clips comprising an invented U-shaped portion to hold said clips snugly in position against a floor channel leg and an upstanding U-shaped portion to hold said building construction member snugly at the bottom.

21. The building wall of Claim 19 having synthetic polymeric foam bereen said building construction members to insulate said wall.

22. A building wall according to Claim 17 wherein carrier clips hold said building con sttuttion member snugly against a floor channel, said carrier clips comprising an inverted U-shaped portion to hold said clip snugly in position against a floor channel leg and an upstanding U-shaped portion to hold said building conston member snugly at the batrona.

23. A building wall according to Claim 17 wherein a synthetic polymeric foam sheet fills the space between said flanges and the wall panel assembly comprising said construction member and said foam is mounted adjacent the interior of a masonry wall.

24. The building wall or ceiling of Claim 17 having synthetic polymeric foam slabs having a slot for receiving said juxtaposed building construction member flanges, said foam slabs having a lamated layer forming the opposing wall surface to said building construction rnernbers.

25. The building wall or ceiling of Claim 24 wherein said laminated layer comprises precast concrete panels.

26. A building wall having two faces, each of said faces comprising multiple juxtaposed construlotion members as defined in Claim 1 in paralld array with flanges of adjacent members abutting each other, the abutted flanges of those members comprising one face of the wail being medially interspersed with the opposing panel, a synthetic polymeric foam sheet in the space between said flanges, said polymeric sheet having a slot for receiving said juxtaposed building construction member flanges of the opposed construction members, said construction member flange ends in touching bracing contact with the foam of said opposing construction member, thereby providing inslation and sound deadening.

27. The building wall or ceiling of Claim 17 having two adjacent thicknesses of said con struction members.

28. A beam or column cover and fire-proof- ing assembly comprising two aonstruction members as defined in Claim 1 as side covets, adjacent end covering members of the same gypsum board aonstruction having an addi twoal V-groove and end flange at each end thereby forming C-shaped end covers, the opposing end flanges of said end covers abutting the end flanges of said side coverings.

29. A hollow column, column cover, soffit, duct or duct cover, coaaprising gypsum board which may be shipped to the job site in flat condition and formed at the job site, comprising a rectangular panel of gypsum board having face larainae and a core layer of gypsum therebetween, said board having on one face thereof one to three V-grooves set inwardly from the long edges for the full length of the gypsum board which penetrate the gypsum code substantialiy for the entire depth of said core leaving intact a sufficient thick ness of the lnminae of the face opposite the grooved face to act as a hinge, said grooves having adhesive means therein and forming a two, three or four sided structure when the gypsum board is hinged perpendicularly at slid grooves and retained in that position by the adhesive means in said grooves, the adhesive means being present only in the grooves.

30. A solid construction post comprising a rectangular panel of gypsum board having face laminate and a core layer of gypsum therebetween said gypsum board having on one face thersof parallel V-grooves for the full length of the gypsum board set inwardly from the long edges thereof which penetrate the gypsum cores substantially for the entire depth ob said core leaving intact a sufficient thickness of the lamina of the face opposite the grooved face to act as a hinge, said grooves having adhesive means therein and forming a solid post when the gypsum board is hinged perpendicularly at each of said grooves and retained in that position by adhesive means, thereby wrapping the gypsum board around itself forming a solid shape to the desired size, the adhesive means being present only in the grooves.