US20050086905A1 - Shear wall panel - Google Patents

Shear wall panel Download PDF

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Publication number
US20050086905A1
US20050086905A1 US10970497 US97049704A US2005086905A1 US 20050086905 A1 US20050086905 A1 US 20050086905A1 US 10970497 US10970497 US 10970497 US 97049704 A US97049704 A US 97049704A US 2005086905 A1 US2005086905 A1 US 2005086905A1
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Prior art keywords
plate
wall panel
shear wall
material
holes
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Abandoned
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US10970497
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Gregory Ralph
Michael Whitticar
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Dietrich Industries Inc
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Dietrich Industries Inc
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    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04CSTRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/26Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
    • E04C2/28Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups combinations of materials fully covered by groups E04C2/04 and E04C2/08
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04CSTRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/30Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
    • E04C2/34Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts
    • E04C2/3405Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts spaced apart by profiled spacer sheets
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04CSTRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/30Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
    • E04C2/34Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts
    • E04C2/3405Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts spaced apart by profiled spacer sheets
    • E04C2002/3411Dimpled spacer sheets
    • E04C2002/3433Dimpled spacer sheets with dimples extending from both sides of the spacer sheet
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04CSTRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/30Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
    • E04C2/34Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts
    • E04C2/3405Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts spaced apart by profiled spacer sheets
    • E04C2002/3444Corrugated sheets
    • E04C2002/3455Corrugated sheets with trapezoidal corrugations

Abstract

Shear wall panels and methods of manufacturing shear wall panels. Various embodiments comprise wallboard material employed with a sheet stiffener in the form of a plate to form a wall panel that may be used in applications wherein shear panels are desired.

Description

    CROSS-REFERENCE TO RELATED APPLICATIONS
  • This nonprovisional application claims priority and the benefit of under 35 U.S.C. § 119(e) from U.S. Provisional Patent application Ser. No. 60/513,356, filed Oct. 22, 2003, the disclosure of which is herein incorporated by reference.
  • BACKGROUND OF THE INVENTION
  • 1. Field of the Invention
  • The invention relates to construction materials and, more particularly, to shear wall panels for residential and commercial buildings.
  • 2. Description of the Invention Background
  • Regardless of whether the frame of a building is constructed from wood and/or steel, such frame structures are commonly subjected to a variety of forces. Among the most significant of such forces are gravity, wind, and seismic forces. Gravity is a vertically acting force while wind and seismic forces are primarily laterally acting.
  • The walls of a structure fabricated from wood components are commonly formed from a collection of wall studs that are connected to top and bottom members or “plates” at desired spacing schemes (i.e., 16 inches from center to center). The studs and plates usually comprise nominal 2×4 and or 2×6 boards. In metal frame arrangements, the studs and plates commonly comprise C-shaped members that are interconnected, for example, by screws or other fastening techniques.
  • To provide the frame with resistance to the types of lateral forces mentioned above, shear wall panels are commonly attached to portions of the frame formed by the vertically extending studs and top and bottom plates such that they extend therebetween. For example, in a wood frame construction, a shear wall panel is commonly formed by the application of one or more types of sheathing such as plywood, fiberboard, particleboard, and/or drywall to the inside or both sides of the wall frame. The sheathing may be fastened to the wall frame at many points, thus creating a shear wall panel. The shear wall panel is used to transfer the lateral forces acting on the frame of the building to the walls of subsequent floors below it and ultimately to the foundation upon which the walls are supported.
  • One form of wallboard structure purportedly for metal construction applications is disclosed in U.S. Pat. No. 5,768,841 to Swartz et al. That wallboard structure has a metal sheet attached to an entire side of a gypsum panel with an adhesive. Another wallboard panel is disclosed in U.S. Pat. No. 6,412,247 to Menchetti et al. The International Building Code in its “Steel” section also references the use of shear walls utilizing panel type members, i.e., drywall, steel plates and plywood, etc.
  • SUMMARY
  • One embodiment of the subject invention is directed to a shear wall panel that includes a plate that has first and second substantially planar sides and a plurality of holes that extend therethrough. A first flanged portion extends around at least a portion of at least one of the holes and protrudes from the first substantially planar side of the plate. A second flanged portion extends around at least a portion of at least one other of the holes and protrudes from the second substantially planar side of the plate. Wallboard material is applied to the first and second sides of the plate.
  • Another embodiment of the present invention is directed to a shear wall panel that includes a plate that has first and second substantially planar sides and a pair of lateral edges and a pair of end edges. A plurality of holes extend through the plate. A flanged portion extends along each lateral edge and protrudes outward from the first planar side of the plate. Wallboard material is applied to the first planar side of the plate.
  • Yet another embodiment of the present invention comprises a shear wall panel that includes a plate that has first and second substantially planar sides, a pair of lateral edges and a pair of end edges. A plurality of holes extend through the plate. A flanged portion extends along each end edge and protrudes outward from the first planar side of the plate. Wallboard material is applied to the first planar side of the plate.
  • Another embodiment of the present invention comprises a shear wall panel that includes a plate that has first and second substantially planar sides, a pair of lateral edges and a pair of end edges. A plurality of holes extend through the plate. A lateral flange extends along each lateral edge and protrudes outward from the first planar side of the plate. An end flange extends along each end edge and protrudes outward from the first planar side of the plate. Wallboard material is applied to the first planar side of the plate.
  • Another embodiment of the subject invention comprises a shear wall panel that includes a plate that has having first and second substantially planar sides, a pair of lateral edges and a pair of end edges. A plurality of holes extend through the plate. A flanged portion extends around at least a portion of at least one of the holes and protrudes from the first substantially planar side of the plate. A lateral flange extends along each lateral edge and protrudes outward from the first planar side of the plate. Wallboard material is applied to the first planar side of the plate.
  • Yet another embodiment of the subject invention comprises a shear wall panel that includes a plate that has first and second substantially planar sides and a plurality of holes extending therethrough. Wallboard material is applied to the first and second sides of the plate and extends through the holes therein such that the plate is substantially embedded in the wallboard material.
  • Still another embodiment of the subject invention comprises a shear wall panel that includes a corrugated plate that has a first side and a second side and a plurality of holes therethrough. Wallboard material is applied to at least one side of the corrugated plate.
  • BRIEF DESCRIPTION OF THE DRAWINGS
  • In the accompanying Figures, there are shown present embodiments of the invention wherein like reference numerals are employed to designate like parts and wherein:
  • FIG. 1 is a partial perspective view of a portion of a building wall employing an embodiment of a shear wall panel of the present invention;
  • FIG. 1A is an end view of a back-to-back stud assembly that may be used to frame a building wall with which an embodiment of a shear wall panel of the present invention may be used;
  • FIG. 1B is an end view of a tube-shaped stud assembly that may be used to frame a building wall with which an embodiment of a shear wall panel of the present invention may be used;
  • FIG. 1C is an end view of a structural I beam that may be used to frame a building wall with which an embodiment of a shear wall panel of the present invention may be used;
  • FIG. 2 is a cross-sectional view of one shear wall panel embodiment of the present invention;
  • FIG. 3 is an enlarged cross-sectional view of the panel of FIG. 2;
  • FIG. 4 is a perspective view of one plate embodiment of the present invention;
  • FIG. 4A is a perspective view of another plate embodiment of the present invention;
  • FIG. 4B is a perspective view of another plate embodiment of the present invention;
  • FIG. 4C is a perspective view of another plate embodiment of the present invention;
  • FIG. 5 is a perspective view of a mold employed to fabricate a panel embodiment of the present invention;
  • FIG. 6 is a diagrammatic view of an automated assembly process for fabricating various panel embodiments of the present invention;
  • FIG. 6A is a diagrammatic view of another automated assembly process for fabricating various panel embodiments of the present invention;
  • FIG. 6B is a diagrammatic view of another automated assembly process for fabricating various panel embodiments of the present invention;
  • FIG. 7 is a cross-sectional view of one shear wall panel embodiment of the present invention;
  • FIG. 8 is an enlarged cross-sectional view of the panel of FIG. 7;
  • FIG. 9 is a cross-sectional view of one shear wall panel embodiment of the present invention;
  • FIG. 10 is an enlarged cross-sectional view of the panel of FIG. 9;
  • FIG. 10A is an enlarged cross-sectional view of another panel embodiment of the subject invention;
  • FIG. 11 is a perspective view of another plate embodiment of the present invention;
  • FIG. 12 is a perspective view of another plate embodiment of the present invention;
  • FIG. 13 is a perspective view of another plate embodiment of the present invention;
  • FIG. 14 is a cross-sectional view of one shear wall panel embodiment of the present invention;
  • FIG. 15 is an enlarged cross-sectional view of the panel of FIG. 14;
  • FIG. 1 5A is an enlarged cross-sectional view of another panel embodiment of the subject invention;
  • FIG. 16 is a cross-sectional view of one shear wall panel embodiment of the present invention;
  • FIG. 17 is a perspective view of another plate embodiment of the present invention;
  • FIG. 18 is an enlarged cross-sectional view of the panel of FIG. 16;
  • FIG. 18A is an enlarged cross-sectional view of another panel embodiment of the subject invention; and
  • FIG. 19 is a perspective view of a mold employed to fabricate the panel of FIGS. 16-18 of the present invention.
  • DETAILED DESCRIPTION OF THE INVENTION
  • Referring now to the drawings for the purposes of illustrating the present embodiments of the invention only and not for the purposes of limiting the same, FIG. 1 illustrates a portion of a building wall 10 that employs a shear wall panel 100 of the present invention. The wall 10 shown in the Figure is constructed from conventional steel studs 20 that extend between and are attached to an upper track 30 and a lower track 40. The panel 100 may be attached to the studs 20 and upper and lower tracks by screws or other suitable fastener arrangements.
  • The wall 10 may be located in a portion of a building structure wherein it is desirable to employ wall panels that are better adapted to resist forces generated by, for example, wind loading, seismic loading and other lateral and vertical loads resulting from building design when compared to standard plywood or gypsum wall panels. The reader will appreciate that various embodiments of the present invention will work equally as well in connection with walls that are fabricated from wood studs, plates, etc.
  • Depending upon the particular application, various types of stud arrangements could be employed. For example, FIG. 1A a depicts the use of back-to-back stud assembly 21 which may be formed by attaching two conventional studs together by screws, welds, etc. The back-to-back stud assemblies 21 may be used in place of the studs 20 that are shown in FIG. 1. FIG. 1B depicts the use of tube-shaped stud assemblies 23 which may be fabricated by welding two conventional studs 20 or pieces of track together. Such tube shaped assemblies 23 may be used in place of the studs 20 that are shown in FIG. 1. In other applications, structural I beams 25 may be used in place of the studs 20 that are shown in FIG. 1. See FIG. 1C.
  • FIGS. 2 and 3 illustrate one shear wall panel embodiment of the present invention. As can be seen in those Figures, this shear wall panel 100 embodiment comprises a plate 110 that has a series of holes 130 therethrough. In one embodiment, the plate 110 is eight feet long (dimension “A”) and four feet wide (dimension “B”). See FIG. 4. Such plate size corresponds to the standard wallboard lengths that are commonly employed in the industry. Other shear wall panel embodiments of the present invention may be provided in a myriad of different sizes, depending upon the application. For example, dimension “A” may be ten feet long, twelve feet long, etc.
  • In one embodiment, the plate 110 is fabricated from 22 gage steel. However, other embodiments may employ plates fabricated from other gages of steel or other types of materials such as, for example, stainless steel, aluminum, wood, lead, plastic and other polymeric products. In this embodiment, plate 110 is substantially planar. As used herein, the term “substantially” means within the manufacturing tolerance levels that are commonly achievable and utilizing conventional manufacturing processes and which are commonly accepted within the construction industry. Plate 110 has two substantially planar faces 112, 114 and four edges 116, 118, 120, 122.
  • As will be discussed in further detail below, the holes 130 may be formed in the plate 110 by utilizing conventional punching, drilling, molding, etc. techniques. In the embodiment depicted in FIGS. 3 and 4, the plate 110 is provided with nine rows 132 of holes 130. See FIG. 4. In this embodiment, holes 130 have a diameter of one inch. However, holes 130 could be provided with diameters ranging from one inch to twelve inches, for example, depending upon the application. In other embodiments, the holes may have non-circular shapes to allow better flow of the gypsum slurry as will be discussed in further detail below. In the embodiment depicted in FIG. 4, the centerlines of the end rows 132 of holes 130 may be approximately three inches (dimension “C”) from the edges 118 and 122. However, such distance may depend upon the particular application and other factors such as the size, number and arrangement of holes 130 in the plate 110. Also in this particular embodiment, the centerlines of each hole 130 in a respective row 132 are aligned along a common axis (D-D) across the faces of the plate 110. In this embodiment, the distance (E″) between axes D-D is approximately six inches. Again, however, the spacing between rows of holes may vary depending upon the size, number and arrangement of holes 130. Also in alternate embodiments, an upstanding flange 125 may be formed along lateral edges 116 and 120 (FIG. 4A) or along end edges 118 and 122 (FIG. 4B) or along all edges 116, 118, 120, 122 (FIG. 4C) to provide edge surfaces for the wallboard material to abut as will be discussed below.
  • FIGS. 2 and 3 illustrate a cross-sectional view of the shear wall panel 100 of this embodiment of the present invention. As can be seen in those Figures, the shear wall panel 100 also includes a layer of wallboard material 140 and two paper backing sheets 150 and 160. The wallboard material 140 may comprise a variety of different types of commercially available gypsum material such as, for example, those materials sold under the trademarks of FIBEROCK®, AQUA TOUGH™, SHEET ROCK® or HYDROSTONE™ by U.S. Gypsum Company. However, other wallboard and cementitious wallboard materials such as those materials sold under the trademarks of DUROCK™, WONDERBOARD™, DENS GLASS™, etc. could also be employed. Moreover, depending upon the wallboard material used, the backing sheets may be made from other materials that are more compatible with the wallboard material. It is conceivable that for some wallboard materials, no backing sheets would be necessary.
  • FIG. 5 illustrates one method of manufacturing the shear wall panel 100 described above. In this method, the shear wall panel 100 is molded in a mold 170 that has a bottom 172 and four upstanding walls 174, 176, 178, 180. The bottom 172 of the mold 170 is sized to achieve a desired size of panel. In one method, the first backing sheet 150 which is cut to size is placed on the bottom 172 of the mold 170. Thereafter, the plate 110 is placed on the backing sheet. The wallboard material 140 is then introduced into the mold 170 on top of the plate 110 in sufficient quantity such that when the material 140 is evenly distributed and pressed into the holes 130 of plate 110 utilizing conventional rollers, or other forms of smoothing and striking techniques and then cured, the resulting panel 100 has a desired thickness. After the wallboard material 140 has been smoothed out, the final backing sheet 160 is applied thereto (by adhesive—depending upon the type of wallboard material used) and, depending upon the wallboard material employed, may be passed into a drying oven. After the wallboard material has cured or dried, the panel is removed from the mold.
  • The process of fabricating shear wall panels of the present invention may also be automated as diagrammatically illustrated in FIG. 6. As can be seen in that Figure, the material 200 (sheet steel, etc.) from which the plate 110 is fabricated may be stored on a roll 202. The material 200 may be automatically unrolled from the roll 202 and then passed through a conventional stamping press 210 that serves to punch the desired number and arrangement of holes 130 in the strip of material 200. Conventional driven rolls 204 may be employed through out the process to drive the strip material through the process. After the strip material 200 exits the stamping press 210, it passes into a molding operation 220 that includes a support surface 222 wherein a first sheet of backing 150 is supported. The backing sheet 150 may be automatically rolled off of a roll 152 as illustrated. The material 200 is rolled onto the first backing sheet material 150 on the support surface 222 and a slurry of wallboard material 140 is deposited onto the material 200 as it passes thereunder. The wallboard material 140 is then spread and pressed into the holes 130 in the material 200 in the striking/leveling operation 230, which may be accomplished by smoothing blocks, rollers, etc or by the use of vibration. After the wallboard material 140 has been smoothed to a desired thickness, the second backing sheet 160 is introduced onto the wallboard material 140. The second backing sheet 160 may be automatically rolled off of a roll 162. Then, depending upon the type of wallboard material employed, the panel material enters a drying oven 240. In this embodiment, after the material has been dried, it is cut to length utilizing conventional cutting methods in station 250. Other methods of manufacture may also be used.
  • FIG. 6A is a diagrammatic view of the manufacturing arrangement described above, except in this embodiment, the cutting operation (designated as 250′ in FIG. 6A) is located before the drying oven 240. Thus, in this embodiment, after the second backing sheet 160 has been applied to the wallboard material, the panel 100 is cut to length at station 250′. After the panel 100 has been cut to length, it is cured in the oven 240.
  • FIG. 6B is a diagrammatic view of yet another manufacturing arrangement of the present invention. As can be seen in that Figure, after the holes 130 have been formed into the sheet material 200 in station 210, the sheet material 200 is cut to length in station 250″ utilizing conventional cutting techniques to form the plate 110. The slurry of wallboard material 140 is then introduced onto the plate 110 and spread and pressed into the holes 130 in the striking/leveling operation 230, which may be accomplished by smoothing blocks, rollers, etc or by the use of vibration. After the wallboard material 140 has been smoothed to a desired thickness, the second backing sheet 160 is introduced onto the wallboard material 140. The second backing sheet 160 may be automatically rolled off of a roll 162. Then, depending upon the type of wallboard material employed, the wallboard material is cut at station 250′ to form panel 100 which then enters a drying oven 240 to be cured.
  • FIGS. 7 and 8 illustrate another embodiment of the shear wall panel 300 of the present invention. In this embodiment, a plate 110 of the type and construction described above is embedded in the wallboard material. In particular, this embodiment includes a first backing material 350, a first amount of wallboard material 340, the plate 110 and a second amount of wallboard material 340′. In this embodiment, the wallboard material 340, 340′ extends through the holes 130 in the plate 110. A second backing material 360 is applied to the wallboard material 340′ as shown. Wallboard materials of the types described above may be used. The first and second backing materials 350, 360 may comprise conventional paper backing material used in fabricating conventional gypsum wallboard. However, other material may also be employed that are compatible with the type of wallboard material used. In other embodiment, the backing materials could be omitted. This embodiment may be molded in the above-described manner. However, it is conceivable that this embodiment may also be fabricated utilizing an automated manufacturing line of the type described above.
  • Another embodiment of the present invention is depicted in FIGS. 9 and 10. As can be seen in those Figures, each of the holes 430 in the plate 410 has a flanged 432 portion protruding from one side of the plate 410. It is conceivable that in other embodiments, some, but not all, of the holes 430 have such a flanged portion 432. When a plate 410 fabricated from sheet metal is employed, conventional metal drawing techniques may be used to form the flanged portion 432 around each hole 430. When other types of materials are employed to form the plate 410 such as, for example, a polymer material, the flanged portions may be molded.
  • As can be seen in FIGS. 9 and 10, a first backing material 450 is applied to the planar side 412 of the plate 410 utilizing conventional adhesive. The wallboard 440 material is then applied to the side 414 of the plate 410 from which the flanges 432 protrude such that the wallboard material 440 enters the holes 430 and is level with the top of the flanges 432. See FIG. 10. A second backing material 460 is then attached to the wallboard material 440 by adhesive to complete the panel 400. This embodiment may be molded utilizing the techniques described above or it may be formed on an automated manufacturing line of the type described above. In another embodiment, the wallboard material 440 may be applied such that a layer thereof covers the tops of the flanges 432.
  • FIG. 11 illustrates yet another plate embodiment which may be used to form another panel embodiment of the present invention. As can be seen in that Figure, in one embodiment, edge flanges 490 which correspond in height to the flanges 432 are provided along edges 416 and 420 and form elongated support surfaces along those edges for the wallboard material. In another embodiment, the height of the edge flanges 490 is greater than the height of the flanges 432. See FIG. 10A. In yet another plate embodiment as shown in FIG. 12, edge flanges 492 may be provided along edges 418 and 422 and form elongated support surfaces along those edges for the wallboard material to abut. In the plate embodiment of FIG. 13, edge flanges 494 may be provided on each edge 416, 418, 420, and 422 to form support edges for the wallboard material.
  • Another embodiment of the shear wall panel of the present invention is depicted in FIGS. 14 and 15. This embodiment is similar to the embodiment depicted in FIGS. 9 and 10, except that the flanges 532 protrude from both sides 512, 514 of the plate 510. The pattern in which the flanges 532 protrude may vary. For example, every other hole 530 may have a flange 532 that protrudes in the opposite direction from the direction in which the flanges 532 of adjacent holes 530 (located in the same row of holes or column of holes) protrude. Other arrangements may include flanges 532 in a common row or column protruding from the same side and the flanges 532 of the holes 530 in adjacent rows or columns protruding from the other side of the plate 510. It is also conceivable that the flanges 532 may protrude from the sides 512, 514 of the plate 510 in a random arrangement.
  • In this embodiment, an amount of wallboard material 540 is applied to a first backing material 550 and the plate 510 is then applied to the first wallboard material 540 such that the ends of the flanges 532 protruding from that side 512 of the plate 510 are level with the backing material 550 and do not pierce therethrough. In other embodiments, the ends of the flanges 532 may actually extend through the backing material 550 or a layer of wallboard material may extend between the ends of the flanges 532 and the first backing material 550. See FIG. 15A.
  • Additional wallboard material 540′ is then applied to the other side 514 of the plate 510. In this embodiment, the wallboard material 540′ is level with the ends of the flanges 532 and the wallboard material 540, 540′ extends through the holes 530 as shown. A second backing material 560 is then applied to the wallboard material 540′ to cover that side of the panel 500. In other embodiments, the flanges 532 may extend through the second backing material 560 or a layer of wallboard material may be provided between the ends of the flanges 532 and the second backing material 560. In this embodiment, the wallboard material 540, 540′ on both sides of the plate and which extends through the holes comprises the same wallboard material. Other embodiments are contemplated wherein the wallboard material on one side of the plate 510 has a composition and characteristics that differ from the composition and characteristics of the wallboard material on the other side of the plate 510. This embodiment may be manufactured utilizing the molding or automated manufacturing arrangement described above.
  • FIGS. 16-19 illustrate yet another shear wall panel embodiment of the present invention. As can be seen in those Figures, the plate 610 is of a corrugated design. In particular, the plate 610 has one planar side 612 that is defined by the bottom portion of spaced parallel “first” troughs 616 and a second planar side 614 defined by the bottom portions of spaced parallel “second” troughs 618. In the embodiment depicted in FIGS. 16-19, the first and second troughs 616, 618 are formed along the longest dimension of the panel (length “F”). In other embodiments, however, the troughs 616, 618 may extend across the shortest dimension (width “G”). In this embodiment, each first trough 616 has a bottom surface 617 and each second trough has a bottom surface 619. The bottom surfaces 617 and 619 are interconnected by lateral walls 621. In the embodiment depicted in FIGS. 16-19, the lateral walls 621 are inclined with respect to the first and second bottom surfaces. In other embodiments, however, the lateral walls 621 may be substantially perpendicular with respect to the first and second bottom surfaces 617, 619. In one embodiment, a series of holes 630 are provided through the first and second bottom surfaces 616, 618. The holes 630 may be arranged as shown in FIG. 17. However, other hole arrangements are contemplated. For example, the holes 630 may only be provided through every other trough. In yet another embodiment depicted in FIG. 18A, the holes 630 may be provided through the inclined walls 621. The pattern, configuration, sizes and shapes of the holes 630 in the walls 621 could vary. In one embodiment, holes 630 are only provided through the first and second bottom surfaces 616, 618. In another embodiment, holes 630 are only provided through the inclined walls 621. In yet another embodiment, the holes are provided in the first and second bottom surfaces 616, 618 and the inclined walls 621.
  • In this embodiment, the panel 600 includes a first backing material 650 and a first amount of wallboard material 640 of the type and composition described above such that the wallboard material 640 fills each trough 616 that opens toward the first backing material 650 when the plate 610 is arranged on the first backing material 650 as shown in FIG. 18. Another amount of wallboard material 640′ is introduced into the opposing troughs 618 and is leveled with the outer surfaces 619 of the troughs 618. A second backing material 660 is then applied as shown. The wallboard material 640, 640′ preferably extends through the holes 630 in the bottom of each trough 616, 618. See FIG. 18.
  • FIG. 19 illustrates one method of fabricating the panel 600. As can be seen in that Figure, a mold 700 is employed. The first backing sheet 650 is cut to size and placed into the bottom 702 of the mold 700. Adhesive is applied to the upper surface of the backing sheet 650, if employed. A first amount of wallboard material 640 is applied to the first backing sheet 650 in a uniform manner such that it is equally dispersed across the first wallboard material 640 in sufficient quantity such that when the plate 610 is placed thereon, the wallboard material 640 substantially fills the downwardly troughs 616. Pressure may be applied to the plate 610 if necessary to ensure that the wallboard material 640 fills each trough. Wallboard material 640′ is then distributed into the upwardly open troughs 618 in the plate 610 and it is leveled off with the plate surfaces 619. Thereafter, the second backing material 660 is placed onto the wallboard material 640′. Adhesive may be used if necessary to adhere the second backing material 660 to the wallboard plate 610. The mold 700 may then be introduced to an oven, if heat curing is required by the wallboard material. Other methods may be employed to manufacture panel 600.
  • The invention which is intended to be protected is not to be construed as limited to the particular embodiments disclosed. The embodiments are therefore to be regarded as illustrative rather than restrictive. Variations and changes may be made by others without departing from the spirit of the present invention. Accordingly, it is expressly intended that all such equivalents, variations and changes which fall within the spirit and scope of the present invention as defined in the claims be embraced thereby.

Claims (63)

  1. 1. A shear wall panel, comprising:
    a plate having first and second substantially planar sides and a plurality of holes extending therethrough;
    a first flanged portion extending around at least a portion of at least one of said holes and protruding from said first substantially planar side of the plate;
    a second flanged portion extending around at least a portion of at least one other of said holes and protruding from said second substantially planar side of the plate; and
    wallboard material applied to said first and second sides of said plate.
  2. 2. The shear wall panel of claim 1 wherein said wallboard material extends through at least some of said holes and at least some of said other of said holes.
  3. 3. The shear wall panel of claim 1 further comprising:
    a first backing sheet attached to said wallboard material on said first side of said plate; and
    a second backing sheet attached to said wallboard material on said second planar side of said plate.
  4. 4. The shear wall panel of claim 1 wherein said plate comprises material selected from the group consisting of steel, aluminum, wood, lead and plastic.
  5. 5. The shear wall panel of claim 1 wherein the wallboard material comprises a material selected from the group consisting of gypsum material and cementitious material.
  6. 6. The shear wall panel of claim 1 wherein at least some of said holes are round.
  7. 7. The shear wall panel of claim 1 wherein at least some of said other of said holes are round.
  8. 8. The shear wall panel of claim 1 wherein at least some of said holes are round and at least some of said other holes are round.
  9. 9. A shear wall panel, comprising:
    a plate having first and second substantially planar sides, a pair of lateral edges and a pair of end edges;
    a plurality of holes extending through said plate;
    a flanged portion extending along each said lateral edge and protruding outward from said first planar side of said plate; and
    wallboard material applied to said first planar side of said plate.
  10. 10. The shear wall panel of claim 9 further comprising:
    a first backing sheet attached to said wallboard material on said first side of said plate; and
    a second backing sheet attached to said second planar side of said plate.
  11. 11. The shear wall panel of claim 9 wherein said plate comprises material selected from the group consisting of steel, aluminum, wood, lead and plastic.
  12. 12. The shear wall panel of claim 9 wherein the wallboard material comprises a material selected from the group consisting of gypsum material and cementitious material.
  13. 13. The shear wall panel of claim 9 wherein at least some of said holes are round.
  14. 14. A shear wall panel, comprising:
    a plate having first and second substantially planar sides, a pair of lateral edges and a pair of end edges;
    a plurality of holes extending through said plate;
    a flanged portion extending along each said end edge and protruding outward from said first planar side of said plate; and
    wallboard material applied to said first planar side of said plate.
  15. 15. The shear wall panel of claim 14 further comprising:
    a first backing sheet attached to said wallboard material on said first side of said plate; and
    a second backing sheet attached to said second planar side of said plate.
  16. 16. The shear wall panel of claim 14 wherein said plate comprises material selected from the group consisting of steel, aluminum, wood, lead and plastic.
  17. 17. The shear wall panel of claim 14 wherein the wallboard material comprises a material selected from the group consisting of gypsum material and cementitious material.
  18. 18. The shear wall panel of claim 14 wherein at least some of said holes are round.
  19. 19. A shear wall panel, comprising:
    a plate having first and second substantially planar sides, a pair of lateral edges and a pair of end edges;
    a plurality of holes extending through said plate;
    a lateral flange extending along each said lateral edge and protruding outward from said first planar side of said plate;
    an end flange extending along each said end edge and protruding outward from said first planar side of said plate;
    wallboard material applied to said first planar side of said plate.
  20. 20. The shear wall panel of claim 19 further comprising:
    a first backing sheet attached to said wallboard material on said first side of said plate; and
    a second backing sheet attached to said second planar side of said plate.
  21. 21. The shear wall panel of claim 19 wherein said plate comprises material selected from the group consisting of steel, aluminum, wood, lead and plastic.
  22. 22. The shear wall panel of claim 19 wherein the wallboard material comprises a material selected from the group consisting of gypsum material and cementitious material.
  23. 23. The shear wall panel of claim 19 wherein at least some of said holes are round.
  24. 24. A shear wall panel, comprising:
    a plate having first and second substantially planar sides, a pair of lateral edges and a pair of end edges;
    a plurality of holes extending through said plate;
    a flanged portion extending around at least a portion of at least one of said holes and protruding from said first substantially planar side of the plate;
    a lateral flange extending along each said lateral edge and protruding outward from said first planar side of said plate; and
    wallboard material applied to said first planar side of said plate.
  25. 25. The shear wall panel of claim 24 wherein each said flanged portion has an end and wherein said wallboard material covers said ends of said flange portions.
  26. 26. The shear wall panel of claim 25 wherein said lateral flanges protrude from said first planar side a first distance and wherein each said flanged portion protrudes from said first planar side a second distance that is substantially equal to said first distance.
  27. 27. The shear wall panel of claim 26 wherein said second distance is less than said first distance.
  28. 28. A shear wall panel, comprising:
    a plate having first and second substantially planar sides, a pair of lateral edges and a pair of end edges;
    a plurality of holes extending through said plate;
    a first flanged portion extending around at least a portion of at least one of said holes and protruding from said first substantially planar side of the plate;
    an end flange extending along each said end edge and protruding outward from said first planar side of said plate; and
    wallboard material applied to said first planar side of said plate.
  29. 29. The shear wall panel of claim 28 wherein each said flanged portion has an end and wherein said wallboard material covers said ends of said flange portions.
  30. 30. The shear wall panel of claim 29 wherein each said end flange protrudes from said first planar side a first distance and wherein each said flanged portion protrudes from said first planar side a second distance that is substantially equal to said first distance.
  31. 31. The shear wall panel of claim 30 wherein said second distance is less than said first distance.
  32. 32. A shear wall panel, comprising:
    a plate having first and second substantially planar sides, a pair of lateral edges and a pair of end edges;
    a plurality of holes extending through said plate;
    first flanged portion extending around at least a portion of at least one of said holes and protruding from said first substantially planar side of the plate;
    a lateral flange extending along each said lateral edge and protruding outward from said first planar side of said plate;
    an end flange extending along each said end edge and protruding outward from said first planar side of said plate; and
    wallboard material applied to said first planar side of said plate.
  33. 33. The shear wall panel of claim 32 wherein each said flanged portion has an end and wherein said wallboard material covers said ends of said flange portions.
  34. 34. The shear wall panel of claim 33 wherein each said lateral flange and each said end flange protrudes from said first planar side a first distance and wherein each said flanged portion protrudes from said first planar side a second distance that is substantially equal to said first distance.
  35. 35. The shear wall panel of claim 34 wherein said second distance is less than said first distance.
  36. 36. A shear wall panel; comprising:
    a plate having first and second substantially planar sides and a plurality of holes extending therethrough; and
    wallboard material applied to said first and second sides of said plate and extending through said holes therein such that the plate is substantially embedded in said wallboard material.
  37. 37. The shear wall panel of claim 36 further comprising:
    a first backing material applied to the wallboard material applied to said first substantially planar side of said plate; and
    a second backing material applied to the wallboard material applied to said second substantially planar side of said plate.
  38. 38. The shear wall panel of claim 36 wherein said plate comprises material selected from the group consisting of steel, aluminum, wood, lead and plastic.
  39. 39. The shear wall panel of claim 36 wherein the wallboard material comprises a material selected from the group consisting of gypsum material and cementitious material.
  40. 40. The shear wall panel of claim 36 wherein at least some of said holes are round.
  41. 41. A shear wall panel comprising:
    a corrugated plate having a first side and a second side and a plurality of holes therethrough; and
    wallboard material applied to at least one side of the corrugated plate.
  42. 42. The shear wall panel of claim 41 wherein said corrugated plate has a plurality of open first troughs on a first side thereof and a plurality of open second troughs on a second side thereof and wherein at least some of said first and second troughs have wallboard material therein.
  43. 43. The shear wall panel of claim 42 wherein each of said first troughs has a first bottom surface and wherein each of said second troughs has a second bottom surface, said first and second bottom surfaces interconnected by corresponding lateral walls.
  44. 44. The shear wall panel of claim 43 wherein each of said lateral walls are inclined with respect to said first and second bottom surfaces.
  45. 45. The shear wall panel of claim 43 wherein each of said lateral walls is substantially perpendicular to said first and second bottom surfaces.
  46. 46. The shear wall panel of claim 43 wherein said holes extend through at least one of said first and second bottom surfaces.
  47. 47. The shear wall panel of claim 43 wherein said holes extend through at least one of said lateral walls.
  48. 48. The shear wall panel of claim 43 wherein said holes extend through said first and second bottom surfaces and said lateral walls.
  49. 49. The shear wall panel of claim 41 further comprising:
    a first backing material applied to the first side of the plate; and
    a second backing material applied to the second side of the plate.
  50. 50. A method of manufacturing a shear wall panel comprising:
    forming a series of holes in a plate having substantially planar first and second sides; and
    applying wallboard material to the first and second planar sides of the plate such that the wallboard material extends into the holes in the plate to form a panel assembly.
  51. 51. The method of claim 50 further comprising curing the wallboard material.
  52. 52. The method of claim 50 wherein said curing comprises placing the panel assembly into an oven.
  53. 53. The method of claim 52 further comprising applying a first backing material to the wallboard material on the first planar side of the plate.
  54. 54. The method of claim 52 wherein the first backing material is applied to the wallboard material on the first planar side of the plate prior to said curing.
  55. 55. The method of claim 54 further comprising applying a second backing material onto the second substantially planar side of the plate.
  56. 56. The method of claim 55 wherein the first and second backing materials are applied prior to said curing.
  57. 57. The method of claim 50 further comprising:
    forming a first flanged portion around at least one hole such that the first flanged portion protrudes from the first substantially planar side; and
    forming a second flanged portion around at least one hole such that the second flanged portion protrudes from the second substantially planar side.
  58. 58. A method of fabricating a shear wall panel comprising:
    forming holes in a plate; and
    embedding the plate in a wallboard material such that the wallboard material is received in the holes in the plate.
  59. 59. A method of fabricating a shear wall panel comprising:
    placing a first backing sheet into a mold cavity;
    applying an adhesive to the first backing sheet;
    applying a first amount of wallboard material onto the adhesive and first backing sheet;
    placing a first side of a plate having a series of holes therethrough onto the wallboard material;
    applying pressure to the plate to cause the wallboard material to substantially uniformly disperse along one side of the plate and extend through at least some of the holes in the plate; and
    curing the first amount of wallboard material.
  60. 60. The method of claim 59 further comprising adhering a second backing material onto a second side of the plate
  61. 61. The method of claim 59 further comprising:
    applying a second amount of wallboard material onto a second side of the plate;
    uniformly dispersing the second amount of wallboard material onto the second side of the plate; and
    curing the second amount of wallboard material.
  62. 62. The method of claim 61 wherein the curing of the first and second amounts of wallboard materials comprises placing the mold containing the plate and first and second amounts of wallboard material into an oven.
  63. 63. The method of claim 61 further comprising adhering a second backing material onto the second amount of wallboard material.
US10970497 2003-10-22 2004-10-21 Shear wall panel Abandoned US20050086905A1 (en)

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