US2815542A - Laminated partition - Google Patents

Description

Dec. 10, 1957 G. w. BAKER LAMINATED PARTITION 3 Sheets-Sheet 1 7/lw7//////ll/////l /////////7/////7///// .0 1 7 ?A 26 7/; V/A r Filed 001'.- 22, 1954 INVENTOR.

Dec. 10, 1957 G. w. BAKER LAMINATED PARTITION 5 Sheets-Sheet 2 Filid Oct. 22. 1954 IllIlIll/ll ANNA a3 Frill/1111A INVENTOR.

GEORGE If BAKER A T TORNEY Dec. 10, 1957 G. w. BAKER LAMINATED PARTITION 3 Sheets-Sheet 3 Filed Oct. 22. 1954 \\\\\\A 9 v 3 7 Y\\\\\\\\\\\ 2 2 xx 2 v a 6 fi 9 2 .m ///J e 9 3 9 Q 6 Q i x 2 L m Z x 2 69 7 2 M 2 J J J 9 9 United States Patent LAMINATED PARTITION George W. Baker, Chicago Heights, Ill., assignor to United States Gypsum Company, Chicago, lllL, a corporation of Illinois Application October 22, 1954, Serial No. 463,938

2 Claims. (Cl. 204) This invention relates to a process of erecting laminated partitions and to a product formed thereby, and more particularly to a solid non-load bearing partition formed from several layers of gypsum boards.

This application is a continuation in part of S. N. 681,115, filed July 2, 1946.

It has been found in certain types of construction that a considerable savings in space can be obtained if partitions are made only 2" thick instead of the usual /2. In the case of large apartment buildings, this apparently small saving in space actually means that several more rooms can be obtained for the same volume.

Usually 2" solid partitions are made from plaster which is applied to both sides of a plaster base such as on plaster board or metal lath. Various satisfactory systems have been devised for construction of these partitions. However, there are many situations in which it is desirable to construct partitions from gypsum boards, for example when quick occupancy is desired.

In the past, when solid partitions have been formed from gypsum board they were made in units of full partition thickness which resulted in certain disadvantages which greatly hindered their commercial applications; such for example as: (1) Owing to the excessive weight of a 2" thickness of gypsum board, the units to be erected must be relatively small resulting in a great number of joints which must be treated, a very great disadvantage. (2) Conduits, pipes, fittings, etc., could not be installed without patching the surface area; this is a decided disadvantage as a non-discernable patching of such areas is expensive and difficult to accomplish. (3) No good lowcost system of joining the boards at the top and bottom and to each other has been found.

It is therefore an object of this invention to set forth a partition which can be easily erected by the ordinary tradesman without the use of special tools.

It is an object of this invention to set forth an improved method of erecting a partition in which relatively lightweight units can be used with the minimum of joint treatments.

It is a further object of this invention to set forth a method of erecting a solid laminated gypsum board partition in which pipes and conduits can be concealed without a special surface treatment.

Various other objects will readily occur to those skilled in the art of which this invention is a part.

With the above and other objects in view, this invention has been devised, of which preferred embodiments are shown in the accompanying drawings and described in detail in the forthcoming part of this specification.

In the drawings:

Figure l is a vertical section through a partition erected in accordance with this invention in which five laminae of gypsum board are attached to the floor and ceiling by means of an angle clip.

Figure 2 is a vertical section through a laminated Patented Dec. 10, 1957 ICC gypsum board partition in which four layers of gypsum board are secured to a concealed runner.

Figure 3 is a horizontal section through a partition showing the base wall formed from gypsum board panels on the inside with non-interlocking edges.

Figure 4 is a perspective view of a partition formed from two layers of boards in the base wall panels and illustrates how electrical conduits and fittings can be applied.

Figure 5 is a section through 5-5 of Figure 4 and shows one method of mounting electrical conduits and outlets.

Figure 6 is a sectional view through 6-6 of Figure 5.

Figure 7 illustrates a method of mounting a plumbing fixture such as a lavatory.

Figure 8 is a perspective view of a partition formed from three layers of boards in the base wall panels with the exterior boards in a horizontal direction.

Figure 9 is a sectional view illustrating a method of mounting a window in the partition.

Figure 10 is a horizontal sectional view of one side of a door buck along with means for mounting it to the partition for the purpose of supporting a door.

Figure 11 is a horizontal sectional view through the partition showing the joining of partitions to each other at right angles. An edge joint for a three-ply laminated gypsum wallboard panel forming the base wall is also illustrated.

Figure 12 depicts a means of forming a corner following this invention in which the relation of the exterior surface to that of the interior panel is also shown.

The essential elements of this invention entail the method of erecting a solid wallboard partition which has a minimum of surface joints, thereby enabling the use of lightweight units for ease in handling, which will permit the installation of conduits, pipes, etc., within the partition with little concern as to surface mutilations and which can be readily secured to the ceiling and fioor of the structure to be partitioned. Briefly, the invention is carried out by forming panels of laminated wallboards, particularly those formed from gypsum encased in papcr in a factory or upon the job into sizes that are easily handled. These panels are then placed in edge to edge and coplanar relation to form a base wall and attached to the ceiling and floor of the structure to be partitioned such as by means of runners. The panels are cut and fitted around conduits, pipes, ducts, etc., without much concern as to the effect upon the surface. Then a final layer of gypsum board of as large a dimension as can conveniently be handled is then adhesively secured to both faces of the partition in such a manner as to span the joint between adjoining panels of the base wall and preferably nailed to runners attached to the ceiling and floor. A moulding can then be applied to the floor and ceiling if desired.

Turning now to a more detailed description of the method to be followed in erecting a preferred embodiment of this invention, wooden runners 2 and 4 preferably 1 /4 x 1M4 in section are secured opposite each other to the ceiling and the floor of the structure to be partitioned. These runners can be nailed to the surface with the nails 3 and 5, such as in Figure 2, or if the surface is concrete, concrete nails or other means of at taching the runners to the structure may be used. The base wall is then secured to these runners. This wall is formed from laminated gypsum boards panels placed in edge to edge and coplanar relation with respect to themselves and to the runners. The panels are formed from two or more gypsum wall boards bonded together such as by means of an adhesive or by stapling. While this laminating can be done on the job, it is preferred that such be done in a factory preferably where the boards are made. These panels can be of any width as the joints between them are relatively unimportant. Thus it is possible to use narrow size boards which will form panels that can be easily handled by one man. The use of this narrow width panels is an outstanding advantage of this invention. The panels are attached to the runner preferably by toe nails 17 such as shown in Figures 2, 4, and 8 or by an angle clip such as 34 in Figure 1. These base panels are fitted around conduits and pipes such as illustrated in Figures 4, 5, and 6. No great care need be exercised in fitting the panels around them as any mutilation in the wall will be covered later.

It is not necessary that each individual panel be joined to the one adjacent by an interlocking edge such the tongue and groove type illustrated in Figures 1, 8, ll. and 12, a non-staggered edge may also suffice. Thus it is within the scope of this invention to have the panels adjacent to butt against each other or with a small space left in between, such as shown in Figure 3, and still obtain a suitable partition. However, by having the panels interlock it may help in aligning the panels.

The panel should be of full height between the runners, free from horizontal joints, and can be made of three layers of boards which have their edges offset to form a tongue and groove type joint. In which case an angle 34 can be inserted into the groove and attached to the floor and ceiling runners; directly, such as in Figure I. In determining the proper thickness of boards to use in preparing the panel, they should be figured upon the basis of an over all partition thickness of two inches. Inasmuch as will be disclosed, an additional layer of wallboard will be applied to each face of the panels, these additional or surface boards should also be considered in making the calculation. These surface or reinforcing boards should be $45 in thickness so that larger size sheets can be used without excessive weight, though /4" or even ,1 thick boards may be satisfactory and may even be preferred.

If only two layers are used in forming the units for the base wall such as panel 7, the panel laminae should be made from 78" thick boards and the surface board 8 of /8" thickness, while if three layers are used, they should be about /2" and the surface boards V4" in thickness. These panels which when finally attached to the runners in edge to edge and coplanar relation and properly fitted around pipes or conduits and frames for windows or doors installed, are now ready for the surface or reinforcing layers. Examples of how the base wall formed from the panels are fitted for conduits and pipes are shown in Figures 4, 5, and 6 and for openings in Figures 9 and it). The surface layers 8 are applied to both faces of the base wall and, as referred to above, are preferably made as large and as thin as possible so as to reduce the number of joints to a minimum and to decrease the weight. They are secured to the base wall formed from the panels 6 or 7 by means of an adhesive layer 9. This layer is preferably applied to the back of the board upon the job, before it is applied to the base wall: however, the adhesive can also be applied to the base wall first. In order to temporarily hold sheets 8 to the base wall, it has been found expedient to drive the nails 10. Figure 1, through the face sheet into the base wall. While the nail holding power of the panel is not great. there is sufficient pressure to hold the structure togethcr until the adhesive has set.

Any glue type material, preferably that in which water is the vehicle, can be used as an adhesive, such for example as an aqueous suspension of a mixture of partially dextrinized starch made by grinding hot roll-flaked steamed corn flour and emulsified asphalt such as set forth in Patent No. 2,518,281, issued to Thomas P. Camp and Chester N. Kolmodin. Various proportions can be used; a mixture of two parts of paste to one of emulsified asphalt has been found to be satisfactory. A

powdered glue made from calcined gypsum and cold water soluble animal glue mixed with water as well as other glues made from casein, soya beans, dextrine, rubber compositions are also suitable.

The preferred method of mounting the electrical fixtures is shown in Figures 4, 5, and 6 where the Wall panels 6 or 7 are cut away to fit around pipes, conduits 12, or electrical outlets to be mounted. The electrical outlet box 11 is attached to the wooden supporting member 30 by means of screws or nails 31. This wooden supporting member is of sufficient thickness so that the over all dimension with the box is about the same as the thickness of the panel thus preventing any movement when the surface layer is glued or nailed thereto. A similar arrangement can be made for pipes and plumbing fixtures.

In Figure 7 there is illustrated a means by which a bracket 14 can be mounted to the partition for installing a plumbing fixture such as the sink 15. The same method can be used to attach cabinets and other fixtures. The bracket is attached after the base wall has been erected and the adjacent surface layer is secured thereto by means of the elevator bolts 13; the head upon the opposite side of the bolt is embedded into the panel so that the other surface layer can readily be applied.

Figures 9 and 10 show a method of mounting a window and a door. In the figures, 19 are wooden nailing frames which extend around the opening and to which are attached the panels 6 forming the base wall by means of the toe nails 20. The surface layers 8 are then nailed to the frame after they have been adhesively secured to the panels 6. If the opening is to be a window which is not to be opened, strips 29 are nailed to the inside surface of the frame 19 upon both sides of the glass, thereby fastening it securely in place as shown in Figure 9. If the opening is a door, a door buck 23 is nailed directly to the frame 19 as shown in Figure 10. A trim 21 is nailed to the frame 19 by means of the nail 22.

In Figures 11 and 12 there is illustrated how adjoining walls of partitions are connected together to form a T or an L type of intersection. The partitions as illustrated are made from a three-ply base wall panel 6 with the inner ply offset to form a tongue and groove joint. A nailing strip 24 is attached to one partition such as by nails as in Figure 11 or by bolts 13 as in Figure 12. The groove of an adjoining panel is then inserted over the nailing strip and the panel secured thereto by means of the nails 27, which are driven into the panel and through the strip. The exterior boards 8 are then adhesively secured to the panels and if possible nailed to the strip 24. Thus the adjoining partitions are securely joined to each other. A non-offset edge panel such as 7 in Figure 3 can also be used, in which case the strip 24 would be of the same width as that of the base wall and the adjacent panel toe nailed thereto. The exterior sheets are nailed to the strip. If desired, the joints can be treated by a tape 25 which is adhesively secured to cover the intersection or as in the case shown in Figure 8 the joint between adjacent boards. The tape is covered with a cement 35.

Figures 11 and 12 also illustrate how the panels 6 are joined together to form the partition. Figure 12, as well as Figures 3, 4, and 8, show the joints in the outer reinforcing layer 8 and their relation to those of the panels forming the base wall. As mentioned previously, it is important that the outer reinforcing layer span the joints in the base wall and be secured to both adjoining panels to give adequate strength to the partition. Hence the distance the joints in the outer layer are from those in the interior panels should be at least the thickness of the panels as shown in Figures 3, 4, and 12. This is necessary to assure that the exterior face or reinforcing layer is adequately bonded to each adjoining unit. If this bond is not adequate, the strength of the partition will be impaired and its value greatly reduced. Thus it is an important part of this invention that the surfacing layers upon both sides of the partition be properly bonded to each panel adjacent the panel joint, and that joints between the layers be spaced from those in the inner or base walls a sufficient distance to give adequate strength.

In order to improve the appearance of the partition, it is desirable to place a quarter round 33 along the top and nailed to the ceiling 1 and a base board such as 28 near the bottom adjacent the floor and nailed thereto.

While the above description illustrates certain preferred embodiments of this invention, it is not the intention to be limited thereby for various modifications may be made by those skilled in the art of which this invention is a part without varying from its true scope. For example, it is possible to use metal instead of wooden runners, in which case the runner may form the metal base. Various board thicknesses can be used for the exterior surface such as 5 to %3" and in the interior panel such as from A to It is possible to form the base wall from only one thickness of board, i. e., 1" in thick ness or more. However, in the manufacture of gypsum board, a thickness greater than about /2" becomes less practical because the machine speed must be appreciably decreased owing to the difficulty of drying the board, though boards in thickness have been made commercially. It is preferred, however, to use more than one board for thicknesses over about /2". The partition need not be limited to a 2" thickness as it can vary from 1" to 3" or more.

It is important and one of the limitations of this invention that all the various layers be made from gypsum board as it has been discovered that when the board forming the partition are exclusively a gypsum board that it withstands atmospheric conditions much better and that the over all characteristics of the partition are superior to other wallboards such for example as those made from fiber boards.

The manufacture of the gypsum board is well known in the art and a detailed description of its manufacture need not be given in the description of this invention.

While the advantages of 2" solid plaster partitions are apparent, it has been only recently that the advantages of a dry wall or all gypsum wallboard type of solid partition have been appreciated. These partitions because of their laminated character have a much less tendency to crack. They can be applied to most any type of structure in places where plaster may be undesirable. They also have more salvage value than those made from plaster. They are particularly useful in areas where plastering is not preferable because of the labor or material situation.

Further advantages of a solid gypsum wallboard partition made in accordance with the principle set forth in this invention over other solid wallboard partitions erected in the past are:

(1) Greater ease and speed in erection as the panels forming the base wall can be larger for the same weight since their thickness is only 1", 1%", or 1 /2", instead of the full 2" as would be required if full thick panels were joined together, and no attention need be given to the joints. Also, sheets of greater area can be used for the exterior surface laminae.

(2) Conduits and pipes as well as electrical and plumbing fixtures can be installed without any concern as to mutilating the exterior surface. A clean smooth exposed wall is formed regardless of the irregularities in the base wall.

(3) A good simplified system of joining the partition to the ceilings and walls.

(4) Regular nails can be used and the joint completely concealed by the exterior surface layers which can subsequently be treated as a regular gypsum wallboard surface.

Many other advantages of this system will readily occur to those skilled in the art of which this invention is a part.

By way of summary, this invention consists of a method of erecting a solid partition structure from various laminae of gypsum board by first erecting panels of laminated gypsum board in edge to edge and coplanar relation to form a base wall; these panels are attached to runners extending along the ceiling and floor of the structure and preferably, though not necessarily, have tongue and groove or shiplap edges to aid in their alignment. The openings for the windows and doors are made in the base wall and the frames for supporting them are installed. The base wall is fitted around electrical conduits and pipes, and brackets installed to service or support various fixtures or cabinets. No eflort need be made to prevent mutilating the surface as it is covered on both sides with a surface and reinforcing layer of gypsum board which spans the joint and is attached to the adjoining panels forming the base Wall. An adhesive is usually preferred for adhering the surfacing sheets to the base with temporarily applied nails or other means to hold the sheets in place during the setting of the adhesive. The nails can be driven into the partition and covered with a cement. All necessary trim and treatment of the exposed joints can then be added, followed by decorating with paint or other surface treatments.

Having disclosed a practical embodiment of this invention and specific examples and uses which are given to insure a clear understanding of the essence of this invention, it is not the intention to be limited thereby for obviously many variations may be made by those skilled in the art of which this invention is a part and still be within the scope of this invention which is limited in extent only by the forthcoming claims.

I claim:

1. A laminated gypsum board partition comprising a plurality of vertical gypsum board panels arranged in edge to edge and coplanar relation to form a base wall, the top and bottom edges of said panels attached to nailable runners secured to the ceiling and the floor of a structure, the width of said runners being substantially the same as the thickness of said panels coplanar therewith and a layer of gypsum boards secured to each surface of said base wall upon both sides of a joint in said base wall. and extending over and nailed to said runners.

2. A laminated gypsum board partition comprising opposite spaced nailable ceiling and floor runners secured to a structure, a plurality of vertical gypsum board panels in adjacent but non-engaging edge to edge relation and coplanar to each other and to said runners disposed in the space between said runners and attached to said runners to form a base wall and a surface reinforcing layer of gypsum board in edge to edge and coplanar relation secured to each face of said base wall and to each adjacent panel of a joint thereby spanning and reinforcing the joints between adjacent panels, said gypsum board surface reinforcing layer also extending over said runners and nailed thereto.

References Cited in the file of this patent UNITED STATES PATENTS 1,894,933 Venzie Jan. 17, 1933 1,955,515 Reed Apr. 17, 1934 2,291,498 Odell July 28, 1942 2,399,978 Barthoiomew May 7, 1946 2,618,028 Baker Nov. 18, 1952 FOREIGN PATENTS 541,733 Great Britain Dec. 9, 1941

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