U.S. patent application number 10/970497 was filed with the patent office on 2005-04-28 for shear wall panel.
This patent application is currently assigned to Dietrich Industries, Inc.. Invention is credited to Ralph, Gregory S., Whitticar, Michael D..
Application Number | 20050086905 10/970497 |
Document ID | / |
Family ID | 34526856 |
Filed Date | 2005-04-28 |
United States Patent
Application |
20050086905 |
Kind Code |
A1 |
Ralph, Gregory S. ; et
al. |
April 28, 2005 |
Shear wall panel
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.
Inventors: |
Ralph, Gregory S.;
(Gibsonia, PA) ; Whitticar, Michael D.; (Cleveland
Heights, OH) |
Correspondence
Address: |
KIRKPATRICK & LOCKHART NICHOLSON GRAHAM LLP
535 SMITHFIELD STREET
PITTSBURGH
PA
15222
US
|
Assignee: |
Dietrich Industries, Inc.
|
Family ID: |
34526856 |
Appl. No.: |
10/970497 |
Filed: |
October 21, 2004 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
60513356 |
Oct 22, 2003 |
|
|
|
Current U.S.
Class: |
52/782.1 |
Current CPC
Class: |
E04C 2/28 20130101; E04C
2002/3455 20130101; E04C 2002/3433 20130101; E04C 2/3405
20130101 |
Class at
Publication: |
052/782.1 |
International
Class: |
E04C 002/00 |
Claims
What is claimed is:
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. 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. 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. 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. 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. The shear wall panel of claim 1 wherein at least some of said
holes are round.
7. The shear wall panel of claim 1 wherein at least some of said
other of said holes are round.
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. 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. 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. 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. 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. The shear wall panel of claim 9 wherein at least some of said
holes are round.
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. 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. 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. 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. The shear wall panel of claim 14 wherein at least some of said
holes are round.
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. 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. 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. 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. The shear wall panel of claim 19 wherein at least some of said
holes are round.
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. 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. 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. The shear wall panel of claim 26 wherein said second distance
is less than said first distance.
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. 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. 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. The shear wall panel of claim 30 wherein said second distance
is less than said first distance.
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. 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. 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. The shear wall panel of claim 34 wherein said second distance
is less than said first distance.
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. 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. 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. 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. The shear wall panel of claim 36 wherein at least some of said
holes are round.
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. 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. 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. 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. The shear wall panel of claim 43 wherein each of said lateral
walls is substantially perpendicular to said first and second
bottom surfaces.
46. The shear wall panel of claim 43 wherein said holes extend
through at least one of said first and second bottom surfaces.
47. The shear wall panel of claim 43 wherein said holes extend
through at least one of said lateral walls.
48. The shear wall panel of claim 43 wherein said holes extend
through said first and second bottom surfaces and said lateral
walls.
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. 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. The method of claim 50 further comprising curing the wallboard
material.
52. The method of claim 50 wherein said curing comprises placing
the panel assembly into an oven.
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. 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. The method of claim 54 further comprising applying a second
backing material onto the second substantially planar side of the
plate.
56. The method of claim 55 wherein the first and second backing
materials are applied prior to said curing.
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. 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. 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. The method of claim 59 further comprising adhering a second
backing material onto a second side of the plate
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. 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. The method of claim 61 further comprising adhering a second
backing material onto the second amount of wallboard material.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This nonprovisional application claims priority and the
benefit of under 35 U.S.C. .sctn. 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
[0002] 1. Field of the Invention
[0003] The invention relates to construction materials and, more
particularly, to shear wall panels for residential and commercial
buildings.
[0004] 2. Description of the Invention Background
[0005] 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.
[0006] 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.times.4 and or 2.times.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.
[0007] 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.
[0008] 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
[0009] 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.
[0010] 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.
[0011] 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.
[0012] 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.
[0013] 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.
[0014] 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.
[0015] 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
[0016] In the accompanying Figures, there are shown present
embodiments of the invention wherein like reference numerals are
employed to designate like parts and wherein:
[0017] 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;
[0018] 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;
[0019] 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;
[0020] 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;
[0021] FIG. 2 is a cross-sectional view of one shear wall panel
embodiment of the present invention;
[0022] FIG. 3 is an enlarged cross-sectional view of the panel of
FIG. 2;
[0023] FIG. 4 is a perspective view of one plate embodiment of the
present invention;
[0024] FIG. 4A is a perspective view of another plate embodiment of
the present invention;
[0025] FIG. 4B is a perspective view of another plate embodiment of
the present invention;
[0026] FIG. 4C is a perspective view of another plate embodiment of
the present invention;
[0027] FIG. 5 is a perspective view of a mold employed to fabricate
a panel embodiment of the present invention;
[0028] FIG. 6 is a diagrammatic view of an automated assembly
process for fabricating various panel embodiments of the present
invention;
[0029] FIG. 6A is a diagrammatic view of another automated assembly
process for fabricating various panel embodiments of the present
invention;
[0030] FIG. 6B is a diagrammatic view of another automated assembly
process for fabricating various panel embodiments of the present
invention;
[0031] FIG. 7 is a cross-sectional view of one shear wall panel
embodiment of the present invention;
[0032] FIG. 8 is an enlarged cross-sectional view of the panel of
FIG. 7;
[0033] FIG. 9 is a cross-sectional view of one shear wall panel
embodiment of the present invention;
[0034] FIG. 10 is an enlarged cross-sectional view of the panel of
FIG. 9;
[0035] FIG. 10A is an enlarged cross-sectional view of another
panel embodiment of the subject invention;
[0036] FIG. 11 is a perspective view of another plate embodiment of
the present invention;
[0037] FIG. 12 is a perspective view of another plate embodiment of
the present invention;
[0038] FIG. 13 is a perspective view of another plate embodiment of
the present invention;
[0039] FIG. 14 is a cross-sectional view of one shear wall panel
embodiment of the present invention;
[0040] FIG. 15 is an enlarged cross-sectional view of the panel of
FIG. 14;
[0041] FIG. 1 5A is an enlarged cross-sectional view of another
panel embodiment of the subject invention;
[0042] FIG. 16 is a cross-sectional view of one shear wall panel
embodiment of the present invention;
[0043] FIG. 17 is a perspective view of another plate embodiment of
the present invention;
[0044] FIG. 18 is an enlarged cross-sectional view of the panel of
FIG. 16;
[0045] FIG. 18A is an enlarged cross-sectional view of another
panel embodiment of the subject invention; and
[0046] 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
[0047] 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.
[0048] 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.
[0049] 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.
[0050] 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.
[0051] 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.
[0052] 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.
[0053] 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.RTM., AQUA TOUGH.TM., SHEET ROCK.RTM. or HYDROSTONE.TM. by
U.S. Gypsum Company. However, other wallboard and cementitious
wallboard materials such as those materials sold under the
trademarks of DUROCK.TM., WONDERBOARD.TM., DENS GLASS.TM., 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.
[0054] 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.
[0055] 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.
[0056] 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.
[0057] 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.
[0058] 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.
[0059] 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.
[0060] 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.
[0061] 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.
[0062] 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.
[0063] 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.
[0064] 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.
[0065] 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.
[0066] 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.
[0067] 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.
[0068] 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.
* * * * *