Metal Clad Gypsum Walls

Abstract

A demountable wall assembly comprising two rows of panels having metal sheets adhered to the faces thereof, and characterized by the vertical edges of the sheet extending across the space between the rows to support the panels without the need for separate studs.

Description

BACKGROUND OF THE INVENTION

An improved type of wallboard or panel which has been introduced into the building industry is gypsum panel clad or adhered to a metal sheet. In partitions or walls assembled from these panels, the sheet may constitute the exposed face of the panel and thus impart greater durability to the panel. In addition, the sheet permits a variety of exterior finishes that are not posssible on gypsum wallboard alone, such as baked-on enamel.

However, one drawback of such metal clad panels heretofore available has been their reliance on separate, and often complicated, studs for support. Such studs not only are quite expensive to manufacture, they also are time consuming to erect, and render difficult if not impossible the independent disassembly of individual panels. An example of such a construction is shown in U.S. Pat. No. 3,026,977. In part, the use of studs has been required in such constructions because the metal sheet does not extend appreciably beyond the back face of the panel attached thereto.

Therefore, considerable advantages in terms of inexpensive manufacturing and ease of assembly could be obtained if metal clad panels could be provided which would not require separate studs.

SUMMARY OF THE INVENTION

The invention relates to a hollow wall assembly of opposed, spaced rows of panels some of which are clad with metal sheet, wherein at least one of the vertical edges of the sheet extend back into the space between rows into releasible contact with the opposite row of panels, whereby the edge portions of the sheet provide the support of the panel without the need for separate studs. More specifically, an improved wall assembly is provided from two opposed, parallely extending, spaced-apart rows of panels, each row assembled independently of the other, the panels of at least one of the rows each having a core, a front face, a back face, and a metal sheet adhered to the front face; the improvement comprising at least one vertical edge of the sheet being bent back beyond the back face of the panel so as to define a portion extending across the space between the rows until it releasibly abuts against the back face of a panel of the opposite row. In addition, means are provided for releasibly engaging one edge portion of one clad panel with the adjacent edge portion of an adjacent panel in the same row.

Accordingly, it is an object of the invention to provide a demountable wall assembly incorporating panels clad with metal sheet, wherein support means are provided integral with the panel which eliminate the need for separate studs.

It is a further object of the invention to provide such a wall in an inexpensive, yet versatile manner.

It is a related object of the invention to provide such a wall wherein adjacent panels in the same row can be releasibly engaged with respect to each other so as to be releasibly fixed relative to each other when assembled.

Other objects and advantages will become apparent upon reference to the following discussion of the drawings and of the preferred embodiments of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a fragmentary plan view in section, parts of which are broken away, of a wall constructed in accordance with the invention, the floor runner having been omitted for clarity;

FIG. 2 is a fragmentary elevational view in section of the wall of FIG. 1, illustrating the conventional components of the construction;

FIG. 3 is a fragmentary perspective view of a panel illustrating another embodiment of the invention;

FIG. 4 is a plan view in section similar to FIG. 1, but illustrating yet another embodiment of the invention;

FIG. 5 is an enlarged fragmentary plan view illustrating the details of the embodiment shown in FIG. 4; and

FIG. 6 is a fragmentary plan view in section similar to FIG. 1, but illustrating still another embodiment of the invention.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

The disclosure concerns an assembly of wall panels faced with sheet metal adhered to a core, the sheet metal being either the exposed surface, or a base upon which a decorative coating may be applied. The core, the sheet metal, and the adhesive bonding the two all are conventional in and of themselves, so that a variety of each may be used in addition to those specific examples disclosed hereafter, without departing from the invention.

Turning now to FIGS. 1 and 2, there is illustrated a hollow, demountable wall assembly 10 incorporating two opposed, parallely extending, spaced-apart rows 12 and 14 of panels 30. The entire wall is mounted in ceiling and floor runners 18 and 20, respectively (FIG. 2) in a conventional manner. That is, the floor edges of the partition may be finished with either a "top set" base 22 or a base and attachment clip 24. The panels may be of any conventional material, preferably gypsum wallboard, having a core 31, a back face 32, and a front face 34 to which metal sheets 40, described hereafter, are adhered by a suitable adhesive 36. Portions of the sheet 40 have been removed for illustration, in FIGS. 1 and 2. Examples of such adhesives, which are included by way of illustration only, and not as limitations, are SBR rubber, epoxy, hot-melt, polyvinyl acetate-based, and neoprene-based adhesives, as well as a terpolymer acrylic emulsion adhesive available from the United States Gypsum Company as "Durabond 700" adhesive.

In accordance with one aspect of the invention, the sheet 40 is provided with vertical edge portions 42 and 44 which are extended and bent back so as to extend across the space between the two rows of panels until they abut against, without interengaging, the back face 32 of the panels of the opposite row. The abutment is preferably accomplished by end flanges 46 provided on each edge portion, which extend generally parallel to the abutted back face of the panel. The edge portion 42 of one panel, when assembled, also releasibly abuts against the edge portion 44 of the adjacent panel. Each edge portion extends down to substantially the floor level 48 of the panel, FIG. 2.

By means of the foregoing, it will be readily apparent that a greatly simplified assembly is provided wherein each panel supports itself by virtue of its edge portions, independently from every other panel and without the need for separate studs. Furthermore, each panel is independently and quickly accessible, permitting immediate access to the interior of the wall, if necessary, without requiring disassembly of the remaining panels. The elimination of studs greatly reduces the cost of both the manufacturing and the labor involved in the installation.

A variety of gauges and materials may be provided for the metal sheet. For example, steel may be used in gauges as thin as 30. However, for the wall assembly to be load-bearing, the sheet should be no thinner than 20 gauge. As for the core 31, regardless of the use, gypsum wallboard having thicknesses ranging from 1/2 to 3/4 of an inch are appropriate, as are larger sizes.

The surface of the sheet 40 left exposed on the wall may be left so exposed, or decoratively covered in any conventional fashion, such as by paint.

FIG. 3 illustrates an alternate embodiment of the panels, which will permit the alternate use of a different, although conventional, ceiling runner, not shown. Parts similar to those previously described bear the same reference numeral to which the distinguishing suffix a has been added. Thus, some ceiling runners include depending rails interiorly located which assist in holding the wallboard against the exterior side flanges of the runner. These rails would interfere with the edge portions of the panels, and accordingly the edge portions have been modified. That is, panel 30a comprises as in the previous embodiment a core 31a, a metal sheet 40a clad or adhered to the front face 34a thereof by an adhesive 36a, the vertical edge portions such as 42a being bent back to extend across the space between the rows of panels. However, to accommodate the different ceiling runner, the top part of the edge portions is cut out as at 50, leaving a shortened edge portion 52. Or alternatively, instead of the metal sheet extending the full height of the panels as shown in FIGS. 1-3, a shorter sheet may be used which will extend up only to the height of portion 52 all along its circumference.

In accordance with another aspect of the invention, FIGS. 4 and 5 illustrate yet another embodiment wherein the panels of either or both row may be releasibly fixed with respect to the adjacent panel of that row when assembled. Parts similar to those previously described bear the same reference numeral to which the distinguishing suffix b has been added. Thus, the wall 10b comprises two rows of panels 30b which are identical to those described with reference to FIGS. 1 and 2, except that the edge portions 42b and 44b of each panel have been modified. That is, edge portions 42b have been lanced at spaced intervals to form socket flanges or tabs 60 in a manner similar to that disclosed in my copending application Ser. No. 288,197, filed on Sept. 11, 1972. However, instead of tabs formed on studs, the tabs are formed as part of the edge portions in the absence of studs. Specifically, flanges 60 project from the side of the edge portion 42b which is opposite from the side from which flanges 46 project, to define a vertical slot 62 opening outwardly towards the adjacent panel of that row. Flanges 60 are each characterized by a socket (FIG. 5) formed by shaping the flanges so as to extend outwardly away from the edge portion and generally perpendicular thereto, defining a stop surface 64. Thereafter, the flange extends generally parallel to the edge portion, back towards the panel, and thence back at 66 towards the edge portion, completing the socket. Finally, to form a guide means for guiding the edge portion 44b into the socket, as indicated below, the flange has a portion 68 which is inclined outwardly away from the edge portion but towards the row of panels, an extension of portion 68 back to the edge portion defining an angle alpha, which is preferably about 45.degree. (FIG. 5). This angle causes the edge portion 44b to be readily guided into engagement with the flange 60 as will be seen. Terminal portion 69 of flange 60 abuts against the adjacent panel.

The lancing of the flanges 60 out of the edge portion 42b leaves holes 70. Such a construction permits the flanges 60 to be formed as a series of three vertically spaced tabs, preferably located 2 feet, 8 inches; 4 feet; and 5 feet, 4 inches; respectively, from the floor. However, if desired, the flanges can extend the full length of the stud member, in which case the metal sheet 40b is preferably extruded.

The other edge portion 44b is provided with a bead terminus 72. Preferably, to permit ready deliberate disengagement of the bead terminus from flange 60, it is rounded slightly so as to provide some space, designated as S, FIG. 5, between the return and the rest of the edge portion. Thus, for an edge portion having a thickness of about 0.027 inch, spacing S should be about 0.011 inch, defining a bead terminus having an exterior width of about 0.065 inch. On the other hand, spacing S must be such as to permit the bead 72 to lock within the socket 63 against accidental release. That is, the extreme edge 78 of the return abuts against portion 66 of flange 60 when engaged within the socket, so as to require a deliberate, forceful separation of the edge portion 44b from flange 60. Accidental forces are not sufficient, however, to cause separation. For this function, the closest approach of flange 60 to the rest of the edge portion 42b at the slot 62 should be, in the case of the dimensions listed above, on the order of about 0.02.

As in my aforesaid application, assembly of edge portions 42b and 44b is accomplished by pushing portion 44b into place so that the bead terminus 72 slips into the socket and is stopped against surface 64. Edge 78 of the bead terminus locks the two edge portions together against all but deliberate separation.

By means of the embodiments shown in FIGS. 4 and 5, the row of panels incorporating the embodiment is rendered progressively accessible only. Although both rows 12b and 14b may be so constructed, row 14b may, for example, be left as in the previous embodiments. Furthermore, individual panels of row 12b can be made individually accessible by forming the sheet with only vertical edge portions 44b. Both of the adjacent panels then must have the adjacent vertical edge portions be portions 42b. As the panels are symmetrical about a horizontal axis, this is readily accomplished by rotating one of the adjacent panels end for end.

Turning now to FIG. 6, there is illustrated yet another embodiment of the invention wherein the wall assembly is an exterior wall. Parts similar to those previously described bear the same reference numeral to which the distinguishing suffix c has been added. Thus, wall 10c is an exterior or curtain wall wherein row 12c composed of panels 30c as in the first embodiment above, is exposed to the elements. Unlike the previous embodiments, row 14c is conventional wallboard 80 attached conventionally in a double layer by means of screws or other fasteners secured to flanges 46c of the panels 30c. To assist in the weathering of the metal sheet 40c, a baked-on enamel layer 82 may be coated thereover.

Although the invention has been described in connection with certain preferred embodiments, it is not intended that it be limited thereto. Rather, it is intended that it cover all alternate arrangements, embodiments, and equivalents as may be included within the scope of the following claims.

Claims

1. In a demountable hollow wall assembly including two opposed, parallely extending, spaced-apart rows of panels, each row assembled independently of the other, the panels of at least one of the rows each being provided with a core having a front surface and a back surface, and a metal sheet adhered to the front surface; the improvement wherein said sheet includes an edge portion integral with said sheet along a vertical margin of said sheet which depends out of the plane of said sheet along the edge of said core and extends inwardly of said wall to a point beyond the back surface of the panel it covers, said edge portion being in releasible contact engagement with the back surface of a panel of the opposite row, and runner means at both the upper and lower ends of said panels providing lateral restraint for maintaining the inner walls of said panels in engagement with edge portions of opposite panels, whereby said panels are

2. The assembly as defined in claim 1, wherein the portion of said vertical edge in abutment with the back face of the opposite row includes a flange

3. The assembly as defined in claim 1, wherein one of said edge portions of each panel in one of the rows releasibly abuts against an edge portion of

4. The assembly as defined in claim 1, wherein the panels of both of said rows are provided with said core and said metal sheet, the edge portions of all of said sheets extending inwardly of the wall beyond the back surface of the adhered core so as to releasibly contact the back surface

5. The assembly as defined in claim 1, wherein said one row is the exterior wall of a building row is attached to said supporting means of said one

6. The assembly as defined in claim 5, and further including a layer of

7. The assembly as defined in claim 1, and further including means on adjacent edge portions of the metal sheet of adjacent panels in one of

8. The assembly as defined in claim 7, wherein said engaging means includes a flange on one of said edge portions projecting from one side thereof defining a vertical socket between the flange and the edge portion opening outwardly towards the front face of said adjacent panels, and a bead terminus on the adjacent vertical edge releasibly snapped into said socket, whereby said adjacent panels may be held in a releasibly fixed

9. The assembly as defined by claim 8, and further including on said flange, means resisting inward movement of the bead terminus with respect

10. The assembly as defined by claim 8, wherein said flange is shaped so as to extend outwardly away from said one edge portion generally perpendicularly thereto, then so extending generally parallel to said one edge portion and outwardly towards the adjacent panel, and thence

11. The assembly as defined by claim 8, and further including on said

12. The assembly as defined by claim 11, wherein said guiding means includes a portion of said flange inclined outwardly away from said one edge portion and towards said adjacent panel so as to define, if extended, an angle with said one edge portion of about 45.degree..