Note: Descriptions are shown in the official language in which they were submitted.
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BACKGROUND OF THE INVENTION
This invention relates to a novel wallboard and
stud combination particularly adapted for compact storage
and shipment and for easy transformation into perpendicu-
larly disposed wallboard and stud elements for use in
constructing interior walls and partitions.
Prior wall constructions ha~e included combina-
tions includinq gypsum board facing elements with
elements which are foldably affixed for compact storage
and shipment, to be unfolded to a perpendicular disposi-
tion to function as the wall supporting studs. U.S.
Patent 3,112,532 discloses a wall panel of two parallel
wallboards with a foldable cardboard core, of corrugated
configuration, foldable from a flat compact condition in
which all elements are in substantially parallel planes,
to an open condition in which the cardboard ribs are
perpendicular to the wallboards, forming a hollow panel.
U.S. Patent 3,188,773 discloses a gypsum wallboard which
has been cut into a plurality of alternating wide and
narrow sections, which are foldable from a flat compact
condition in which all elements are in substantially
parallel planes, to an open condition in which the narrow
sections are perpendicular to the wide sections, forming
a hollow panel.
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SUMMARY OF THE TNVENTION
The present invention is directed to a combina-
tion of gypsum wallboard with an attached foldable sheet
metal stud element which is adhered along the edge of the
wallboardO The sheet metal foldable stud is af a contin-
uous elongate form having a narrow elongate inner edge
portion firmly adhered to the wallboard back face, inward
from, but parallel to and near the wallboard side edge, a
relatively wider elongate central web portion definitely
not adhered to the wallboard, foldable from a position
extending out over the wallboard side edge to a position
perpendicular to the wallboard back face, and a third
narrow elongate outer edge flange portion, extending
perpendicular to the web portion, in a direction from the
web portion opposite to the direction the inner edge
portion extends when the web is folded perpendicular to
the wallboard.
It is an object of the invention to provide an
improved structure for forming both wallboard and stud,
in a wall construction.
It is a Eurther object to provide a novel
foldable steel sheet for compact placement for storage
and shipment and foldable to provide a strong, rigid wall
stud, when adhered to a wallboard.
It is a still further object to provide a novel
hollow wall having a metal stud factory affixed to a
wallboard.
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BRIEF DESCRIPTION OF THE_DRAWINGS
These and other objects and advantages will be
more readily apparent when considered in relation to the
preferred embodiments of the invention as set forth in
the specification and shown in the drawings in which:
Fig. l is an isometric end view of a sheet of
gypsum wallboard with a foldable sheet metal stud element
affixed along each side edge of the wallboard, in accor-
dance with the invention.
Fig. 2 is an enlarged isometric end view of one
corner of the wallboard of Fig. 1, with the metal stud
element shown in phantom in a folded out disposition, for
use as a wall stud.
Fig. 3 is an isometric sectional plan view of a
hollow partition wall constructed of the wallboards with
stud elements of Fig. 2.
Fiy. 4 is a view similar to Fig. 2 further
including a stud element bending tool, in accordance with
the invention.
Fig. 5 is an enlarged isometric end view of one
corner of a modified form oE the wallboard of Figs. 1-4,
with the metal stud shown in phantom in a folded out
disposition, for use as a wall stud.
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DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to Figs. 1 and 2, there is shown a
factory laminated wallboard and stud wall unit 10,
consisting of a paper covered bevelled edge gypsum
wallboard 12 adhesively affixed to two roll-formed sheet
metal stud elements 19, 14, which extend almost the full
length of the wallboard 12.
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Each stud element 14 is an elongate strip of
.015 inch thick steel which includes an attachment
portion 16 of about two inch width along the inner edge
of the stud element 14, a web portion 18 of about
two-and-a-half-inch width adjoined to and coplanar with
the attachment portion 16, and a downwardly extending
flange portion 20 adjoined to and perpendicular to the
web portion 18. Flange portion 20 preferably also
includes a reversely bent upwardly extending edge portion
22.
The attachment portion 16 is the only part of
stud element 14 that is adhesively affixed to the back
face 24 of the wallboard 12, and is affixed along a strip
26 on the back face 24, which is spaced inwardly from the
side edge 28 of the wallboard 12, a distance of almost
two-and-a-half inches, whereby web portion 18 lies
against the edge portion 30 of back face 24 and flange
portion 20 extends downwardly closely adjacent wallboard
side edge 28. The width o flange portion 20 is e~ual to
or slightly less than the thickness of wallboard 12,
which is preferably between about 3/8 to 5/8 inch.
A fold line 32 is formed along the ~unction of
the attachment portion 16 and web portion 18, preferably
in the form of a s].ight elongate depression in the metal
and preferably a plurality of small diamond shaped holes
34 are located along fold line 32, spaced apart about
every two to six inches.
Slightly raised reinforcing ribs 36 extend
perpendicular to the fold line 32 in the web portion 18,
spaced evenly apart about every four to twelve inches.
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Ribs 36 can be formed with a slit 38 through the sheet
metal at both ends 40, 90', leaving an opening completely
through ribs 36 for a reason to be discussed below.
Alternatively, the slits 3~ can be eliminated and a
triangular or diamond shaped hole, such as holes 39, can
be formed along the fold line 32, at the one end of each
rib 36.
Eig. 2 shows how the stud element is Eolded
from a flat original storage form to a right-angled
Z-shaped functional form, in phantom lines.
Fig. 4 shows a novel tool 92 for folding the
stud element 14 to its functional form. The tool 42
includes a rigid elongate body 49, which has a length
approximately the length of the longest units 10
available, which will be about eight to twelve feet.
Projecting forwardly from body 49 are a plurality of pegs
46, spaced evenly apart about every four to twelve
inches, depending on the spacing of ribs 36. Pegs 46
have a length and diameter suitable for firmly fitting
through the ribs 36 and extending slightly out of the
remote end 90', terminating at or short of fold line 32.
At least one handle 48 extends rearwardly from body 44,
preferably two or more, for raising the web portion 18 in
a folding motion around fold line 32.
Fig. 3 shows a hollow wall 50 formed of a
; plurality of units 10. With the web portion 18 and
flange portion 20 on each of the two stud ele~ents 14 on
the two side edges 28, 28 of each unit 10 in the
functional form, the stud elements 14 each provide the
normal functions of prior wall studs, holding the
:
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wallboard in place and providing suitable rigidity to the
wall.
In forming the wall 50, one set of wallboard
and stud units 10 is arranged with wallboard edges 28
abutting one another to form a front side 52 of wall 50,
with stud web portions 18 projecting rearwardly. A
second set of units 10 is arranged, also with their
wallboard edges 28 abutting one another, forming a rear
side 54 of wall 50, with their stud web portions 18
projecting forwardly. The wall 50 is constructed by
placing one unit 10 against the outside of a floor track
56 and the outside of a ceiling track (not shown), and
the two ends of the wallboard 12 are screwed to a flange
58 of floor track 56 and a flange of the ceiling track
(not shown). Each end of each stud element 14 is enough
short of the end of the wallboard 12 to allow room for
the wallboard ends to extend down along the outside of
the track flanges. The web 60 of the floor track 56 and
the web of the ceiling track tnot shown) are both equal
in width to the width of the web portion 18 of each stud
element 14.
A plurality of additional wall units 10 can
then be afflxed to the floor and ceiling tracks, on the
same side, with the same procedure. Subsequently, a
plurality of similar wall units lO are mounted on the
opposite side of the floor and ceiling tracks and screwed
to the flange 58 of floor track 56 and an opposite flange
of the ceiling track (not shown). Because the floor
track and ceiling track webs are equal in width to the
width of the web portions 18 of the stud elements 1~, the
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flange portions 20 of each unit 10 abut the ~ac~ face 24
of wallboard on the opposite side of wall 50.
In the embodiment shown in Fig. 3, the adjacent
units 10 on each respective side of wall 50 are also
adjoined one to another by the use of preferred, but
optional, clips 62. Clips 62 are narrow, prefolded
strips of spring steel having a central web 64 disposed
firmly against the back of the wallboard edges 28,
bridging the edges 28 or the two abutting wallboards 12,
maintaining the abutting wallboards in coplanar relation-
ship. Angled upwardly and outwardly from each side of
web 64 is a short angled leg 66, followed by a perpendic-
ular leg 68. At the outer end of each perpendicular leg
68 and extending perpendicularly outwardly therefrom, is
an opposite side web 70, disposed against the outer face
72 of a flange portion 20.
Each opposite side web 70 is slightly wider
than the width of a flange portion 20, and has along its
opposite edge a hook-type flange 74 extending downwardly
around the remote side web portion 18. An inwardly
depressed hump 76 on flange 74 engages an outwardly
depressed hump 78 on web portion 18, locking the two
together. With one such interlocking of humps 76 and 78
on each of the two adjacent stud elements, the clip 62
tends to hold the two abutting side edges 28, 28 in tight
abutment.
The wallboard side edge 28 is shown to have a
bevelled edge, however, tapered edge board, for use with
a ioint concealing drywall treatment, or square edge
board may also be used in accordance with the invention.
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With the bevelled edye board or the square edge board, a
decorative vinyl film or cloth facing may be used on the
board face and side edges. One reason for providing a
small space between the side edge 28 of the board and the
flange portion 20 of the clip is to permit the use o a
subsequently added film of decorative vinyl or cloth on
the wallboard face and side edges.
Referring to Fig. 5, there is shown a modified
form of factory laminated wallboard and stud unit 80,
consisting of a paper covered bevelled edge gypsum
wallboard 82 adhesively affixed to two roll-formed sheet
metal stud elements 84 (one not shown), which extend
almost the full length of the wallboard 82, along each
side edge 86 (one not shown) thereof.
Each stud element 84 is an elongate strip of
.015 inch thick steel which includes an attachment
portion 88 of about two inch width, a 180 fold 90
disposed remotely from edge 86, a narrow elongate flat
section 92 overlying attachrnent portion 88, a relatively
wide web portion 94, of about two-and-a-half-inch width
adjoined to and coplanar with the flat section 92, and a
downwardly extending flange portion 96 adjoined to and
perpendicular to the web portion 94. Flange port.ion 96
preferably also includes a reversely bent upwardly
extending edge portion 98.
The attachment portion 88 is adhesively affixed
to the back face 100 of the wallboard 82, and is affixed
along a strip 102 on the back face 100 which is prefera-
bly spaced inwardly from the side edge 86 a short
distance, whereby web portion 94 overlies part of
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attachment portion 88 and also an edge portion 104 of
back face 100 and flange portion 96 extends downwardly
closely adjacent wallboard side edge 86. The width of
flange portion 96 is equal to or slightly less than the
thickness of wallboard 82, which is preferably between
about 3J8 to 5/8 inch.
A fold ].ine 106 is formed along the junction of
the flat section 92 and web portion 94, preferably in the
form of a slight elongate depression in the metal and
preferably a plurality of small diamond shaped holes 108
are located along fold line 106, spaced apart about every
two to six inches.
Slightly raised reinforcing ribs 110 extend
perpendicular to the fold line 106 in web portion 94,
spaced evenly apart about every four to twelve inches.
Fig. 5 also shows, in phantom lines, how the
stud element 84 is folded from a flat original storage
form to a right angled Z shaped functional form. The
wallboard and stud wall unit 80, in its Z-shaped
functional form is then in suitable condition to be used
in forming a hollow wall, in a manner similar to the way
units 10 are used to form hollow wall 50.
Having completed a detailed disclosure of the
preferred embodiments of our invention, so that others
may practice the same, we contemplate that variations may
be made without departing from the essence of the
invention.
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