Note: Descriptions are shown in the official language in which they were submitted.
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TECHNICAL FIELD
This invention relates to a composite insulated
gypsum wallboard and system for securing same spaced
from a wall to be insulated thereby, such as a concrete
basement wall of a building structure. The method of
constructing an insulated wall over a concrete basement
wall is also described.
BACKGROUND ART
There are various methods used to insulate the
inside face of concrete basement walls of building
structures, with such methods including securing a
solid insulating foam sheet directly on the concrete
inside surface in the area which extends above the
external ground surface. The foam sheet may also
extend to the basement floor. However, in order to
secure a finishing wall over the insulated sheet, it is
necessary to secure to the concrete wooden or metal
studs to attach the facing material over the insulated
foam sheet. Accordingly, it is the practice to secure
studs directly to the concrete wall and to insulate
with the foam sheets between the studs. These nailing
studs can be disposed either horizontally or
vertically, or both, and usually spaced apart a
distance of 4 feet. It is now possible to secure a
finishing material over the foam insulators.
A disadvantage of the above method of insulating
concrete walls is that, because nailing studs are in
direct contact with the concrete wall, it acts as a
thermal conductor and affects the insulating properties
of the structure. Furthermore, such a method is time
consuming and the insulating R-value of the structure
is weak. Also, when securing gypsum wallboards over
these structures, it is necessary to drive screws
therein all along the securement studs. It is then
necessary to joint the wallboards and plaster around
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the screw heads and taped board joints, as is
conventional in the trade.
SUMMARY OF INVENTION
It is a feature of the present invention to
provide a composite insulated gypsum wallboard for use
in insulating concrete basement walls of building
structures, and which substantially overcomes the
above-mentioned disadvantages of the prior art.
Another feature of the present invention is to
provide a composite insulated gypsum wallboard for use
in a wall system having connector strips for securing
the insulated gypsum wallboards spaced a predetermined
distance in front of a concrete wall to be insulated
thereby.
Another feature of the present invention is to
provide a composite insulated gypsum wallboard formed
from a gypsum board having a sheet of insulating
material bonded to a rear face thereof to obtain a
desired R-value and wherein the board is spaced from a
concrete basement wall of a building structure so that
the board, together with the air gap between the board
and the wall, constitute an improved thermal barrier to
insulate the basement wall.
According to the above features, from a broad
aspect, the present invention provides a composite
insulated gypsum wallboard for securement from opposed
top and bottom end edges and spaced from a wall to be
insulated thereby. The wallboard comprises a
rectangular gypsum board having a rectangular sheet of
insulating material bonded to a rear face thereof. A
securement connector strip is provided for securing a
top and a bottom edge portion of the wallboard thereto
and for maintaining the wallboard secured and spaced in
front of the wall to be insulated, with the insulated
material facing the wall. A vertical edge
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interconnecting strip is also provided to interconnect
adjacent wallboards together.
According to a further broad aspect of the present
invention there is provided a method of constructing
insulated walls over concrete basement walls of
building structures. The method comprises constructing
composite insulated gypsum wallboards by bonding a
sheet of insulating material to a rear face of the
gypsum wallboards. A ceiling connecting strip having a
connector channel is secured to a sealing structure
adjacent a concrete basement wall to be insulated and
spaced therefrom. A floor connector strip, also having
a connector channel, is secured to a floor adjacent a
concrete basement wall to be insulated with the floor
connector strip disposed in a common vertical plane
with the ceiling connector strip, and the channels
aligned in facing relationship. One or more wallboards
are slid between the channels in close fit therein.
The wallboards are then secured to the channels.
BRIEF DESCRIPTION OF DRAWINGS
A preferred embodiment of the present invention
will now be described with reference to the
accompanying drawings, in which:
FIGURE 1 is a perspective view of the composite
insulated gypsum wallboard of the present invention;
FIGURE 2 is an enlarged section view of the
composite insulated gypsum wallboard;
FIGURE 3 is a section view of the ceiling
connector strip;
FIGURE 4 is a section view of the floor connector
strip;
FIGURE 5 is a section view of the vertical edge
interconnecting strip;
FIGURE 6 is a fragmented side ~iew showing the
composite insulating gypsum wallboard of the present
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invention as secured spaced adjacent a concrete
basement wall of a building structure;
FIGURE 7 is a section view showing how the
vertical edge interconnecting strip is secured to the
wall boards; and
FIGURE 8 is a fragmented section view showing the
floor connector strip with a floor covering material
extending over the attachment flange thereof. ~
DESCRIPTION OF PREFERRED EMBODIMENTS ~ -
Referring now to the drawings, and more
particularly to Figures 1 and 2, there is shown -~
generally at 10 the composite insulated gypsum -
wallboard of the present invention, and comprised of a
rectangular sheet of gypsum board 11 having a
rectangular sheet of insulating material 12 bonded to a
rear face 13 of the gypsum board 11. The insulating ~ -
material sheet 12 is a rigid insulated foam material ~
which is glued to the rear face 13 of the gypsum board, -
and has a thickness dependent on the desired insulating ~-
R-value of the composite wallboard. The insulating
sheet material 12 may be a plastics material, such as
polystyrene, polyurethane, phenolic foam, or may be
constituted by a sheet of cellulosic fibers, or a sheet
having thermal as well as sound insulating properties.
Many other rigid or semi-rigid insulating materials may
be used. --~
As ~hown in Figure 6, the composite insulating -~ ~
gypsum wallboard 10 is for securement from opposed top ;
and bottom end edges 14 and 15, and spaced from a wall ~-
16, herein a concrete basement wall of a building
structure, to be insulated thereby. An air space 17 is
provided between the wallboard 10 and the inner face 18
of a concrete wall 16. The air space 17 provides
improved insulation. ~ -
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In order to secure the composite insulating gypsum
wallboard 10 in a vertical level plane and spaced from
the concrete wall 16, there is provided, as shown in
Figures 3 to 5, connector strips. Figure 3 illustrates
the construction of the ceiling connector strip 19 and,
as herein shown, it is formed from an extrusion of
metal or plastics material and is of generally U-shape
cross-section to define an attachment base wall 20 and
opposed spaced wallboard receiving and connecting
transverse flanges 21. Figure 4 illustrates the floor
connector strip 22, and it is also formed from an
extrusion of like material and is of substantially F-
shaped cross-section to define a wallboard receiving
channel having a base wall 23 and space connecting
transverse flanges 24. The spacing between the flanges
21 and 24 is such as to receive the top and bottom end
edges of the wallboard 10 in close sliding fit therein.
The floor connector strip 22 is further provided with a
securement flange 25 which extends outwardly of one of
the connecting transverse flanges and coplanar with the
base wall 23. These connector channels are made of
anti-corrosive material to prevent oxidation, as these
connectors are usually installed in damp areas.
Figure 5 illustrates the construction of the
vertical edge interconnecting strip 26. It is
essentially a T-shape strip which is extruded from the
same material as the ceiling and floor connector strips
19 and 22. The T-shaped strip defines opposed
connecting flanges 27 which extend in planar alignment
with one another, and a transverse flat wall 28. The
opposed connecting flanges 27 each extend over the
exterior face 29 of the sheet of insulating material 12
and along a vertical edge thereof of a respective one
of adjacent wallboards 10' and 10", as shown in Figure
7. As also shown in that Figure, the transverse flat
wall 28 is disposed between the vertical end edges 29
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and 29' of the wallboards 10' and 10" respectively.
Fastener means in the forms of screws 30 are driven
from the outer face 31 of the gypsum board 11, through
the insulating material 12 and into the connecting
flanges 27. Jointing compound 32 and a jointing tape
33 then conceal the joint and the screws, as is well
known in the art. This jointing is only effected after
the insulating wall has been constructed, and the
method of its construction and erection will now be
described.
Referring now more particularly to Figure 6, there
will be described the method of constructing the
insulated composite wall of the present invention and,
as herein shown, in order to provide lateral stability
to the wall, it is desirable to secure abutment
insulating foam blocks or strip 34 to the concrete wall
16 at about mid-height thereof. A caulking compound 35
having insulating properties may be beaded along the
outer face of the abutment so that when the sheet is
slid between the connector strips 19 and 22, the
exterior face 29 of the insulating sheet 12 will set in
securement with the strip 34 through this bead of
compound. The strip or blocks 34 provide lateral
stability to the wall. Of course, other material could
be used as spacer means, such as the blocks 34.
Furthermore, the blocks 24 of insulating foam material
may be glued to the inner face of the concrete wall or
the insulating sheet 12.
The method of constructing the wall 10 consists in
securing the ceiling connector strip 19 with its
connector channel facing downwardly and spaced a
desired predetermined distance from the inner face 18
of a concrete wall. The ceiling connector strip is
secured to a ceiling structure, such as floor joists
36, by means of screws or nails 37 and in parallel
alignment with the inner face 18 of the concrete wall
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16 to be insulated. The floor connector strip 22 is
then secured to the floor surface 38 and in vertical
alignment with the ceiling connector strip 19, and its
channel facing upwardly. Concrete nails 39 or glue can
secure the floor connector strip to the floor surface
38 with the securement flange 25 facing inwardly or
outwardly, as shown in Figure 8, of the inner face 18
of the concrete wall. The composite wall boards 10 are
then slid from an end of the floor connector channels,
which is not installed from wall to wall, and
positioned side by side in a common plane. These
connector channels 19 and 22 may be extruded in lengths
of 8 to 12 feet, or any other desired lengths and
easily cut with a standard tool, such as a handsaw.
After the first wallboard is slide in between the
channels the wallboard is attached to the connector
strip 19 and 22 by driving screws 40 through an outer
one of the connecting transverse flanges 21 or 24. The
T-shape vertical edge interconnecting strip is then
secured to adjacent vertical edges of adjacent
wallboards. This is done by securing the strip to the
firstly placed wallboard 10', as shown in Figure 7, and
then sliding the next wallboard 10" in position with
the transverse flat wall 28 sandwiched between the end
edges 29 and 29' of the wallboards. As herein shown,
the transverse flange 28 is shorter than the thickness
of the composite wall board to provide a cavity between
the wallboard to permit a jointing compound to enter
the cavity between the wallboards to provide a more
solid joint, as is obvious in the art.
Because the wallboards are slid from an end of the
connector strips and in close fit between the connector
channels 19 and 22, they provide good insulating
property by eliminating air leaks. The end wall panel
must be installed differently, because the panels are
slid in position from an end of the floor track or
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strip 22. Accordingly, with the end wall panel a floor
connecting strip 22 is cut to the width of the panel
and installed thereon with its securement flange 25
extending outwardly, as shown in Figure 8. The top
edge of the panel is then fitted in the ceiling
connector strip 19 and the panel is aligned with the
previously installed panels. A nail or glue secures
the floor connector strip in position. It is pointed ;
out that these connector strips are provided of thin
web extrusion, and it is therefore possible to easily
cover the securement flange 25 when a floor covering,
such as a carpet 41, is glued to the floor surface 38
which is usually concrete. -~
It is also appreciated that when openings are to
be formed in the wallboards 10, such as window
openings, these are cut out from the wallboard and the
insulating space 17 between the wallboards and the
concrete wall is framed with strips of insulating foam
material or nailing studs.
It is within the ambit of the present invention to ~ -
cover any obvious modifications of the preferred
embodiment described herein, provided such
modifications fall within the scope of the appended
claims. For example, the strips 19 and 22 may be
formed differently, such as with L-shaped channels and
may be formed of separated sections to facilitate
installation.
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