US1986309A - Wall and ceiling construction - Google Patents

Description

Jan. 1, 1935. G. R. WALPER 1,986,309

l WALL AND CEILING CONSTRUCTION 4 Sheets-Sheet 2 Original Filed Dec.' 2, 1929 INVENTOR Gard??? .irai/wref ATTORNEYAZl Jan. l, 1935. G. R. WALPER 1,986,309

WALL AND CEILING CONSTRUCTION Original Filed Dec. 2, 1929 4 Sheets-Sheatl 3 ATTOFiNEYSl Jan. 1, 1935. G, R WALPER 1,986,309

WALL AND CEILING CONSTRUCTION Original Filed Dec. 2, 1929 4,Shee'cs-Sheerl 4 INVENTOR Patented Jan. 1, 1935 UNITED STATES PATENT OFFICE.

WALL AND CEILING CONSTRUCTION Gordon a. wanner, Huntington woods, Mich., as. signor to Curry Ora Walper, Royal Oak, Mich.

Application December 2, 1929, Serial No. 411,189 Renewed June 4, 1934 9 Claims. (Cl. 'l2-115) erally methods and means of this character.

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In wall and ceiling constructions of the character to which this invention particularly pertains it is customary to provide channel members adapted to receive the parallel edges of the plaster boards or the like,to reinforce and support the same with respect to the studding or other frame members. In wall or ceiling structures, wherein the channel members are secured to wooden frame members, attachment is preferably made by means of driven headed members, and in structureswherein steel channel-shaped frame members or studding is employed, the channel meme bers are customarily secured in place by metallic attaching clips.

The present invention contemplates improvements in the elements and members from which such wall and ceiling structures are constructed, and has as its object generally to simplify, cheapen and otherwise facilitate the manufacture of these elements and members; to provide a structure which may be quickly and easily assembled; and one which will be strong, durable and otherwise commercially satisfactory.

To this end one of the important objects of this invention is to provide an improved construction of double channel-shaped members which may be quickly and economically produced in large quantities, either from a single strip of metal bent to produce the desired construction or from two strips of metal which are iirst suitably shaped and then subsequently united to produce the desired double channel-shaped member.

Still another object of the invention is to provide, in connection with any of the forms of channel members herein illustrated. means constituting and providing a plaster gauge whereby a minimum thickness for the plaster coat, which is subsequently applied to the wall or ceiling structure, is established.

The invention further contemplates and has as its objects improvements in the means for attaching the double channel members to both wooden and metallic studding or frame members;

to the means for insuring an adequate union or bond between the plaster coat and the double channel member; and to the means for reinforcing and otherwise strengthening the attaching elements employed in connection with the metallic frame members.

In addition, the invention contemplates a construction wherein a solid section of plaster is made possible at the joints supported by the double channel members so that expansion and,

contraction at these points is made uniform and the possibility of surface cracking eliminated. Another important object of the invention is to provide a wall and ceiling construction of the described character wherein, when wooden frame members are employed, the plaster board supporting means cooperate therewith to'rigidly tie together the spaced frame members, whereby a strong, rigid and commercially practicable wall or ceiling is produced.

The invention further contemplates the use of pre-marked plaster boards or the like, whereupon the cutting of the boards to size to com-` plete irregular-shaped portions of the wall and ceiling is facilitated.

The several objects, advantages and novel details of this construction will be made more apparent as this description proceeds, especially when considering the accompanying drawings wherein,

Figure 1 is a vertical section through a wall and ceiling construction, showing in general the application of the present invention;

Figure 2 is an enlarged sectional view taken substantially on 'the plane indicated by line 2 2 in Figure 1;

Figures 3, 4 and 5 are views showing the manner in which one of the sections of one of the forms of channel member is developed;

Figure 6 is a view showing semi-diagrammatically the manner in which the plaster gauge projections can be formed in the channel part illustrated in Figures 3, 4 and 5;

Figure 7 is a fragmentary perspective view of this form of channel member;

Figure 8 is aA fragmentary sectional view showing semi-diagrammatically one means by which the sections of channel member, illustrated in Figure 7, may be united;

Figure 9 is a central vertical sectional view through a portion of a channel member united in accordance with the means illustrated in Figure 8; Figure 10 is an edge view of the blank from which another form of double channel member may be developed;

Figure 11 is a sectional view through the form of channel member developed from the single strip of metal illustrated in Figure 10;

Figure 12 is a view somewhat similar to Figure 11 of a slightly modified 'form of channel construction developed from a single strip of etal;

Figure 13 is a fragmentary perspective view ofv l age means:

Figures 21 and 22 are respectively transverse sectional and elevational views of a double channel member formed of two separate channels united in the manner illustrated senil-diagrammaticallyrin Figure 8;

Figure 23 is a fragmentary sectional view through a wall construction illustrating a modied means for securing the channel member to th studding; s

Figure 24 is a similar view but modified to the extent that the channel securing means constitutes the plaster gauge;

Figure 25 is a fragmentary perspective view showing the double channel members attached to a steel frame member;

Figure 26 is a perspective view of one of the attaching clips employed;

Figure 27 is a view illustrating more clearly the manner in which the attaching clip illustrated in Figures 25 and 26 is connected to the frame member;

Figure 28 is a fragmentary perspective view 4'showing a modified form of an vattaching clip associated with the frame member;

Figure 29 is a similar view showing still another modified form of attaching clip;

Figure 30 is a similar view showing another 'modified form of attaching clip;

Figure 31 is a sectional view through a clip taken substantially on a plane indicated by the line 31-31 in Figure 29;

Figure 32 isa fragmentary vertical sectional view of a ceiling construction showing in general the application of the present invention when metal frame members are employed;

Figures 33 and 34 are perspective views of modied forms of attaching clips;

Figure 35 is a view of still another modified form of attaching clip;

Figure 36 is a sectional view through a different l form of frame member showing the clip and channel member secured thereto;

Figure 37 is a plan view of a pre-marked plaster board or the like.

Figures 38 and 39 are respectively sectional and elevational views of a modied form of means for securing the two parts of the double channel member together.

Figures 40 and 41 illustrate semi-diagrammatically another method and means for securing together the two parts of the double channel member; and

Figure 42 is an elevational view, with certain parts broken away, of a wall construction illustrating the manner in which the plaster board supporting .means act to reinforce the frame members.

Referring now more particularly to the drawings wherein like reference characters indicate corresponding parts throughout the several views, and more particularly to Figure 1, it will be noted that there is illustrated a vertical section through a wall and ceiling construction in Whig!! ih@ mi' erence character 10 indicates the horizontal ceiling frame members and 11 the vertical wall frame members. In Figure l these frame members are of wood, and as a consequence the manner in which a wall constructed in accordance with the present invention is attached to wooden frame members will be first described.

As seen from Figure 2, the invention contemplates the attachment of plaster boards or the like 12 to the frame members 10 or 11 by means oi.'

means of driven headed elements 14.

The invention contemplates means whereby these channel members may be economically produced in large quantities and to this end several forms of channel member and several methods of constructing the same are herein illustrated.

As will be apparent from an examination of Figure 7, one form of channel member comprises two parts and 16, pre-formed and united in the manner to be later referred to. The channel member is formed from strips of sheet metal and the section 16 is bent to the desired cross sectional contour in the manner most clearly suggested in Figures 3, 4 and 5.

In Figure 3 it will be noted that the flat strip 16a is bent along the lines 16b to the cross sectional contour illustrated in Figure 4, and then further bent along the lines 16c wherein the bases 16e of the completed channel are provided, together with an intermediate portion 16f for attachment to the other section l5 of the channel.

The two sections 15 and 16 of the channel member, illustrated in Figure 7, may be united, as for instance, by spot welding, as indicated at 17, or they may be united by cutting tongues from the abutting portions of the sections 15 and 16 and bending these tongues back upon the adjacent portion as illustrated in Figures 8 and 9. In Figure 8 there is semi-diagrammatically illustrated a tool 18 having a portion 19 which may be run through the channel formed by the bases 16e to the double channel member to cut therefrom tongues 20, which are subsequently bent back uponv the abutting portion of the members 15 and 16, as illustrated in Figure 9. This not only secures the members 15 and 16 together to produce the form of channel illustrated in Figure 7, but Y provides apertures 21 permitting the passage therethrough of the driven headed elements 14, employed for securing the channel members to the frame members. The formation of the tongues 20 may obviously be accomplished by a stamping operation.

The outer flanges of the channel members are provided with plaster gauge means, which in the present form are shown as pressed out loops or extensions 22. These pressed out loops may be conveniently formed by producing a pair of spaced parallel short slits and then displacing the metal therebetween outwardly out of the general plane of the flanges in which they are formed. The manner in which this might be economically accomplished is illustrated semi-diagrammatically in Figure 6, in which cooperating forming members 23 and 24 are provided. This operation may 911.50 be accomplished by a stamping operation.

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By forming the channel illustrated in Figure 7 in two sections lthe plaster gauge projections 22 can conveniently be formed in the section 16 before this section is assembled with the section 15,

thus making the production of vthis form of channel member commercially acceptable.

In Figures 10 and 11 there is illustrated an improved form of channel member, formed from a single strip of metal. In constructing this form of channel member the plaster gauge projections 22av wouldin order to facilitate the manufacture. be formed in the blank 25 before the same is folded. The blank is folded along the lines 25a, 25h and 25e, to produce respectively the portions 26, 27, 28 and 29 of the completed channel member illustrated in Figure 11. Itwill be noted that the portions 25 and 26 are bent tightly back upon themselves so as to produce a double wall thickness throughout the greater portion of that side of the channel member.

rated when the headed element 14 is driven in place, is of but a single thickness, so that it is unnecessary to perforate these channels as the metal is sufficiently thin, so that the headed element may be driven therethrough and into the frame member 10. This is particularly true because the ange 26 of the double channel member is supported directly against the frame member 10 and cannot spring or give when the headed member 14 is driven therethrough.

It is important to note that in all of the forms of channels constituting a part of this invention the head 14a of the driven securing element 14 spans the space between the bases of the channels and engages the side flanges thereof, (see, for instance, Figures 2 and 1l) whereby the channel member is rigidly secured in place.

In Figure 12 there is illustrated a modified form of channel member 20; also developed from a single strip of metal, but in this form of construction the side anges 31 are extended beyond the longitudinal edges of the side flanges 32. In this form of construction the plaster gauge loops or projections 22h may be formed in the channel member after the channel member has been produced, and in Figure 12 there is indicated in dotted lines forming dies or tools 23a and 24a, similar to the forming dies illustrated in Figure 6.

While heretofore the plaster gauge means has been described and illustrated as consisting of loops pressed out from the general pla-ne of the flanges in which they are formed, it will be noted from an examination of Figures 13, 14 and 15 that various other forms of plaster gauge means may be employed. In Figure 13 the double channel member 13 has the flanges at one side thereof formed with longitudinally extending ribs 33 which project outwardly beyond the general plane of these flanges so as to provide a gauge for insuring a minimum thickness of plaster. In Figure 14 the edges of the flanges of the double channel member are uted or undulated as indicated at 34, thus producing plaster gauge projections or extensions. In Figure 15 the iianges are perforated as indicated at 35 to produce outwardly extending tubular bosses 36.

It will be understood that when the plaster coat is applied to wall or ceiling structures embodying double channel members of any of the forms herein illustrated and described, the plaster enters and lls the channel 37 formed by the bases 16e of the opposed channels. It is ofttimes desirable to provide means acting as an anchorage for the section of plaster which enters and fills However, the mej dial line of the channel, which must be perfo this channel 37, and in Figures 16 to 20 inclusive, several forms of plaster anchorage means are illustrated. For instance, in Figures 16v and. 17 the bases 16e have loops 38 similar to the' loops 22,

vpressed outwardly therefrom, it being apparent from Figure 17 that these loops are staggered with reference to one another, so that the loops of one of the bases 16e project into the spaces between the loops of the other base 16e. Thus when plasterenters the channel 37 it will extend not only in the spaces under the loops 38, but also in the tortuousspace between this loop to thus provide an adequate anchor for this section of plaster.

In the modification shown in Figures 18 and 19 the plaste'r anchorage means is also employed as a reinforcement for the channel member, and to this end portions or enlargements 39 are struck out from the bases 16e of the channels, these struck-out portions being arranged in opposed relation and abutting and they may be welded or otherwise secured together if desired, so as to strengthen the bases of the channels of the double channel member at this point. Obviously, the plaster swhich enters the channel 37 will flll in around and behind this abutting projection 39 so that this section of plaster is also adequately anchored. 1

In Figure 20 the anchorage of the plaster coat 40 is accomplished by inclining the bases 16e of the channels to 'provide a tapered or wedgeshaped channel 41, which is smaller at its open side, so that when the plaster enters and fills the wedge-shaped channel 41 and subsequently sets or hardens, the loosening or removing of this section of plaster from within the channel will be prevented by reason of this Wedge shape. In

Figures 21 and 22 there is illustrated another Obviously, the channel members may be secured to the studding or frame members in other ways than by driving the headed elements through the medial line or center thereof, and in Figure 23 the channel member 13 is shown as secured in place by driven headed elements 44, driven into the studding 1Q at both sides of the channel member, with the heads 44a thereof overlapping the adjacent edges of the channel member. Obviously these driven elements 44 are also passed through the plaster boards l2.

In Figure 24 a construction is shown wherein the driven headed element which is employed for securing the channel member to the studding also acts as a plaster gauge, and in this form of construction the driven element 45 is shown as provided with an enlarged head 46 which in and of itself constitutes a plaster gauge.

' In assembling wall or ceiling structures in which the channel members are secured to the frame members by driven headed elements, a channel member is first nailed to the frame member, whereupon a plaster board is put in position with one of its longitudinal edges engaged in a channel of the channel member. Thereupon another channel member is engaged with the opposite edge of the plaster board and this channel member is then secured to the frame member. This operation is continued until the wall or ceiling is completed. l

In every instance where the longitudinal edges of the plaster boards are engaged and supported by the double channel members, which in turn are secured to the frame members, the other or adjacent end edges of adjacent plaster boards may also be reinforced by lengths of double channel members which extend between the lengths of channel bars secured to the frame members. In this manner all weaving and relative displacement between adjacent edges of adjacent plaster boards is prevented.

While throughout the description thus far the wall and ceiling structure has been generally described as connected to woodenframe members, it will be obvious that the present invention also contemplates the attachment to steel frame members. As a consequence, in Figures 25 to 31 there is illustrated means for attaching the double channel members to steel frame members. It will be obvious, however, without specific reference thereto, that any of the heretofore described forms of channel members may be utilized notwithstanding the fact that the form of channel member illustrated in Figure 7 has been shown in Figure 25.

In Figure 25 the' frame member is in the form of a metal channel'member 47 and the channel members 13 are secured thereto by attaching clips 48. AWhile the illustration in Figure 25 is of a ceiling construction, it will be obvious that the same arrangement and organization of parts may be employed in connection with walls, in which event the frame members 47 would extend vertically instead of horizontally. When metal frame members 47 are employed in a ceiling construc-` tion they may be supported by suspension elements 47'. As seen in Figure 32, these suspension elements can be connected to nails or the like 47" driven into the wooden frame members 10. In this manner any shrinkage of the wooden frame members 10 which generally causes a distortion thereof at their lower edges, willnot result in a cracking of the ceiling structure.

The form of clip illustrated in Figures 25, 26 and 27 consists of a channel portion 49 and a right angularly extending flange 50 with an open sided slot 5l, thus providing a pair of opposed jaws or lugs 52. Attachment of the clip 48 to the frame member 47 is accomplished inthe manner suggested in Figure 27, wherein one of the jaws 52 is engaged over one of the side flanges of the frame member, the other jaw engaging the base of the frame member to prevent longitudinal movement of the clip. 'I'he duplicate opposed jaw members or lugs 52 provide means for attaching the clip so that the channel portion 49 thereof may extend in either direction. l'

In assembling wall or ceiling structures in which the clips 48 are employed, one of the clips is rst engaged with the frame member, whereupon a channel member is engaged with the clip and then another clip is engaged with the other channel of the channel member and with the frame member. Thereupon the edge of a plaster board is inserted in the last mentioned clip and the adjacent channel of the channel member, and thereafter another clip is engaged with the opposite edge of the plaster board and with the frame member. Thereafter another double channel member, clip and board are assembled with the frame member and with one another in the manner just described and this sequence of operation is continued throughout the assembling of the entire ceiling or wall structure.

In Figure 28 a slightly modiiied form of clip construction is illustrated. In this form of construction the clip .comprises a channel portion 53 and a return bent flange portion 54, slotted as at 55 to provide the opposed lugs or jaws for engagement with the frame member 47.

In Figure 29 the clip comprises a channel portion 56 and a ange portion 57 extending laterally therefrom in the same general plane as the adjacent side of the channel portion 56, but slightly offset therefrom so that by reason of the slotted portion 58 thereof it may be engaged with the frame member 47.

In Figure 30 still another form of modlded clip is illustrated, and in this form of construction the clip is substantially U-shaped, so as to straddle the frame member 47. Each clip is formed with a pair of channel portions 59 and a vertically extending portion 60, the vertically extending portion being connected by a horizontal portion or ilange 61 so that each clip may straddle the frame member 47 'and rest upon the upper' y flange thereof.

In all of the forms of clips herein illustrated the frame engaging DOrtions thereof may be reinforced or otherwise strengthened by means of ribs 62 pressed therein. A section through the clip shown in Figure 29 is illustrated ln Figure 31.

In Figure 33 another modified form of clip is illustrated. 'I'his clip is formed with a channel portion and a 'flanged portion 81 from which the jaws. or lugs 82 are struck up preferably by slitting the metal and displacing the portion between the slits upwardly to form the opposing attaching lugs or jaws.

In Figure 34 another modified form of clip is shown provided with a channel portion 83 and opposed lugs or jaws 84 formed by slitting the flange 85 thereof from the edge portion inwardly and then bending the slitted portion angularly upwardly and then parallel to the flange 85 to form the opposed attaching lugs.

In Figure 35 still another modified form of construction is shown which comprises a channel portion 86 and a ange portion 87 having a return bent edge portion 88. This forms a portion of double thickness and from this portion of double thickness the attaching lugs 89 are struck up. This provides a simple but eillcient means for reinforcing the attaching lugs.

In Figure 36 a modified form of frame member 90 is illustrated, the frame member being bent to form longitudinally extending grooves 91. In assembling the attaching clip with the frame member 90, the lugs or jaws thereof are adapted to extend into one of the grooves 91 to thus further insure that the clips will not become accidentally disengaged.

In Figure 37 a plaster board 12 is illustrated in plan view, and it will be noted that the surface thereof is ruled to provide a plurality of vertical and horizontally extending marks or lines 83. The purpose of these lines is to facilitate the cutting of the plaster boards when boards of smaller dimensions than the standard size boards are desired. By the use of these lines the points at which the board must be cut can be readily determined by the workman constructing the ceiling or wall and the board cut to size rapidly and accurately without necessitating accurate measurements and the subsequent marking of the board to indicate the lines of cut.

In Figures 38 and 39 there is illustrated the two parts and 101 of the type of double' channel member hereinbefore referred to. In this form of construction the infringing parts are united by punching the metal as indicated at 102 to provide a plurality of tongues 103 which are subsequently tightly bent back upon the adiacent wall structure as illustrated be'st in Figure 38. 'Ihe punching and folding back may be carried out by a rotary or stamping method.

In Figures 40 and 41 still another method and means for uniting the two parts of the channel member hereinbefore referred to are illustrated. In this form of construction the two parts 104 and 105 are united by pairs of tongues which may be conveniently formed by forming members 106 and 107, the forming member 106 being shaped to provide a transverse slit and pairs of longitudinally extending slits whereby pairs of tongues 108 are provided. Subsequently these tongues can be bent back upon the adjacent metal by means of forming members 109 and 110.

In Figure 42 there is illustrated several of the vertically extending wooden spaced members 11 illustrated in Figure 1. In practice the plaster boards 111 are secured in place by the double channel members 112 which are arranged in longitudinally spaced relation transversely of the frame members 1l. These double channel members receive and support and reinforce the 'adjacent edges of the plaster boards, as previously pointed out. In practice these double channel members are secured to wooden frame members by driven headed elements, such as nails or the like, andy in Figure 42 two such driven headed elements 113 are shown as passing through the double chanf nel members at each point of intersection with a frame member. When the parts are secured in position the frame members are rigidly tied together and weaving or relative movement between adjacent frame members or between the frame 'members and the plaster board supporting members and the plaster boards themselves is prevented. Employment of two driven headed members at each point of intersection of the channel and frame members insures a further ldegree of' this manner the adjacent edges of the plasterl boards are accurately aligned and all independent movement or weaving of the boards at the edges thereof is prevented. Furthermore, the use of an integral double channel member facilitates the construction of the wall or ceiling and enables the same to be constructed quickly so as to be commercially acceptable and practicable.

In accordance with the present invention the construction of the double channel members is such that they may be quickly and economically manufactured in large quantities. The association with each form of channel member of a vplaster gauge means insures the application of a sufcient amount of plaster to the finished wall to insure a commercially satisfactory job. Moreover, the numerous other features and details of construction of the various elements comprising parts of this invention are such as to render this invention of .practical valuein the art.

While several forms of the invention have been described herein somewhat in detail, it will be readily apparent that many other changes and modifications may be resorted to, without departing from the spirit and scope of the invention,

and to this end reservation is made to make such changes as may come within the purview of the accompanying claims.

What I claim as my invention is:

1. In a structure of the class described, a plaster board supporting element having opposed -channels formed of an elongated at strip of sufiicient width to constitute one side of each channel and a second elongated strip shaped to form the bases and other sides of said channels.

2. In a ceiling and wall construction, a double channeled plaster board supporting element formed of two connected strips of substantially equal length constituting respectively one side of each channel and the other sides and bases of said channels.

3. A double channeled plaster board supporting element for use in wall and ceiling structures formed of two strips of sheet metal, one of which is shaped to form one side and the base of each channel portion, said elongated strips being united along their longitudinal medial line.

4. A double channeled plaster board supporting element for use in walland ceiling structures formed of two strips of sheet metal, one of which is shaped to form one side and the base of each channel portion, said strips being permanently connected at their longitudinal centers. v

5. A double channeled plaster board supporting element for use in wall and ceiling structures formed of two strips of sheet metal, one of which is .shaped to form one side and the base of each channel portion, said strips being united by tongues struck out therefrom thereby providing apertures, for the purpose set forth.

6. In a structure of the class described, an elongated strip comprising one side of each of two opposed continuous channels, and a second strip shaped to form the bases and other .sides of said channels.

7. In a Vstructure of the class described, means providing opposed channels the bases of said channels being spaced from each other, and means providing apertures between the spaced bases of said channels for receiving securing elements by which the channels may be secured as a unit in position.

8. In a structure of the class described, va strip of metal constituting one side of each of two opposed channels, a second strip of metal shaped to form the bases and lother sides of sauf channels, said second strip ofl metal having a web portion which spaces the portions thereof constituting the bases of said channels, and means providing openings through the web lportion of said v second mentioned strip of metal and the adjacent( portion of the first mentioned strip to receive securing elements by which the channels may be secured as a unit in position.

9. In a structure of the class described, a strip constituting one side of each of two opposed channels, a second strip shaped to form the bases and other sides of said channels, said second strip being provided with a web portion spacing the portions thereof constituting the bases of said channels, and tongues struck from the web of said sec-` ond strip and the adjacent portion of said first strip for securing said strips together and for providing apertures between the bases of the channels.

GORDON R. WALPER..

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