EP0489764B1

EP0489764B1 - Drywall construction

Info

Publication number: EP0489764B1
Application number: EP90912137A
Authority: EP
Inventors: Frank D. Greenwood; Kazimir Kobielski
Original assignee: Individual
Current assignee: Individual
Priority date: 1989-08-22
Filing date: 1990-08-21
Publication date: 1996-10-30
Anticipated expiration: 2010-08-21
Also published as: CA1337096C; DE69029041D1; AU6173990A; ES2096591T3; EP0489764A1; DE69029041T2; WO1991002857A1

Abstract

An interior wall mounting device comprising an elongated element having a base plate (20) and at least one side flange (22) projecting laterally from the base plate. The free edge of the side flange is turned inwardly to form a channel opening (24) in a direction normal to the base plate and outwardly therefrom. The channel is adapted to have a plurality of studs (33) securable laterally to the channel and shaped to receive the edge of a planar sheet (81) securable against the studs to form a wall.

Description

This invention relates to a device for interior wall installation in building construction.
The conventional method of installing an interior wall is a time consuming and cumbersome process. Metal tracks with channels are attached to the floor and ceiling and spaced, vertical wall studs interconnect the tracks. The wall substrate is then attached to the studs. If the substance is drywall the grooves between successive sheets must be taped and plastered, after which the wall is painted. Finally, a baseboard is usually attached to the bottom of the wall to provide a finished appearance, and a cornice may be applied at the top of the wall, either preformed or of plaster.
Various improvements on the foregoing technique have been known, some for many years.
CH-A-577,612 shows an arrangement using metal uprights in conjunction with an elongate metal pressing which acts as a combination baseboard and board support. The metal uprights must be individually located and secured to floor and ceiling.
US-A-1,981,239 makes use of a continuous base plate which is secured to the floor and is provided with means for locating metal studs. A number of discrete elements are then secured to the base plate and/or the studs; these elements may include a channel section for supporting a drywall board, and a baseboard. This arrangement uses a considerable number of separate parts and would be time consuming to erect.
It is an object of the invention to provide a baseboard and/or cornice for simplified construction of the interior wall of a building.
The invention accordingly provides a wall mounting device comprising an elongate base plate, a side flange extending from one side of the base plate and having a free edge turned in and shaped to form an elongate channel extending longitudinally of the base plate and in spaced relation therewith, the channel opening in a direction normal to the base plate and outwardly therefrom to receive an edge of a planar sheet, and the outer surface of the flange forming a decorative trim in the finished construction of the wall, characterised in that the base plate, the flange and the channel are integrally formed to provide a unitary structure, and in that the base plate extends laterally of the channel a sufficient distance to permit a plurality of wall studs to be positioned spaced along the device with each stud bearing on the base plate and fixed laterally to a channel wall of the channel.

BRIEF DESCRIPTION OF DRAWINGS

Example embodiments of the invention are shown in the accompanying drawings in which:

FIG. 1 is a perspective view of a room indicating sites of use of an interior wall mounting device for interior wall construction;
FIG. 2 is a vertical cross sectional view of the ceiling element of an interior wall mounting device for an interior double sided wall, taken along line 2-2 of Figure 1;
FIG. 3 is a vertical cross sectional view of the floor element of an interior wall mounting device for an interior double sided wall, taken along line 3-3 of Figure 1;
FIG. 4 is a horizontal cross sectional view of an interior wall mounting device adapted to provide a door frame, taken along line 4-4 of Figure 1;
FIG. 5 is a horizontal cross sectional view of an interior wall mounting device adapted to provide a window frame, taken along line 5-5 of Figure 1;
FIG. 6 is a vertical cross sectional view of the ceiling element of an interior wall mounting device for an interior single sided wall, taken along line 6-6 of Figure 1;
FIG. 7 is a vertical cross sectional view of the floor element of an interior wall mounting device for an interior single side wall, with a variation in the side flange-base plate junction, taken along line 7-7 of Figure 1;
FIG. 8 is a vertical cross sectional view similar to Figure 6 including a carpet gripping device, taken along line 8-8 of Figure 1;
FIG. 9 is a perspective view of an interior wall mounting device of Figure 8;
FIG. 10 is a plan view of the outside corner of the junction of two walls taken in the direction of arrow 10 in Figure 1;
FIG. 11 is a plan view of the inside corner of the junction of two walls taken in the direction of arrow 11 in Figure 1;
FIG. 12 is a vertical cross sectional view of the ceiling element of an interior wall mounting device for use with ceiling substrate;
FIG. 13 is a vertical cross sectional view in elevation of a cornice in the form of a corner bead mounting device for installing with an interior wall and ceiling substrate at an inside corner junction;
FIG. 14 is a vertical cross sectional view in elevation of a cornice in the form of a corner bead mounting device for installing with an interior wall and ceiling substrate at an outside corner junction.

MODES FOR CARRYING OUT THE INVENTION

The example embodiments of the invention shown in the drawings each consist of an interior wall mounting device comprising a ceiling element 12, floor element 14, a door element 16, and a window element 18.
Ceiling element 12, shown in Figure 2, consists of a base plate 20 having, extending therefrom, a pair of space side flanges 22, terminating in a pair of downwardly opening channels 24 which are spaced apart a distance corresponding to the thickness of a wall stud 33. Channels 24 are each defined by a downwardly projecting outer side wall 26 contiguous with the side flange, a bottom 27 and an inner side wall 28 lying in a plane normal to the base plate. Base plate 20 and inner side wall 28 carry apertures 30 and 32 respectively for receiving fastening elements 34 which are shown as screws.
Floor element 14, shown in Figure 3, consists of a base plate 36 having, extending therefrom, a pair of spaced side flanges 38 terminating in a pair of upwardly opening channels 40 which are space apart a distance corresponding to the thickness of wall stud 33. Channels 40 are each defined by an upwardly projecting inner side wall 42, a bottom 43, and an upwardly projecting outer side wall 44 contiguous with the side flange. Base plate 36 and inner plate 42 carry apertures 46 and 48 respectively for receiving fastening elements 34.
A door frame element 16 is shown in Figure 4 and consists of a face plate 50 having, extending therefrom, a pair of side flanges 51, each terminating in a channel 52, the channels being spaced apart a distance corresponding to the thickness of wall stud 33. Channels 52 are each defined by an outer side wall 56 contiguous with the side flange, a bottom 57, and an inner side wall 58 lying in a plane normal to the base plate lying against wall stud 33. The outer end of inner side wall 58 of each channel 52 terminates in a channel extension plate 60. A stop 64 projects from face plate 50 and protrudes into the door area, with an abutment face 66 parallel to the face of a closed door 68. Channel extension plates 54 carry apertures 68 for receiving fastening elements 34.
A window frame element 18 shown in Figure 5, consists of a face plate 70 adjacent the window having, extending therefrom, a pair of side flanges 72 spaced apart a predetermined distance and terminating in a pair of channels 74. Extending from face plate 70 opposite side flanges 72 is a window receiving channel 73. Face plate 70 and window receiving channel 73 carry receiving apertures 75 and 752 respectively for receiving fastening elements 34. Channels 74 are each defined by an outer side wall 76 contiguous with the side flange, a bottom 77, and an inner side wall 78 lying in a plane normal to the base plate. Inner side wall 78 of channel 74 carries apertures 82 for receiving fastening elements 34.
In the use of the embodiment shown in Figures 2 and 3 ceiling element 12 is fastened by screws 34 to ceiling 31 through apertures 30. Floor element 14 is aligned vertically with ceiling element 12 and fastened to floor 35 by screws 34 through apertures 46. When ceiling element 12 and floor element 14 have been secured in place, the ends of vertical wall studs 33 are located in these elements in the usual manner. Then ceiling element 12 and floor element 14 are securely fastened by screws 34 to wall studs 33 through apertures 32 for ceiling element 12 and aperture 48 for floor element 14. Following this, where necessary, door element 16 and window element 18 are fastened to wall studs 33 by screws 34 through aperture 68 for door element 16 and aperture 82. For window element 18. All elements are now ready to receive a series of wall substrate panels 81 which are mounted by inserting the upper edge portions of the panels into ceiling channel 24 which is deeper than, channel 40 in floor element 14, channel 52 in door element 16, and channel 74 in window element 18, and then dropping the bottom of the panels into channels 40, 52, and 74. Channels 24, 40, 52, and 74 are narrow enough to adequately secure panels 81. Screws 34 protruding from apertures 32 and 38 may provide an extra means of securing panel 81 by gouging and gripping the back of panels 81 upon insertion of the edges of the panels into the channels.
A variation of ceiling element 12, indicated by numeral 112 in Figure 6 consists of a base plate 120 and extending therefrom a side flange 122 terminating in a downwardly opening channel 124. Channel 124 is defined by a downwardly projecting outer side wall 126 contiguous with the side flange, a bottom 127, and a downwardly projecting inner side wall 128 lying in a plane normal to base plate 120. A top rest plate 121 projects downwardly from base plate 120 in the plane of inner side wall 128 of channel 124. Base plate 120, inner side wall 128, and rest plate 121 carry apertures 130, 132, and 133 respectively for receiving fastening elements 34.
A variation of floor element 14, indicated by numeral 114 in Figure 7, consists of a base plate 136 having, extending therefrom, a side flange 138 terminating in an upwardly opening channel 140. Channel 140 is defined by an upwardly projecting outer side wall 142 contiguous with side flange 138, a bottom 143, and an upwardly projecting inner side wall 144 lying in a plane normal to base plate 136. Extending from base plate 136 is an upwardly projecting rest plate 146 located to lie against wall stud 33. Base plate 136, inner side wall 144, and rest plate 146 carry apertures 147, 148, and 150 respectively for receiving fastening elements 34. In this embodiment the junction of base plate 136 and side flange 138 is recessed to form a cavity 137.
In the use of the embodiment shown in Figures 6 and 7, ceiling element 112 is fastened by screws 34 to ceiling 31 through aperture 130. Floor element 114 is aligned vertically with ceiling element 112 and is then fastened to floor 35 by screws 34 through aperture 147. Wall studs 33 are inserted into elements 112 and 114 in the usual manner. Ceiling element 112 is securely fastened by screws 34 to wall studs 33 through apertures 132 and 133 and floor element 114 is securely fastened by screws 34 to the wall studs through apertures 148 and 150. Where required, door elements 16 and window elements 18 are appropriately positioned as described above. All elements are ncw ready to receive wall substrate panels 81 which are mounted by flexing and inserting the edge portions of the panels in channels 124, 140 and where necessary, channels 52 and 74 for the door and window elements. Wall substrate panels 81 are then fastened to wall studs 33. The edge of carpet 160 is inserted into cavity 137 to improve appearance of the combination. It will be appreciated that rest plate 121 of ceiling element l12 and rest plate 146 of floor element 114 are two aspects of the same concept and either may be used as desired, i.e. the rest plate may be located to abut either side of stud 33.
A carpet gripping device 84, associated with floor element 14 or 114 and shown in Figures 8 and 9, consists of a separate further plate 86 which carries a locator rail 90 perpendicular to the plate and running longitudinally the length of the plate. A row of barbs 88 projects from plate 86 on one side of rail 90 at an upward angle towards the rail and an array of barbs 92 projects from the plate on the other side of the rail at an upward angle towards the rail. Base plate 94 carries a row of apertures 96 for receiving the upward projecting row of barbs 88.
In the use of the embodiment shown in Figures 8 and 9, floor element 114 (or floor element 14) and gripping device 82 are located on the floor, the gripping device being underneath the floor element, with barbs 88 engaging apertures 96 and with locator rail 90 abutting the base of side flange 138. Floor element 114 (or element 14) is fastened to the floor by screws 34 through aperture 147 (or aperture 46). Then ceiling element 12 (or element 112) is vertically aligned with the floor element and the previously described procedure is followed to mount wall substrate panels 81, after which a carpet 160 is laid with its edges being held down by the array of barbs 92 on gripping device 82.
The corners of side flanges 38 and 138 of floor elements 14 and 114 may be mitred as shown in Figure 10 and Figure 11 for an outside corner and inside corner respectively. The same mitring may be used in the corners of the ceiling elements.
A variation of ceiling element 12 is shown in figure 12 of the drawings. That embodiment consists of ceiling element 212 with a base plate 220 having, extending therefrom, a side flange 222 which terminates in a downwardly opening channel 224. Base plate 220 is recessed at each lateral edge to form a ledge 223. Channel 224 is defined by a downwardly projecting outer side wall 230, a bottom 232, and a downwardly projecting inner side wall 234 lying in a plane normal to base plate 220. Base plate 220 and inner side wall 234 carry apertures 236 and 238 respectively for receiving fastening elements 34.
In the use of the embodiment shown in figure 12, ceiling element 212 is fastened by screws 34 to ceiling joists 240 through aperture 236. Floor elements 14 or 114 are attached to the floor as described above. Wall studs 33 are inserted into elements 212 and, either floor element 14, or 114, in the usual manner. Ceiling element 212 is securely fastened to wall studs 33 by screws 34 through aperture 238. Wall substrate panels 81 are mounted inserted in the usual manner. Ceiling substrate panels 242 are mounted by inserting the edge portions of the panels into the cavity created by ledge 223 and ceiling joists 240, and then fastening the panel to the ceiling joists.
In Figures 13 and 14 a variation of ceiling element 12 provides an inside corner cornice in the form of a bead 312 and an outside corner cornice in the form of a bead 412. In Figure 13 bead 312 consists of an arcuate face plate 320 with the lateral edges thereof terminating in channels 322 and 324. Channel 322 is defined by an outer side wall 326, a bottom 328 and an inner side wall 330 adapted to lie against wall stud 33. Channel 324 is defined by an outer side wall 326, a bottom 328 and an inner side wall 332 adapted to lie against ceiling joist 240. Channels 322 and 324 open in a direction normal to and away from each other and carry apertures 334 for receiving fastening elements 34. In Figure 14 bead 412 consists of an arcuate face plate 420 with the lateral edges thereof terminating in channels 422 and 424. Channel 422 is defined by an outer side wall 426, a bottom 428 and an inner side wall 430 adapted to lie against exposed surface 450. Channel 424 is defined by an outer side wall 426, a bottom 428 and an inner side wall 432 adapted to abut exposed surface 460. Channels 422 and 424 open in a direction normal to and away from each other and carry apertures 434 for receiving fastening elements 34. Channels 422 and 424 are adapted to lie against exposed surfaces 450 and 460 of frame 500 of a two tiered ceiling.
In the embodiments shown in Figures 13 and 14, ceiling element 312 may be used with ceiling and wall panels where there is an inside corner junction, i.e. at the junction of ceiling joists 240 and wall studs 33, to have inner side wall 332 lying against joists 240 and inner side wall 330 lying against wall studs 33. Ceiling element 312 is secured to ceiling joists 240 by screws 34 through apertures 334. Any necessary floor elements are then vertically aligned and secured to the floor in the manner described above. Wall studs 33 are then located in the runners of floor element 14 with the sides of their upper ends lying against inner side wall 330 of ceiling element 312. Ceiling element 312 is then firmly secured to wall studs 33 by screws 34 through apertures 334. Ceiling element 412 may be used at an outside corner junction, i.e. at the corner junction of the two exposed surfaces when a two tiered ceiling frame is installed, and is located so that arcuate face plate 420 envelops the outside corner with inner side wall 430 lying against exposed surface 450 and inner side wall 432 lying against exposed surface 460. Ceiling element 412 is securely fastened by screws 34 to the frame of the two tiered ceiling through apertures 434. Wall substrate panels 81 are then inserted into channels 422 and 424 in the manner described above.
It will be appreciated that the floor, ceiling, door, and window elements of the wall mounting device may be preformed into various shapes which may be especially efficient when used to construct closets or showers; otherwise they may be roll formed on the site.
It will also be appreciated that the various elements may be roll formed from any suitable material such as sheet metal or aluminum, or the elements may be formed by using various plastics in appropriate moulds. Also the side flanges of the various elements may be pre-finished with suitable materials such as marble, paint, or plastics.
The term "wall substrate" as used herein refers to sheet materials such as drywall, gyproc, pressboard, and panelling.

Claims

A wall mounting device comprising an elongate base plate (20, 36), a side flange (22, 38) extending from one side of the base plate and having a free edge turned in and shaped to form an elongate channel (24, 40) extending longitudinally of the base plate and in spaced relation therewith, the channel (24, 40) opening in a direction normal to the base plate (20, 36) and outwardly therefrom to receive an edge of a planar sheet (81), and the outer surface of the flange (22, 38) forming a decorative trim in the finished construction of the wall, characterised in that the base plate (20, 36), the flange (22, 38) and the channel (24, 40) are integrally formed to provide a unitary structure (12, 24), and in that the base plate (20, 36) extends laterally of the channel (24, 40) a sufficient distance to permit a plurality of wall studs (33) to be positioned spaced along the device with each stud (33) bearing on the base plate (20, 36) and fixed laterally to a channel wall (28, 42) of the channel (24, 40).
A device as claimed in claim 1, wherein the flange (38) constitutes a baseboard.
A device as claimed in claim 1, wherein the flange (22) constitutes a cornice.
A device as claimed in any of claims 1 to 3, including a second flange (22, 38) extending from the other side of the base plate (20, 36) and turned in and shaped to form a second elongate channel (24, 40) extending longitudinally of the base plate (20, 36) and in spaced relation therewith, the second channel (24, 40) opening in a direction normal to the base plate (20, 36) and outwardly therefrom to receive an edge of a second planar sheet (81), and the outer surface of the second flange (22, 38) forming a decorative trim in the finished construction of the wall, the second flange (22, 38) and second channel (24, 40) being integral with the other elements to provide a unitary structure (12, 24), the spacing between said channels (24, 40) being such that said studs (33) may be secured to side walls (28, 42) of both said channels (24, 40).
A device as claimed in any preceding claim, in which the base plate (20, 36) is securable to a supporting structure (31, 35) through a plurality of apertures (46, 30) in the base plate (20, 36).
A device as claimed in any preceding claim, in which the device is securable to the studs (33) through a plurality of apertures (48, 32) in the inner side wall (28, 42) of each channel (24, 40).
A device as claimed in any preceding claim positioned on a floor as a floor element (14), in combination with a second wall mounting device as claimed in any preceding claim positioned on a ceiling as a ceiling element (12), the floor (14) and ceiling (12) elements being aligned vertically one above the other to receive floor-to-ceiling studs (33) bearing upon their base plates (36, 20) and planar sheets (81) received within their aligned channels (40,24).
A device as claimed in Claim 7, in which the floor element (14) comprises a pair of spaced parallel baseboards and the ceiling element (12) comprises a pair of spaced parallel cornices, whereby the plurality of vertical studs are locatable between the channels (24,40) of each element and securable thereto, and a pair of planar sheets (81) are receivable in the channels (24,40) and securable against the studs to form a double wall.
A device as claimed in Claim 7 or Claim 8 in which the floor and ceiling elements each comprise a single baseboard and cornice respectively and each floor and ceiling element has a single channel, said side flanges joining said channels at one end of the base plates of the floor and ceiling elements, and wherein there is joined at the other end of the base plate a rest plate (146) extending substantially normal to its respective base plate and being located to abut the studs on the side remote from the side flange.
A device as claimed in any of Claims 1 to 6, wherein a single side flange joins a channel to the base plate at one end of the base plate and having a rest plate (146) joined at the other end of the base plate, the rest plate extending substantially normal to the base plate and being located to abut the studs bearing on the base plate on the side of the studs remote from the flange.
A device as claimed in any of Claims 1 to 6 including carpet gripping means (82) comprising an outward extension of the base plate (20,36), the extension carrying means (92) to grip a carpet placed over the extension.
A device as claimed in Claim 11 in which the extension is a further, separate plate (86) contiguous with the base plate (20,36) and including means (88,96) to anchor said further plate to the base plate.
A device as claimed in Claim 12 in which the means to anchor said further plate to the base plate comprises a plurality of barbs (88) extending upwardly from said further plate, the base plate including a plurality of apertures (96) to receive the barbs (88).
A device as claimed in Claim 12 or Claim 13, in which said further plate includes a locator rail (90) upstanding therefrom and spaced from the side edges thereof.
A device as claimed in any of Claims 1 to 6, in which the base plate (20,36) includes a longitudinal shoulder outstanding therefrom to form a door stop (64).
A device as claimed in Claim 1 wherein said channel wall is an inner side wall (58) lying in a plane normal to the base plate for abutting first sides of the plurality of studs, the remote end of the inner side wall having a channel extension plate depending from the inner side wall and being substantially normal to the inner side wall of the channel to abut a second side of the plurality of studs, and the channel extension plate having a plurality of apertures (68) through which the channel extension plate is securable to the plurality of studs.
A device as claimed in Claim 1 in which the base plate (20,36) carries a channel (73) outwardly facing therefrom and adapted to receive an edge of a sheet of window glass.
A device as claimed in Claim 7 in which at least one side edge of the base plate (20) of the ceiling element (12) is recessed laterally to form a ledge (223).
A device as claimed in Claim 4 in which the base plate (20,36) is recessed at both side edges to provide a pair of ledges (223) opening in directions opposite to each other, and normal to the openings of the channels (24,40).