Wall

Abstract

 A sheet metal post (4), for use with a wall structure comprising wallboards (1) joined by tongue and groove joints (2,3), which comprises a metal sheet, preferably of galvanized sheet iron or steel, and having a flange (5) at each end of the section of the post, is characterized by one or more of the following features.

1. The post has a series of lips (8) having a reduced profile (8a), and also a series of slots (9) for receiving the smaller ends (8a) of a like sheet metal post, for easier stacking.

2. The flanges (5) are bent back on themselves at least once to provide flanges of increased thickness, to increase rigidity and also to improve fire resistance.

3. The post is provided with further flanges (10), to be bent back for retaining fire insulation material.

4. The flanges (5) are disposed at a small angle with respect to the plane of the post, to allow the strength of the wall structure as a whole to be improved.

Description

[0001] This invention relates to a wall, which term is intended to include within its scope not only interior walls and outer walls but also floors and ceilings.

[0002] The invention particularly relates to a vertical or horizontal wall (interior wall, outer wall, floor or ceiling) comprising wallboards joined by tongue and groove joints and posts (structural posts or joists) of sheet metal, preferably of galvanized sheet iron. The invention will be subsequently described with particular reference to an interior wall, but can also be applied to an outer wall, a floor and a ceiling.

[0003] The invention more particularly relates to a wall structure as described in European patent application no. 87303444.1 (publication no. EP-0243134). The preferred relationship between the parallel wallboards and the sheet metal posts is as shown in figures 3 and 17 of EP-0243134. The present invention is especially concerned with increasing the fire resistance of such wall structures.

[0004] The wallboards 1 as shown in EP-0243134 will usually be of gypsum pulp board (GPB), which incorporates recycled or natural wood pulp, gypsum flake board (GFB), or gypsum card board (GCB), or alternatively cement flake board.

[0005] The sheet metal post 4 as shown in EP-0243134 is usually provided with lips for the purpose of fixing mineral wool insulation in the space between the wallboards. Such lips typically comprise arcuate portions cut out from the plane of the sheet metal post and disposed generally perpendicular to the plane of the post. Such lips are typically arranged in a staggered pattern with respect to the plane of the post, some lips protruding on one side of the plane of the post and some protruding on the other side.

[0006] However, sheet metal posts provided with lips in such a manner are difficult to stack, in the manner shown in figure 9 of EP-0243134.

[0007] The present invention in a first aspect provides a sheet metal post, for use with a wall structure according to EP-0243134, that is a wall structure comprising wallboards joined by tongue and groove joints, which comprises a metal sheet, preferably of galvanized sheet iron or steel, having a flange at each end of the section of the post, said flanges preferably extending in the same direction with respect to the plane of the post, characterized in that the metal sheet post has lips extending generally perpendicular to the plane of the post, which lips have a smaller profile at the end thereof remote from the post than at the end thereof adjacent the post, and the said post also having a series of slots for receiving said smaller ends of the lips of a like sheet metal post.

[0008] The lips are preferably cut out from the plane of the post and extend generally perpendicular thereto in a staggered pattern, some of the lips extending from one side of the plane of the post and some extending from the other side thereof.

[0009] In one preferred embodiment the lips each have a stepped shape as seen in profile. In another preferred embodiment the lips each have a profile wherein the part thereof remote from the plane of the post tapers to a flat end of width narrower than the width of the base of the lip adjacent the post.

[0010] Thus, when it is desired to stack a number of such sheet metal posts, the narrower portions of the lips of one such post are received in and supported by the corresponding slots of another such post.

[0011] According to another aspect of the invention there is provided a sheet metal post, for use with a wall structure according to EP-0243134, which comprises a metal sheet, preferably of galvanized sheet iron or steel, having a flange at each end of the section of the post, said flanges preferably extending in the same direction with respect to the plane of the post, characterized in that the said flanges are bent back on themselves at least once, preferably several times, to provides flanges of greater effective thickness than that of the plane of the post.

[0012] Preferably each of the flanges is bent back upon itself three times, to produce a flange having a thickness four times that of the sheet metal.

[0013] Increasing the thickness of the flanges, according to the second aspect of the invention, has two advantageous effects, the first being to increase the rigidity and overall stiffness of the post in the direction of the plane of the post (in the direction from the one flange to the other), and the second effect being to improve the fire resistance of the wall structure as will be described in more detail below.

[0014] Simultaneously with increasing the rigidity of the post in the one direction by increasing the thickness of the flanges, the sideways flexibility of the post (i.e. in the direction transverse to the plane of the post) may be increased by reducing the thickness of the sheet metal post, typically from 0.8 cm as presently used conventionally to say 0.5 cm. The increased sideways flexibility of the post is useful in building up a wall structure, in that a post secured to one wallboard can be deformed sideways to allow mineral wool to be inserted into a space defined by two parallel wallboards and a pair of posts used to secure the wallboards, after which the deformed post can be bent back and fixed to the respective other wallboard.

[0015] According to a third aspect of the invention there is provided a sheet metal post, for use with a wall structure according to EP-0243134, which comprises a metal sheet, preferably of galvanized sheet iron or steel, having a flange at each end of the section of the post, said flanges preferably extending in the same direction with respect to the plane of the post, characterized in that the post is provided adjacent its ends (but spaced from the said flanges) with further flanges (which term hereby includes fingers, flaps, lips and the like) extending laterally of the plane of the post on either side thereof, which said further flanges may be bent back to retain fire insulation material against the post.

[0016] While said further flanges will usually be provided on both sides of the post, they may alternatively be provided on one side only thereof.

[0017] The fire insulation material to be thus retained by the said further flanges will usually be boardstrips of gypsum fiber or gypsum particleboard, whereby crystallic water in the boards may be used for cooling the post itself in the event of fire on one said of a wall structure, thus improving the fire resistance of the wall structure as will be explained in more detail below.

[0018] The improved fire resistance of a wall structure according to EP-0243134, provided with posts according to the second and/or third aspects of the present invention, will now be explained in more detail.

[0019] The fire resistance of such a wall structure is usually determined such that, in the event of fire occurring on one side (i.e. the exposed side) of the wall, the temperature on the other, non-exposed, side of the wall structure should not exceed 200°C, being 180°C plus room temperature. In the wall structures according to EP-0243134 heat will be conducted from the exposed to the non-exposed side of the wall primarily through the metal posts, especially when such posts are of steel, which is a good thermal conductor.

[0020] By using the posts according to the present invention, the conduction of heat from the exposed to the non-exposed side of the wall can be reduced in several ways.

[0021] Firstly, by bending the flanges at the ends of the posts back upon themselves several times, there is obtained the longest possible distance (and hence heat path) from the exposed to the non-exposed side of the wall.

[0022] Secondly, by providing gypsum wallboards (especially gypsum fibreboard) on both sides of the post, retained by flanges (fingers, flaps, lips) bent back according to the third aspect of the invention, the crystallic water in the gypsum absorbs heat passing along the post to thus provide an enhanced cooling effect.

[0023] Thirdly, openings in the profile of the post, for example resulting from the formation of flanges or lips for retaining heat insulation, lessen the heat flow along the post.

[0024] Furthermore, if gypsum is clad to the wallboards of the wall structure, a further cooling effect can be obtained from the crystallic water within the gypsum.

[0025] It will be appreciated that, for the purpose of providing both fire and sound insulation, mineral wool may be provided in the entire space between two adjacent posts in a wall structure, or alternatively be provided around the edges only (using say 20% of the mineral wool material that would be used in the case of filling the entire space), in which latter case the insulation effect may still be 90% of that obtainable in the case that the material fills the entire space.

[0026] The invention in a fourth aspect provides a sheet metal post, for use with a wall structure according to EP-0243134, which comprises a metal sheet, preferably of galvanized sheet iron or steel, having a flange at each end of the section of the post, said flanges preferably extending in the same direction with respect to the plane of the post, characterized in that the said flanges are disposed at a small angle with respect to the plane of the post. Such small angle will typically be 2 1/2 degrees, and is directed outwardly away from the post itself.

[0027] Such disposition of the flanges at a slight angle with respect to the plane of the post permits improved wedging of the flanges into the respective wallboards and hence increases the strength of the wall structure as a whole.

[0028] Any two or more of the first, second, third and fourth aspects of the invention may be employed in combination.

[0029] The invention will be further described, by way of example only, with reference to the accompanying drawings, in which:

Figures 1a to 1d are perspective views illustrating the construction of a wall structure according to EP-0243134, but modified according to the first aspect of the present invention;

Figure 2 shows a post for use in a wall structure according to EP-0243134, and having features according to the second, third and fourth aspects of the present invention;

Figure 3 is an enlarged view of the flange of a post as shown in figure 2;

Figure 4 is a side view of a part of a post having the feature according to a modified first aspect of the present invention; and

Figure 5 shows the lip of the post of figure 1 in more detail.

[0030] The wall structure shown in figure 1 is generally of the type according to EP-0243134, and comprises two generally parallel wallboards 1, together with a post 4 of sheet metal, preferably of galvanized sheet iron or steel, with a flange 5 at each end of the section of the post. The respective flanges 5 fit into respective kerfs 7 in the edges of the wallboards 1. In addition, each wallboard has a groove 3 in its one edge and a respective tongue 2 at the opposite edge, the tongue 2 of the wallboard fitting into the respective groove 3 of an adjacent wallboard. Preferably, as shown in figure 1, the flanges 5 extend in the same direction with respect to the plane of the post 4, and the kerf 7 for receiving a flange 5 extends in a direction opposite to that of the tongue 2.

[0031] As shown in figures 1a to 1d, such a wall structure is built up by first fitting a post 4 to a pair A of parallel wallboards 1, with the flanges 5 of the post inserted into the respective kerfs 7 of the wallboards. A second pair B of wallboards is then fitted to the wallboards A by inserting the tongues 2 of the wallboards A into the grooves 3 of the wallboards B. Such steps can then be repeated to build up a wall structure comprising a series of wallboards 1 and posts 4.

[0032] The post 4 is provided with a number of lips 8 for the purpose of fixing mineral wool insulation or the like in the space between the wallboards. As shown, such lips 8 comprise portions cut out from the plane of the sheet metal post and disposed generally perpendicular to the plane of the post. The lips 8 are arranged in a staggered pattern with respect to the plane of the post, some lips protruding on one side of the plane of the post and some protruding on the other side.

[0033] In accordance with the first aspect of the present invention, the lips 8 have a smaller profile at the end 8a thereof remote from the post than at the end 8b thereof adjacent the post, and the post also has a series of slots 9 for receiving the smaller ends 8a of the lips of a like sheet metal post. Preferably, as shown, the lips 8 are stepped at 8c to provide the smaller profile end 8a. The slots 9 have a length which is greater than the length of the smaller profile end 8a but smaller than the length of the greater profile end 8b.

[0034] Thus when it is desired to stack a number of such sheet metal posts 4, in the manner of figure 9 of EP-0243134, the narrower portions 8a of the lips 8 of one such post are received in and supported by the corresponding slots 9 of another such post.

[0035] The profile of the lip 8 is shown in more detail in figure 5. By arranging the sides of the ends 8a and 8b at a small angle (3° as shown) the sides of the smaller profile end 8a can be arranged to rest upon the ends of a slot 9 during stacking, rather than the end 8a passing completely through the slot.

[0036] A modified shape of lip 8 is shown in figure 4, wherein the part 8d thereof remote from the plane of the post 4 tapers to a flat end 8e of width narrower than the width of the base 8f of the lip adjacent the post. A corresponding slot 9 has a length which is greater than the length of the end 8e but smaller than the length of the base end 8f, whereby in stacking one such post upon another the tapered part 8d will rest upon the ends of the slot 9.

[0037] In accordance with another aspect of the present invention, as shown in particular in figures 2 and 3, the flanges 5 of the post 4 are bent back upon themselves to provide flanges of greater effective thickness than that of the plane of the post. Specifically, as best seen in figure 3, the flange is bent back upon itself three times, to produce a flange having a thickness four times that of the sheet metal.

[0038] As previously mentioned, increasing the thickness of the flanges 5 has two advantageous effects, the first being to increase the rigidity and overall stiffness of the post in the direction of the plane of the post (in the direction from the one flange to the other), and the second effect being to improve the fire resistance of the wall structure by thus providing a longer distance (and hence heat path) from one end of the flange to the other.

[0039] Simultaneously with increasing the rigidity of the post in the one direction by increasing the thickness of the flanges, the sideways flexibility of the post may be increased by reducing the thickness of the sheet metal post. The increased sideways flexibility of the post is particularly useful in building up a wall structure in the manner illustrated in figures 1a-1d, in that a post 4 secured to one wallboard A by fitting the flange 5 into the respective kerf 7 can be deformed sideways to allow mineral wool or the like to be inserted into the space defined between the two parallel wallboards A, after which the deformed post can be bent back and secured to the respective other wallboard A by fitting its other flange 5 in the respective kerf 7 of the other wallboard.

[0040] In accordance with a third aspect of the present invention, as shown in particular in figure 2, the post 4 is provided adjacent its ends, but spaced from the flanges 5, with further flanges 10 extending laterally of the plane of the post on either side thereof, which further flanges 10 may be bent back to retain fire insulation material against the post. The flanges 10 may themselves be fingers, flaps, lips or the like. While the flanges 10 will usually be provided on both sides of the post, they may alternatively be provided on one side only.

[0041] The fire insulation material to be thus retained by the flanges 10 will usually be boardstrips of gypsum fiber or gypsum particle board, whereby crystallic water in the boards may be used for cooling the post itself in the event of fire on one side of the wall structure, thus further improving the fire resistance of the wall structure.

[0042] In accordance with the fourth aspect of the present invention, as shown in particular in figures 2 and 3, the flanges 5 are disposed at a small angle with respect to the plane of the post, outwardly away from the post itself. Such small angle will be typically 2 1/2 degrees. Such disposition of the flanges 5 at a slight angle with respect to the plane of the post permits improved wedging of the flanges into the respective kerfs 7 of the wallboards 1 and hence increases the strength of the wall structure as a whole.

Claims

1. A sheet metal post (4), for use with a wall structure comprising wallboards (1) joined by tongue and groove joints (2,3), which comprises a metal sheet, preferably of galvanized sheet iron or steel, having a flange (5) at each end of the section of the post, characterized in that the metal sheet post has lips (8) extending generally perpendicular to the plane of the post, which lips have a smaller profile at the end (8a) thereof remote from the post than at the end (8b) thereof adjacent the post, and the said post also having a series of slots (9) for receiving said smaller ends (8a) of the lips of a like sheet metal post.

2. A post as claimed in claim 1, characterized in that the lips (8) are cut out from the plane of the post and extend generally perpendicular thereto in a staggered pattern, some of the lips extending from one side of the plane of the post and some extending from the other side thereof.

3. A post as claimed in claim 1 or 2, characterized in that the lips (8) each have a stepped shape (8c) as seen in profile.

4. A post as claimed in claim 1 or 2, characterized in that the lips (8) each have a profile wherein the part (8d) thereof remote from the plane of the post tapers to a flat end (8c) of width narrower than the width of the base (8f) of the lip adjacent the post.

5. A sheet metal post (4), for use with a wall structure comprising wallboards (1) joined by tongue and groove joints (2,3), which comprises a metal sheet, preferably of galvanized sheet iron or steel, having a flange (5) at each end of the section of the post, characterized in that the said flanges (5) are bent back on themselves at least once to provide flanges of greater effective thickness than that of the plane of the post.

6. A post as claimed in claim 5, characterized in that each of the flanges (5) is bent back upon itself three times, to produce a flange having a thickness four times that of the sheet metal.

7. A sheet metal post (4), for use with a wall structure comprising wallboards (1) joined by tongue and groove joints (2,3), which comprises a metal sheet, preferably of galvanized sheet iron or steel, having a flange (5) at each end of the section of the post, characterized in that the post is provided adjacent its end, but spaced from the said flanges (5), with further flanges (10) extending laterally of the plane of the post on one or both sides thereof, which said further flanges may be bent back to retain fire insulation material against the post.

8. A sheet metal post (4), for use with a wall structure comprising wallboards (1) joined by tongue and groove joints (2,3), which comprises a metal sheet, preferably of galvanized sheet iron or steel, having a flange (5) at each end of the section of the post, characterized in that the said flanges (5) are disposed at a small angle, preferably about 2 1/2 degrees, with respect to the plane of the post.

9. A post as claimed in claim 8, characterized in that the said flanges (5) are directed outwardly away from the post at the said angle.

10. A post as claimed in any of claims 1 to 9, characterized in that the said flanges (5) extend in the same direction with respect to the plane of the post.

Drawing