WO2024253955A1

WO2024253955A1 - Building system enhancing attachment of adjacent panels

Info

Publication number: WO2024253955A1
Application number: PCT/US2024/031828
Authority: WO
Inventors: Frank Pospisil; James M. Ullett
Original assignee: Knauf Gips KG
Current assignee: Knauf Gips KG
Priority date: 2023-06-05
Filing date: 2024-05-31
Publication date: 2024-12-12
Anticipated expiration: 2025-12-05
Also published as: MX2025014213A

Abstract

A building system for attaching adjacent wallboard panels together during building construction involving attachment of wallboard panels to members of a building frame, is provided, including a first wallboard panel having a first panel edge; a second wallboard panel having a second panel edge, the second panel edge being adjacent the first panel edge; a bracket defining a first attachment location for the first panel edge, and a second panel attachment location for the second panel edge so that second panel edge is held adjacent the first panel edge; and at least one first fastener securing the first panel edge in the first attachment location, and at least one second fastener securing the second panel edge in the second attachment location.

Description

BUILDING SYSTEM ENHANCING

ATTACHMENT OF ADJACENT PANELS

RELATED APPLICATION

[0001] The present application is a Non-Provisional of, and claims 35 U.S.C. 119 priority from, US Provisional Application Serial No. 63/506,163 filed June 5, 2023, and US Application Serial No. 18/531 ,334 filed December 6, 2024, the entire contents of which are incorporated by reference herein.

BACKGROUND

[0002] The present invention relates generally to building construction using cementbased wallboard panels, and more specifically relates to apparatus for securing adjacent panels to building frames.

[0003] Exterior walls of buildings serve a number of different functions. Specifically, exterior walls provide structural support and resist uniform, lateral, axial and concentrated loads applied to the building. Additionally, exterior walls act as a water, vapor and air barrier for the building. Further, exterior walls provide protection from flying debris during storms and are noncombustible. While providing these functions, it is desired to reduce the overall thickness of the exterior walls.

[0004] Many modern buildings use a steel frame within the exterior structural walls. Typically, noncombustible paneling is attached to the steel frame members. Such panels are also used to form sub-floors and as such are secured to building frame members or to concrete floor pads. This noncombustible paneling sometimes includes cement panels. For example, U.S. Pat. No. 8,079,198 to Tonyan et al., incorporated herein by reference, discloses a residential and commercial construction including a metal frame and lightweight cement panel shear wall. The shear wall is made from a mixture of inorganic binder and lightweight fillers. The combination of a metal frame with cement panels results in the noncombustible shear wall system.

[0005] Additionally, U.S. Pat. No. 8,122,679 to Tonyan et al., incorporated herein by reference, discloses wall systems having cement panels employed on metal frames. In particular, the disclosed wall system includes structural cement panels which are mechanically and/or adhesively fastened to a fire wall or other fire resistive assembly light gauge cold formed metal framing system, which acts as a shear resistant diaphragm. Moreover, U.S. Pat. No. 8,061 ,108 to Tonyan et al., incorporated herein by reference, discloses a foundation system which includes metal framing members that support a reinforced, lightweight, dimensionally stable cementitious panel.

[0006] However, conventional buildings which utilize a steel frame with noncombustible panels also include sheet steel cross-strapping or complete sheets of steel, referred to as shear walls, to resist lateral loading. Moreover, the steel frame typically includes high gauge studs for accommodating axial loading. In some cases, especially when used to form sub-floors, the cement panels are provided with tongue-in- groove edge construction for enhancing stability of the resulting assembled sub-floor. In such construction, adjacent panels support neighboring panels when loads are applied. However, the creation of panels with tongue-in-groove edges is relatively expensive and time consuming.

[0007] In conventional construction, wall panels, whether made of conventional wallboard or the relatively heavier duty cement fiber panels discussed above, are secured to underlying building frames using fasteners. The building frames are traditionally wood, but more frequently, steel “C”-shaped studs are employed. Building panels are dimensioned to be attached to frame members, including vertical studs and horizontal headers and footers. The vertical studs are spaced according to local building codes, such as 16-inch on center spacing. [0008] In the case of buildings constructed using cement fiber panels, which are often in an exterior application, due to environmental factors such as high winds, the panels are often subject to shear forces that induce vertical and or horizontal movement of the panel against the holding force of the fasteners. In many cases, this movement of the panels causes the fasteners to pull out of the frame, or the panel to pull away from the fastener.

[0009] Another drawback of conventional building systems is that especially when the building frame has an irregular shape, the dimensions of the panel may not coincide with the spacing of the vertical frame members. As such, it is not unusual for two adjacent panels to meet at a place where there is no properly positioned vertical frame member. In such cases installers need to install a supplemental vertical frame member, which adds to the cost of the building in both material and labor to achieve the desired building strength integrity.

[0010] In other cases, when two adjacent panels meet at a vertical frame member, they share the relatively narrow space provided for receiving a fastener to retain the panel to the frame. Operators are often challenged to install the fasteners to properly engage the frame member, while not placing the fastener overly close to the edge of the panel in a way that causes panel fracture. In some cases, placement of fasteners too close to the panel edge has been known to weaken the panel. The required additional installer attention to the assembly process delays the building construction and as such adds to the costs.

[0011] Thus, there is a need for an improved building system that accommodates the attachment of adjacent building panels to avoid the drawbacks discussed above.

SUMMARY

[0012] The above-listed need is met or exceeded by the present building systems which provide specialized brackets for securing adjacent cement-based wallboard panels together. In some cases, adjacent panels of this type are attachable without the use of a supporting vertical frame member or stud. Upon assembly, the two adjacent panels act physically as one continuous panel. In a floor application, the assembled panels provide a joint that is stronger than a conventional tongue-in-groove joint. When used as a shearwall on an interior or exterior of a building, the present system provides a blocked panel configuration to increase the assembled load carrying capabilities.

[0013] Included in one embodiment of the present system are brackets having a rough “H”-shape when viewed from above, creating back-to-back recesses dimensioned for accommodating edges of adjacent cement-based wallboard panels. Specialized threaded fasteners are used to secure the edges of each panel between arms of the adjacent recess. [0014] As the fasteners are fully installed and tightened, the opposing arms, webs or flanges of the H-bracket are pulled together around the panel edge, creating a pinching effect that more securely holds the panels in position. In some applications, the resulting assembly is strong enough that a corresponding vertical building frame stud is not needed at the seam defined by adjacent cement-based panels. Accordingly, when constructing a building using cement-based panels and the present bracket system, there is less cutting and fitting of panels to correspond to existing vertical stud spacing on the building frame. As such, construction speed is increased.

[0015] Once the adjacent panel edges are secured in this manner, the resulting assembly is relatively resistant to vertical or lateral shear forces exerted on the building by severe weather. Also, the panels are held more securely than in conventional construction systems, as the fasteners are less prone to loosening and unwanted falling out, as well as less prone to causing local panel failure at the point of fastener attachment. When used in the construction of a building having a conventional steel frame, the present system provides an alternative procedure for securing adjacent panels without the need for attachment of the panels at their seam to an adjacent frame member.

[0016] More specifically, a building system for attaching adjacent wallboard panels together during building construction involving attachment of wallboard panels to members of a building frame, is provided, including a first wallboard panel having a first panel edge; a second wallboard panel having a second panel edge, the second panel edge being adjacent the first panel edge; a bracket defining a first attachment location for the first panel edge, and a second panel attachment location for the second panel edge so that second panel edge is held adjacent the first panel edge; and at least one first fastener securing the first panel edge in the first attachment location, and at least one second fastener securing the second panel edge in the second attachment location.

[0017] In an embodiment, the bracket is “IT-shaped when viewed from above. In another embodiment, the bracket is “Z”-shaped when viewed from above. In still another embodiment, the bracket is ‘T’-shaped when viewed from above.

[0018] In an embodiment, the bracket is provided in two, “U”-shaped components having clips for releasable fastening to each other in back-to-back configuration. In an embodiment, the fastener has a self-drilling tip. In a preferred embodiment, the fastener is a TEK™-type or Simpson Strong-Tie™ fastener. In a preferred embodiment, the bracket secures the first panel edge to the second panel edge independently of attachment of the panels to the building frame.

[0019] In another embodiment, a bracket is provided for use in a building system for attaching adjacent wallboard panels together during building construction involving attachment of wallboard panels to members of a building frame, the system including a first wallboard panel having a first panel edge, a second wallboard panel having a second panel edge, the second panel edge being adjacent the first panel edge. The bracket includes a first attachment location configured for accommodating the first panel edge, and a second panel attachment location configured for accommodating the second panel edge so that second panel edge is held adjacent the first panel edge; and each attachment location is configured for accommodating at least one first fastener securing the first panel edge in the first attachment location, and at least one second fastener securing the second panel edge in the second attachment location.

[0020] In an embodiment, the bracket is one of “H”-shaped, “Z”-shaped and “T”-shaped when viewed from above. In an embodiment, the bracket is provided in two “U”-shaped components having clip formations for releasably fastening the components together in back-to- back configuration.

BRIEF DESCRIPTION OF THE DRAWINGS

[0021] FIG. 1 is a fragmentary side perspective view of a building frame showing vertical frame studs, and cement-based wallboard panels secured thereto, wherein selected adjacent panels are secured using the present bracket system;

[0022] FIG. 2 is a partial horizontal cross-section of the present bracket used to secure adjacent cement-based wallboard panels, taken along the line 2-2 of FIG. 1 in the direction generally indicated;

[0023] FIG. 2A is a partial horizontal cross-section of an alternate embodiment of the bracket of FIG. 2;

[0024] FIG. 3 is a partial horizontal cross-section of an alternate embodiment of the present bracket shown securing adjacent cement-based wallboard panels; [0025] FIG. 4 is a partial horizontal cross-section of yet another alternate embodiment of the present bracket shown securing adjacent cement-based wallboard panels;

[0026] FIG. 5 is a top perspective view of a preferred fastener used in the present building system;

[0027] FIG. 6 is an exploded partial horizontal cross-section of a still further alternate embodiment of the present bracket system, showing complementary “U”-shaped brackets which each secure an adjacent wallboard panel edge, and the brackets are configured for being clipped together in back-to-back fashion;

[0028] FIG. 7 is a fragmentary top perspective view of the bracket used in the embodiment of FIG. 6; and

[0029] FIG. 8 is a fragmentary top perspective of the bracket shown in FIG. 4.

DETAILED DESCRIPTION

[0030] Referring now to FIG 1 , the present building system including brackets for attaching adjacent wallboard panels together is generally designated 10, and includes a building frame 12 including a plurality of spaced, vertically positioned studs 14 which are joined to floor-mounted footers 16 and ceiling forming headers (not shown). While the studs 14 and footers 16 are shown as generally “C”-shaped metal frame members, it is contemplated that the frame 12 is also alternately made of wood members or other steel frame members as are commonly used in both interior and exterior residential and commercial construction.

Depending on the local building code, the lateral spacing of the studs 14 is often mandated, such as, for example 16-inch on center.

[0031] When wallboard panels 18 are secured to the building frame 12 as through the use of fasteners 20, it often occurs that the dimensions of a particular wall board panel 18a do not fully line up with the studs 14 of the building frame 12. In such cases, the panels 18a need to be trimmed so that an edge of the panel overlaps one half of an adjacent stud 14, allowing sufficient space for the next adjacent panel to be secured in place on the frame. Alternately, an additional stud is inserted into the frame to support the panel edge.

[0032] While in the present application, “wallboard panel” is generally understood to mean fiber-reinforced cement panels used for exterior construction, also referred to as “cement panels,” it is also contemplated that the term is applicable to paper-faced gypsum wallboard panels or other modified types of construction panels, whether used for interior or exterior construction. Regarding the fiber- re info reed cement panels, they are in one embodiment disclosed in commonly-assigned US Patent Nos. 8,079,198; 8,122,679; and. 8,061 ,108, all of which are incorporated herein by reference.

[0033] A feature of the present building system 10 is that adjacent wallboard panels 18a and 18b have respective first and second edges 22 and 24 that are adjacent each other and intersect at a point distant from the next adjacent vertical studs 14. In such situations, a bracket 30 is employed to securely join the adjacent edges 22, 24 to provide sufficient support that the resulting building construction strength integrity is maintained.

[0034] Referring now to FIGs. 1 and 2, the bracket 30 is preferably made of strong, self- supporting material such as steel, extends at least a full width ‘W’ of the panels 18, and defines a first attachment location 32 for the first panel edge 22, and a second panel attachment location 34 for the second panel edge 24 so that the second panel edge is held adjacent the first panel edge. The bracket 30 in FIG. 2 is generally “H”-shaped when viewed from above, and the first and second attachment locations 32, 34 are preferably integrally formed together as one piece, due to conventional metal forming techniques, including but not limited to extrusion, stamping, drawing and casting. [0035] As seen in FIG. 2, the first and second attachment locations 32, 34 are dimensioned to tightly accommodate the respective first and second edges 22, 24. Each attachment location 32, 34 includes a base wall 36 that separates a pair of preferably parallel arms or flanges 38. The base wall 36 separates the adjacent panel edges 22, 24.

[0036] Referring now to FIG. 5, assembly of the wall system 10 is achieved through the use of special fasteners 40 which are contemplated as not necessarily the same as the fasteners 20. In the preferred embodiment, the fasteners 40 are provided with self-drilling tips 42 configured for piercing steel. Opposite the tip 42 is a head 44 configured for being driven by a drill as is known in the art. Between the head 44 and the tip 42 is a thread portion 46 with a helical thread. A suitable type of such fastener is a TEK^TM-type or Simpson Strong-Tie™ fastener. The fasteners 40 pierce both of the arms or flanges 38 and the respective portion of the edge 22, 24 retained in the respective attachment location 32, 34. As such, the panel edges 22, 24 are secured in the respective panel attachment locations 32, 34.

[0037] An advantage of the action of the fastener 40 is that during installation, it draws the separated flanges 38 together in a pinching action about the panel edge 22, 24. The resulting assembly is sufficiently strong that the adjacent panel edges 22, 24 are positively secured in a self-supporting manner so that a respective frame stud 14 is not needed at that location. In other words, the bracket 30 secures the first panel edge 22 to the second panel edge 24 independently of attachment of the panels to the building frame 12.

[0038] Returning to FIG. 1 , it will be seen that in a final building assembly of the building system 10, at least three and preferably four edges of the wallboard panels 18, including the first and second edges 22, 24 are shown secured to adjacent panels with the present brackets 30. An exception is seen where the panel 18 meets a floor 48. In some cases, the bracket 30 assists in securing the panel 18 to the frame 12. The enclosure of the panel edges in the brackets 30 is referred to as their being “blocked.” [0039] Referring now to FIG. 2A, a modification of the bracket 30 is referred to as 30a. The bracket 30a is substantially identical to the bracket 30 and shared components are designated with identical reference numbers. One difference of the bracket 30a is that arms 38a on one side of the bracket are shorter than arms 38b on the other side of the bracket, so that the fastener 40 passes through the panel 18 before engaging the bracket 30a. As such, the arms 38a are preferably not pierced by the fasteners 40.

[0040] Referring now to FIG. 3, another alternate embodiment of the bracket 30 is generally designated 50. Shared components of the bracket 30 are designated with identical reference numbers. A main difference between the brackets 30 and 50 is that instead of being “H”-shaped when viewed from above, the latter is generally “Z”-shaped, with the base 36 joining a first arm or flange 52 extending in a first direction from one end 54 of the base, and an arm or flange 56 extending in an opposite direction from an opposite end 58 of the base. The bracket 50 similarly secures the adjacent panels 18a, 18b in a sufficiently strong manner so that a respective stud 14 is not required to adequately secure adjacent panels together. Also, regarding the bracket 50, it is preferred that the fasteners 40 are driven through the panel 18 before reaching the bracket, similar to the installation of fasteners in the bracket 30a.

[0041] Referring now to FIGs. 4 and 8, another alternate embodiment of the bracket 30 is generally designated 60. Shared components of the brackets 30 and 50 are designated with identical reference numbers. A main difference between the brackets 30 and 60 is that instead of being “H”-shaped when viewed from above, the latter is generally “T”-shaped, with the base 36 joining a unitary arm or flange 62 extending along a common face 64 of both of the first and second edges 22, 24. The bracket 60 similarly secures the adjacent panels 18a, 18b in a sufficiently strong manner so that a respective stud 14 is not required. As is the case with the brackets 30a and 50, in the bracket 60, the fasteners 40 are preferably driven through the panel 18 before engaging the bracket. [0042] Referring now to FIG. 6, still another embodiment of the bracket is generally designated 70. A main feature of the bracket 70 is that it is provided in two, “U”-shaped components 72, 74 having clips or clip formations 76 for releasable fastening to each other in back-to-back configuration. Each of the U-shaped components 72, 74 has a pair of arms 78 similar to the arms 38 respectively defining between them the first attachment location 32 and the second attachment location 34. A base 80 joins the two arms 78 of each of the U-shaped components 72, 74 and is provided with the clips 76 projecting from an opposite side of the base from that which receives the panel 18 as seen in FIG. 6.

[0043] Referring now to FIGs. 6 and 7, it is contemplated that the structure of the clips or clip formations 76 may vary to suit the application, but the bases 80 of the two U-shaped components 72, 74 have complementary clip shapes or clip formations such that they matingly and preferably slidingly engage each other to fasten the two bases together in a back-to-back fashion that resembles the unitary “IT-shape of the bracket 30. One such embodiment is seen in FIG. 8, where one base 80 has both a tongue formation 82 configured for insertion into a complementary clip 76 and a socket formation 84 configured for receiving the tongue of the complementary U-shaped component 72 or 74. It is contemplated that the tongue formations 82 are optionally provided with bosses 86 or other friction-enhancing formations.

[0044] While a particular embodiment of the present building system enhancing attachment of adjacent panels has been described herein, it will be appreciated by those skilled in the art that changes and modifications may be made thereto without departing from the invention in its broader aspects and as set forth in the following claims.

Claims

CLAIMS:

1. A building system (10) for attaching adjacent wallboard panels (18) together during building construction involving attachment of wallboard panels to members of a building frame (12), comprising: a first wallboard panel (18a) having a first panel edge (22); a second wallboard panel (18b) having a second panel edge (24), said second panel edge being adjacent said first panel edge; a bracket (30, 50, 60, 70) defining a first attachment location (32) for said first panel edge (22), and a second panel attachment location (34) for said second panel edge (24) so that second panel edge is held adjacent said first panel edge; and at least one first fastener (40) securing said first panel edge in said first attachment location, and at least one second fastener securing said second panel edge in said second attachment location.

2. The building system of claim 1 , wherein said bracket (30) is “IT-shaped when viewed from above.

3. The building system of claim 1 , wherein said bracket (50) is “Z”-shaped when viewed from above.

4. The building system of claim 1 , wherein said bracket (60) is “T”-shaped when viewed from above.

5. The building system of claim 1 , wherein said bracket (70) is provided in two, “U”-shaped components (72, 74) having clips (76) for releasable fastening to each other in back-to-back configuration.

6. The building system of claim 5, wherein said clips have complementary tongue (82) and socket (84) configurations.

7. The building system of claim 1 , wherein said fastener (40) has a self-drilling tip (42).

8. The building system of claim 1 , wherein said bracket (30, 50, 60, 70) secures said first panel edge to said second panel edge independently of attachment of said panels to the building frame.

9. A bracket for use in the building system of claim 1 , said bracket comprising: a first attachment location (32) configured for accommodating the first panel edge

(22), and a second panel attachment location (34) configured for accommodating the second panel edge (24) so that second panel edge is held adjacent the first panel edge; and each said attachment location being configured for accommodating at least one first fastener securing the first panel edge in said first attachment location, and at least one second fastener securing the second panel edge in said second attachment location.

10. The bracket of claim 9, wherein said bracket is one of “H”-shaped, “Z”- shaped and ‘T’-shaped when viewed from above.