WO2008060230A1 - A wall system as well as a wall board and a method for building a wall - Google Patents

A wall system as well as a wall board and a method for building a wall Download PDF

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Publication number
WO2008060230A1
WO2008060230A1 PCT/SE2007/001026 SE2007001026W WO2008060230A1 WO 2008060230 A1 WO2008060230 A1 WO 2008060230A1 SE 2007001026 W SE2007001026 W SE 2007001026W WO 2008060230 A1 WO2008060230 A1 WO 2008060230A1
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WO
WIPO (PCT)
Prior art keywords
wall
wall boards
boards
board
plane
Prior art date
Application number
PCT/SE2007/001026
Other languages
French (fr)
Inventor
Peter Lindberg
Original Assignee
Moelven Eurowand Ab
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Moelven Eurowand Ab filed Critical Moelven Eurowand Ab
Priority to EP07835224.2A priority Critical patent/EP2089587A4/en
Publication of WO2008060230A1 publication Critical patent/WO2008060230A1/en

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Classifications

    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04BGENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B2/00Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
    • E04B2/74Removable non-load-bearing partitions; Partitions with a free upper edge
    • E04B2/7407Removable non-load-bearing partitions; Partitions with a free upper edge assembled using frames with infill panels or coverings only; made-up of panels and a support structure incorporating posts
    • E04B2/7453Removable non-load-bearing partitions; Partitions with a free upper edge assembled using frames with infill panels or coverings only; made-up of panels and a support structure incorporating posts with panels and support posts, extending from floor to ceiling
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04BGENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/38Connections for building structures in general
    • E04B1/61Connections for building structures in general of slab-shaped building elements with each other
    • E04B1/6108Connections for building structures in general of slab-shaped building elements with each other the frontal surfaces of the slabs connected together
    • E04B1/612Connections for building structures in general of slab-shaped building elements with each other the frontal surfaces of the slabs connected together by means between frontal surfaces
    • E04B1/6145Connections for building structures in general of slab-shaped building elements with each other the frontal surfaces of the slabs connected together by means between frontal surfaces with recesses in both frontal surfaces co-operating with an additional connecting element
    • E04B1/615Connections for building structures in general of slab-shaped building elements with each other the frontal surfaces of the slabs connected together by means between frontal surfaces with recesses in both frontal surfaces co-operating with an additional connecting element the connection made by expansion
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04BGENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B2/00Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
    • E04B2/74Removable non-load-bearing partitions; Partitions with a free upper edge
    • E04B2/76Removable non-load-bearing partitions; Partitions with a free upper edge with framework or posts of metal
    • E04B2/78Removable non-load-bearing partitions; Partitions with a free upper edge with framework or posts of metal characterised by special cross-section of the frame members as far as important for securing wall panels to a framework with or without the help of cover-strips
    • E04B2/7854Removable non-load-bearing partitions; Partitions with a free upper edge with framework or posts of metal characterised by special cross-section of the frame members as far as important for securing wall panels to a framework with or without the help of cover-strips of open profile
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04BGENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B2/00Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
    • E04B2/74Removable non-load-bearing partitions; Partitions with a free upper edge
    • E04B2/82Removable non-load-bearing partitions; Partitions with a free upper edge characterised by the manner in which edges are connected to the building; Means therefor; Special details of easily-removable partitions as far as related to the connection with other parts of the building
    • E04B2/828Connections between partitions and structural walls
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04BGENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B2/00Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
    • E04B2/74Removable non-load-bearing partitions; Partitions with a free upper edge
    • E04B2002/7461Details of connection of sheet panels to frame or posts
    • E04B2002/7462Details of connection of sheet panels to frame or posts using resilient connectors, e.g. clips

Definitions

  • the present invention relates to a wall system for building a wall, comprising first and second board layers on opposite sides of the wall, which each are made up of wall boards which are mounted edge-to-edge and which are adapted to be placed with their board joints opposite each other, wall boards completely put together edge-to-edge resulting in the forming of board joints between the wall boards substantially tight on an outside of the respective board layers, connecting studs for connecting the wall boards at boundary edges of the wall to connecting walls, floor, window portions, doors and/or ceiling, and coupling elements, which each are exteriorly invisibly connectable to each of the insides of the first and second board layers in the area of a board joint to ensure cooperation between the board layers and, thus, stabilisation of the wall.
  • the invention also relates to a wall board and a method of building such a wall.
  • Partitions in the form of a module system are also known, which include rails, beams, wall boards and the like in standard sizes, which can relatively easily be mounted to form partitions and then be demounted and changed, if required.
  • the vertical wall rails will, however, be visible by the wall boards being mounted in grooves in the same, which determines the appearance of the wall and limits the variation in appearance.
  • US 4 477 348 discloses partitions in the form of wall elements which run in rails or grooves in the ceiling.
  • Such a wall system is advantageous since the wall elements can quickly and easily be moved and, once in place, they can be locked and sealed against ceiling and floor by sealing rails which are operated by pneumatic actuators.
  • a serious drawback of such a system is, however, that the location of the wall elements is limited to the places in a room where rails or grooves are arranged in the ceiling.
  • the pneumatically operated sealing rails make it expensive to manufacture such a wall.
  • US 3 729 883 discloses a partition construction, according to the preamble of claim 1 of the present application, which is made up of wall boards arranged on wall studs of bent metal sheet.
  • the wall boards according to the above document are not directly connected to each other. Instead locking against forces acting perpendicular to the plane of the boards occurs in this case by flanges of the wall studs, which engage in grooves formed in the longitudinal edges of the wall boards.
  • the wall studs, and in particular their flanges must be so strong that they can absorb the forces in question, thus making them expensive to manufacture.
  • the coupling elements must extend along almost the entire height of the wall to allow the wall boards to be safely held in the same plane.
  • a wall built according to US 3 729 883 also cannot provide a substantially smooth wall surface without quite visible joints between the wall boards for all types of wall material. This could be possible with, for instance, wall boards of gypsum, where the movements due to moisture are small or non-existent, but not for wood-based wall boards with, for example, veneered outer surfaces, since in such cases the moisture-related movements would be considerably larger.
  • the wall boards are mounted at least at their lower edge by screwing in a stud profile fixed to the floor.
  • the position of the wall boards relative to the floor will be locked, which causes relatively large gaps to occur between adjoining wall boards at low relative humidity, while there is a risk of the wall boards warping at high relative humidity if sufficient allowance, that is gaps, between neighbouring wall boards is not provided in mounting.
  • Connecting the wall boards to the floor joist by means of screws also results in both mounting and demounting, if any, will be unnecessarily time consuming.
  • the invention aims at obviating the problems and drawbacks of prior art walls and creating a wall system, which allows quick mounting and demounting and a substantially smooth surface without quite visible joints or visible heads of nails or screws. At least this object is achieved by a wall system according to claim 1.
  • the invention also relates to a wall board and a method of building such a wall involving substantially the same object as stated above.
  • This object is achieved by a wall board according to claim 10 and a method according to claim 13.
  • the invention is based on the knowledge that the above object can be achieved by constructing the wall boards so that they are exteriorly invisibly connected to each other, in respect of forces acting both in the plane of the wall boards and perpendicular to the plane of the wall boards, and mounting, at the boundary edges of the wall, the wall boards onto connecting studs, which for instance are fixed to connecting walls, floor and/or ceiling and around any doors and windows included in the wall, in such a manner that the wall will have a "floating" mounting, that is they are clamped against and firmly held in place on the connecting studs but are also allowed a certain degree of movability along the plane of the boards.
  • wall boards of wood or wood fibre material, with no risk of problems caused by movements due to moisture in the wood material. Besides no additional studs need be used. Instead the wall boards are placed in such a manner that the board joints in the first and the second board layer are positioned substantially opposite each other and short coupling elements are exteriorly invisibly connectable to the respective board layers in the area of their board joints for cooperation between the opposite board layers and, thus, stabilisation of the wall.
  • the exteriorly invisible mounting of the coupling elements can be carried out in various ways.
  • the invisible mounting is provided in such a manner that the board joint on the inside has a small gap so that an engaging fitting of the coupling element, when putting the wall boards together, is mountable in the board joints in opposite board layers.
  • the first and the second board layer will be connected to each other and the wall will be stabilised.
  • the invisible mounting is carried out in such a manner that in the area of the board joints, the boards have overlapping portions, in which case a first board having an inner overlapping portion is connected in the overlapping portion to the coupling element, by connecting elements such as screws or nails, after which a second board with an outer overlapping portion is connected to the first board in such a manner that the overlapping portion of the second board conceals the overlapping portion of the first board and, thus, the connecting element.
  • the invisible connection of the boards to each other in respect of forces acting both in the plane of the boards and perpendicular to the plane of the boards can be performed in various ways.
  • the matching profile shape of the board edges once the wall boards are tightly put together edge-to-edge, makes it impossible for the boards to be moved relative to each other perpendicular to the plane of the boards.
  • This can be achieved by many different types of profile shapes.
  • the boards must also be locked relative to each other in respect of forces acting in the plane of the boards so that they cannot be moved away from each other. This can also be achieved in different ways, for instance by gluing or by metal fittings which engage each other.
  • glue is generally not preferred since it makes any demounting of the wall difficult and makes reuse of the material impossible.
  • connection of the boards relative to each other occurs both in the plane of the boards and perpendicular to the plane of the boards by pure form-fitting, in which one board edge has a groove and the other a tongue, which are designed so that the tongue can be inserted into the groove when one board is inclined relative to the other while movement of the boards relative to each other is prevented when subsequently the boards are pivoted to the same plane.
  • the coupling elements have the shape of about 1 mm thick and about 150-500 mm long metal sheets, which along there two opposite longitudinal edges are bent to a shape which corresponds to the inner part of the profile shape of the board joints, the inner part of the board joints having a small gap once the boards are put together.
  • the longitudinal edges of the coupling elements can be put into the board joints as the wall boards are being put together and be locked in the same while simultaneously locking the neighbouring wall boards relative to each other, for instance by gluing, by assembly fittings or by locking in a form-fit manner.
  • the coupling elements could also be designed in many other ways, for instance as two thin assembly fittings, which are bent to a correct profile to be mounted and locked in the board joint and which are connected by a metal rod for instance.
  • the coupling elements could also be made of other materials, such as plastic.
  • the coupling elements have the form of blocks or short stud pieces of, for instance, wood, plastic or sheet metal, which preferably also have a length of about 150-500 mm and which are screwed or nailed to the inner overlapping portions of the opposite board layers and, after that, the screw or nail heads are covered by an outer overlapping portion of the respective neighbouring wall boards.
  • clamping elements that are used to clamp the wall boards at the boundary edges of the wall against adjoining connecting studs can be designed in different ways. It is usually preferred for the clamping elements to have the form of strips which are cut to suitable lengths and clamp the wall boards along substantially the entire boundary edge of the wall, but they could also be some other type of clamping element of a short longitudinal extent, which press the wall boards against the connecting studs at points along the boundary edge.
  • the clamping elements have the form of elongate strips of aluminium, which are formed with a clamping portion abutting against the outside of the wall boards and a web portion extending perpendicular inwards from the clamping portion and adapted to be inserted into and engage in a groove in the connecting stud, either in the form of a groove-forming element, for instance of aluminium, which is milled in a connecting stud of wood, or as grooves formed directly in the connecting stud.
  • the clamping element could, however, also be a strip of wood, which is nailed or screwed to the connecting stud in the area outside the wall boards and, thus, presses the wall boards against the connecting stud.
  • the connecting stud is formed with a recess, in which the edges of the wall boards are placed so that the outsides of the wall boards will be substantially aligned with the outermost sides of the connecting studs.
  • the connecting stud could also be without such recesses if, for example, the web portion of the shown clamping element is made sufficiently long to extend beyond the thickness of the wall boards and engage in the groove of the connecting stud.
  • the connecting studs can be optionally made of wood, extruded aluminium or sheet metal.
  • a thin slide-promoting layer of plastic for instance, in the joint, either on both sides of the wall board or on one side only if, for example, clamping elements of aluminium are used which can be imagined to result in a sufficiently low friction.
  • the invention makes it possible to quickly and easily build walls of very different types, such as room-separating walls which extend between floor and ceiling, in which case a connecting stud can suitably be fixed to the ceiling, or a wall which does not extend all the way up to the ceiling but is open at the top, in which case an upper connecting stud is not fixed to the ceiling, or screen walls and walls comprising window portions.
  • the wall is in the form of a non- bearing, room-separating inner wall.
  • the wall could also be a load-bearing wall by selecting a suitable material, for instance if a sufficient number of vertical studs of sufficient strength is arranged between the wall boards, and the wall could also function as an outer wall by selecting a suitable weather-resistant outer coating. If the wall is used as an outer wall, the further advantage of the wall providing an excellent heat-insulating capacity is obtained since the amount of thermal bridges, in the form of studs, can be made very small and the wall can instead contain a larger amount of heat-insulating material.
  • the wall board used may conveniently be a particle board or fibreboard with a decorative surface layer of veneer for instance, but also other types of boards may be used, for instance of homogeneous wood. It is usually preferred that the board joints be arranged vertically in the wall, but it is also possible to arrange them horizontally. In such cases, also the terminal edges of the wall boards should be provided with fitted profiled edges.
  • Fig. 1 is a cut perspective view of part of a wall according to a first embodiment of the invention
  • Fig. 2 is a horizontal longitudinal section of a somewhat larger part of the wall according to Fig. 1 ;
  • Fig. 3 is an enlarged longitudinal section of the board joint in Figs 1 and 2;
  • Fig. 4 shows an alternative embodiment of a board joint for the embodiment in Figs 1-3;
  • Fig. 5 is a view of a wall according to a second embodiment of the invention.
  • Fig. 6 is a schematic, partially exploded longitudinal section illustrating the fundamental composition of a wall according to the second embodiment of the invention.
  • Fig. 7 is a longitudinal section along the line VII-VII in Fig. 5;
  • Fig. 8 is a cross-section along the line VIII-VlII in Fig. 5.
  • Figs 1 and 2 illustrate the construction of an inventive wall in more detail.
  • the wall consists of a first and a second board layer 1 , 2, which each are made up of two or more separate wall boards 3 which are connected edge-to edge in board joints 4.
  • first connecting studs 5 are fixed to walls, floor and/or ceiling or around windows and doors to which the wall is to be connected.
  • the wall according to the invention is connected to a wall 6, which for instance can be a load-bearing inner or outer wall, and the wall according to the invention is further provided with a door 7, which is pivotally connected to a connecting stud 5' by a hinge 8.
  • the shown connecting studs 5 1 around the door differ from the connecting stud 5 fixed to the wall 6 by being slightly thicker and provided with stop strips 9 for the door leaf.
  • the connecting studs 5 and 5' are formed with recesses 10 in which terminal edges of the wallboards 3 are placed.
  • clamping strips 11 The edges of the wall boards are pressed against the connecting stud by means of clamping elements or clamping strips 11. In the embodiment illustrated, this is achieved by the clamping strip having a clamping portion 12, which is adapted to be made to abut the outside of the wall board, and a web portion 13, which is adapted to be inserted in a groove 14 formed in the connecting stud and engage the groove.
  • clamping portion 12 which is adapted to be made to abut the outside of the wall board
  • web portion 13 which is adapted to be inserted in a groove 14 formed in the connecting stud and engage the groove.
  • slide-promoting strips 15 are placed between the wall board and the connecting stud and the clamping element respectively.
  • architrave strips 16 are in the illustrated embodiment arranged on the outside of the clamping strips. They are suitably nailed or screwed to the wall boards.
  • the oppositely facing edges of the wall boards 3 in the joints 4 are matchingly profiled in such a manner that, once the boards are tightly put together, the boards are in the same plane and prevented from being moved relative to each other perpendicular to their plane.
  • the profile shape is designed so that, with maximally put-together wall boards, the joint 4 will be substantially tight on the outside while a small gap 17 remains on the inside, as is best seen in Figs 3 and 4.
  • This design makes it possible to arrange a bent longitudinal edge 18 of a coupling element 19 made of a thin metal sheet.
  • the coupling element 19 has correspondingly bent longitudinal edges 18 along opposite sides and the bent longitudinal edges 18 further have the same profile shape as the inner portion of each joint 4.
  • the bent longitudinal edges 18 of the coupling element can thus be connected to the respective board layers 1 and 2 by means of the joints 4 in the same so that the board layers will cooperate and provide increased stability to the wall.
  • Fig. 4 illustrates an alternative method of connecting the wall boards to each other.
  • one wall board is provided with a projecting flange 20, for example of extruded aluminium, which is milled in one board edge and which can be moved into and engage a milled groove-forming means 21 , preferably also of extruded aluminium, in the other board edge.
  • the connection is only schematically shown, but such mechanical, and in the completed wall invisible, assembly fittings of many types are well known in the art and can be made demountable so that the wall boards can be detached without being damaged so as to make reuse possible.
  • connecting studs 5" are fixed to connecting walls, roof and ceiling.
  • the connecting studs 5" are made of extruded aluminium.
  • the connecting studs 5" are formed with a body portion 22, which on a first side has a recess 23 and on a second side flange portions which protrude from the respective longitudinal edges of the body portion.
  • Each of the flange portions is formed with a recess in the form of an angled portion 24 comprising a flange 25 extending parallel to the plane of the wall, and an engagement groove 26.
  • the flange 25 of the angled portion is adapted to receive an edge portion of a wall board 3, while the engagement groove 26 is adapted to receive and lock a flange 27 of a clamping strip 28 for pressing the wall boards 3 against the flange 25 of the angled portion.
  • the clamping strip 28 is provided with a slide-promoting strip 15 to allow moisture-related movements of the wall boards.
  • the recess 23 is adapted to be connected to different types of assembly components. More specifically, when the connecting studs 5" are to be mounted onto connecting walls, floor and sealing, a sealing strip 30, suitably of plastic or rubber, is arranged in the recess 23.
  • the sealing strip serves to seal against the connecting wall, floor or ceiling surface since, as a rule, this is not perfectly smooth. In this way, sound can be prevented from passing from one side of the wall to the other.
  • a stop strip 31 is pressed into and fixed to the recess 23.
  • the wall boards 3, and in particular the joints 4 between adjoining wall boards, are in this embodiment designed in a manner different from the previously described embodiment. More specifically, locking between the wall boards occurs both in the plane of the boards and perpendicular to the plane of the boards, merely by locking in a form-fit manner.
  • the boards have along their longitudinal edges overlapping portions in such a manner that the right board in Figs 6 and 7 has an inner overlapping portion 32, while the left board has an outer overlapping portion 33.
  • the inner overlapping portion 32 has a ridge 34 at its outermost edge, an intermediate groove 35 and a tongue 36 adjacent the transition towards the outer surface of the board.
  • the outer overlapping portion 33 has a tongue 37 at its outermost edge adjacent the transition towards the outer surface of the board, an intermediate ridge 38 and a groove 39 adjacent the transition towards the inner surface of the board.
  • the boards are then locked relative to each other by the ridge 34 and the groove 39 engaging with each other and preventing movement of the boards relative to each other in the plane of the boards, while the groove 36 and the tongue 37 prevent movement of the boards relative to each other perpendicular to the plane of the boards.
  • a small space remains between the respective intermediate groove 35 and the ridge 38 and results in the head of the screw not preventing the interconnection. Due to the arrangement of the screw, it will further be completely concealed in the completed wall.
  • the coupling element is schematically shown as a block-like stud, for instance of wood, but may suitably be a sheet metal section bent in the shape of a Z or U.
  • the cross-section of the wall in Fig. 8 shows the corresponding connection of the wall boards 3 to floor and ceiling.
  • the wall according to the invention as shown in Figs 5-8 provides an aesthetically pleasing wall surface without well visible board joints and without visible nail or screw heads.
  • the design of the wall allows the wall boards to move and slide between the clamping strip 28 and the flange 25 which is parallel to the plane of the wall boards, due to a varying degree of moisture, without the boards risking to warp or visible gaps occurring between adjoining wall boards.

Abstract

The invention relates to a wall system for building a wall, comprising first (1) and second (2) board layers on opposite sides of the wall, which each are made up of wall boards (3) which are mounted edge-to-edge and which are adapted to be placed with their board joints opposite each other, wall boards completely put together edge-to-edge resulting in the forming of board joints (4) between the wall boards substantially tight on an outside of the respective board layers, connecting studs (5') for connecting the wall boards at boundary edges of the wall to connecting walls (6), floor, window portions, doors (7) and/or ceiling, and coupling elements (191), which each are exteriorly invisibly connectable to each of the insides of the first and second board layers in the area of a board joint to ensure cooperation between the board layers, and, thus, stabilisation of the wall. The wall boards (3) are, at least along the edges that are to be mounted adjacent to each other, exteriorly invisibly connectable to each other to provide locking of the wall boards relative to each other in respect of forces acting both in the plane of the wall boards and perpendicular to the plane of the wall boards, and the wall system further comprises clamping elements (8) which are mountable on the connecting studs (5') for pressing the wall boards against the connecting studs to provide a movable connection of the wall boards to the connecting studs.

Description

WALL SYSTEM AS WELL AS A WALL BOARD AND METHOD FOR
BUILDING A WALL
The present invention relates to a wall system for building a wall, comprising first and second board layers on opposite sides of the wall, which each are made up of wall boards which are mounted edge-to-edge and which are adapted to be placed with their board joints opposite each other, wall boards completely put together edge-to-edge resulting in the forming of board joints between the wall boards substantially tight on an outside of the respective board layers, connecting studs for connecting the wall boards at boundary edges of the wall to connecting walls, floor, window portions, doors and/or ceiling, and coupling elements, which each are exteriorly invisibly connectable to each of the insides of the first and second board layers in the area of a board joint to ensure cooperation between the board layers and, thus, stabilisation of the wall.
The invention also relates to a wall board and a method of building such a wall. Background Art
In basically all building projects, it is desirable to reduce the costs by shortening the building time and using simple, material-saving and inexpensive components. This is also desirable in building of load-bearing and non-bearing inner and outer walls, in particular when building room- separating partition walls in offices and similar environments. It has long been known to erect buildings, which have a very open layout where the number of load-bearing walls and columns between the floor structures of different storeys has been reduced to a minimum. Such an open layout allows the house-owner or tenant to freely arrange the rooms by means of non-bearing inner walls in a manner that suits the intended activities and also later change the arrangement of rooms when required.
In conventional wall construction technology, use is made of vertical wall studs, usually of wood or sheet metal, which are fastened at the top and at the bottom to a rafter fastened to the ceiling and respectively to a floor joist fastened to the floor. Subsequently wall boards are mounted on opposite sides of the wall studs by screwing or nailing. Such a construction method is, however, relatively time consuming, the consumption of material is relatively great, particularly if wood studs are used, and the wall boards will have visible screw or nail heads, which as a rule must be covered with putty and with some kind of surface finish or surface layer to provide an aesthetically pleasing result. In addition, such walls are difficult to demount if there is a need to change the arrangement of rooms and in such cases the material usually cannot be reused.
Partitions in the form of a module system are also known, which include rails, beams, wall boards and the like in standard sizes, which can relatively easily be mounted to form partitions and then be demounted and changed, if required. In such module walls, the vertical wall rails will, however, be visible by the wall boards being mounted in grooves in the same, which determines the appearance of the wall and limits the variation in appearance.
For example, US 4 477 348 discloses partitions in the form of wall elements which run in rails or grooves in the ceiling. Such a wall system is advantageous since the wall elements can quickly and easily be moved and, once in place, they can be locked and sealed against ceiling and floor by sealing rails which are operated by pneumatic actuators. A serious drawback of such a system is, however, that the location of the wall elements is limited to the places in a room where rails or grooves are arranged in the ceiling. In addition, the pneumatically operated sealing rails make it expensive to manufacture such a wall.
US 3 729 883 discloses a partition construction, according to the preamble of claim 1 of the present application, which is made up of wall boards arranged on wall studs of bent metal sheet. The wall boards according to the above document are not directly connected to each other. Instead locking against forces acting perpendicular to the plane of the boards occurs in this case by flanges of the wall studs, which engage in grooves formed in the longitudinal edges of the wall boards. This means that the wall studs, and in particular their flanges, must be so strong that they can absorb the forces in question, thus making them expensive to manufacture. Moreover, the coupling elements must extend along almost the entire height of the wall to allow the wall boards to be safely held in the same plane. As a result, the consumption of material will be great, and thus also the costs, and further the coupling elements will be large and unwieldy to handle. Furthermore the wall stud extending over substantially the entire height of the wall results in the available space in the wall for installations, such as electric cables, water conduits, sewers and breather lines, being unfavourably small. A wall built according to US 3 729 883 also cannot provide a substantially smooth wall surface without quite visible joints between the wall boards for all types of wall material. This could be possible with, for instance, wall boards of gypsum, where the movements due to moisture are small or non-existent, but not for wood-based wall boards with, for example, veneered outer surfaces, since in such cases the moisture-related movements would be considerably larger. The reason is that, for locking the wall boards in respect of forces acting in the plane of the wall boards, the wall boards are mounted at least at their lower edge by screwing in a stud profile fixed to the floor. As a result, the position of the wall boards relative to the floor will be locked, which causes relatively large gaps to occur between adjoining wall boards at low relative humidity, while there is a risk of the wall boards warping at high relative humidity if sufficient allowance, that is gaps, between neighbouring wall boards is not provided in mounting. Connecting the wall boards to the floor joist by means of screws also results in both mounting and demounting, if any, will be unnecessarily time consuming.
Summary of the Invention
The invention aims at obviating the problems and drawbacks of prior art walls and creating a wall system, which allows quick mounting and demounting and a substantially smooth surface without quite visible joints or visible heads of nails or screws. At least this object is achieved by a wall system according to claim 1.
The invention also relates to a wall board and a method of building such a wall involving substantially the same object as stated above. This object is achieved by a wall board according to claim 10 and a method according to claim 13. Thus, the invention is based on the knowledge that the above object can be achieved by constructing the wall boards so that they are exteriorly invisibly connected to each other, in respect of forces acting both in the plane of the wall boards and perpendicular to the plane of the wall boards, and mounting, at the boundary edges of the wall, the wall boards onto connecting studs, which for instance are fixed to connecting walls, floor and/or ceiling and around any doors and windows included in the wall, in such a manner that the wall will have a "floating" mounting, that is they are clamped against and firmly held in place on the connecting studs but are also allowed a certain degree of movability along the plane of the boards. This makes it possible to use wall boards of wood or wood fibre material, with no risk of problems caused by movements due to moisture in the wood material. Besides no additional studs need be used. Instead the wall boards are placed in such a manner that the board joints in the first and the second board layer are positioned substantially opposite each other and short coupling elements are exteriorly invisibly connectable to the respective board layers in the area of their board joints for cooperation between the opposite board layers and, thus, stabilisation of the wall.
The exteriorly invisible mounting of the coupling elements can be carried out in various ways. In a first embodiment of the invention as shown and described below, the invisible mounting is provided in such a manner that the board joint on the inside has a small gap so that an engaging fitting of the coupling element, when putting the wall boards together, is mountable in the board joints in opposite board layers. As a result, the first and the second board layer will be connected to each other and the wall will be stabilised.
In a second embodiment of the invention as shown and described below, the invisible mounting is carried out in such a manner that in the area of the board joints, the boards have overlapping portions, in which case a first board having an inner overlapping portion is connected in the overlapping portion to the coupling element, by connecting elements such as screws or nails, after which a second board with an outer overlapping portion is connected to the first board in such a manner that the overlapping portion of the second board conceals the overlapping portion of the first board and, thus, the connecting element.
Also the invisible connection of the boards to each other in respect of forces acting both in the plane of the boards and perpendicular to the plane of the boards can be performed in various ways. In the first embodiment of the invention as described below, the matching profile shape of the board edges, once the wall boards are tightly put together edge-to-edge, makes it impossible for the boards to be moved relative to each other perpendicular to the plane of the boards. This can be achieved by many different types of profile shapes. However, the boards must also be locked relative to each other in respect of forces acting in the plane of the boards so that they cannot be moved away from each other. This can also be achieved in different ways, for instance by gluing or by metal fittings which engage each other. However, glue is generally not preferred since it makes any demounting of the wall difficult and makes reuse of the material impossible.
In the shown and described second embodiment of the invention, connection of the boards relative to each other occurs both in the plane of the boards and perpendicular to the plane of the boards by pure form-fitting, in which one board edge has a groove and the other a tongue, which are designed so that the tongue can be inserted into the groove when one board is inclined relative to the other while movement of the boards relative to each other is prevented when subsequently the boards are pivoted to the same plane.
In the first embodiment of the invention which is shown and described below, the coupling elements have the shape of about 1 mm thick and about 150-500 mm long metal sheets, which along there two opposite longitudinal edges are bent to a shape which corresponds to the inner part of the profile shape of the board joints, the inner part of the board joints having a small gap once the boards are put together. As a result, the longitudinal edges of the coupling elements can be put into the board joints as the wall boards are being put together and be locked in the same while simultaneously locking the neighbouring wall boards relative to each other, for instance by gluing, by assembly fittings or by locking in a form-fit manner. As a rule, it is sufficient to mount such a coupling element in the centre of the height of the wall in order to obtain sufficient stability in the wall, but it is, of course, also possible to mount more than one coupling element in the same board joint. The coupling elements could also be designed in many other ways, for instance as two thin assembly fittings, which are bent to a correct profile to be mounted and locked in the board joint and which are connected by a metal rod for instance. The coupling elements could also be made of other materials, such as plastic.
In the shown second embodiment of the invention, the coupling elements have the form of blocks or short stud pieces of, for instance, wood, plastic or sheet metal, which preferably also have a length of about 150-500 mm and which are screwed or nailed to the inner overlapping portions of the opposite board layers and, after that, the screw or nail heads are covered by an outer overlapping portion of the respective neighbouring wall boards.
Also the clamping elements that are used to clamp the wall boards at the boundary edges of the wall against adjoining connecting studs can be designed in different ways. It is usually preferred for the clamping elements to have the form of strips which are cut to suitable lengths and clamp the wall boards along substantially the entire boundary edge of the wall, but they could also be some other type of clamping element of a short longitudinal extent, which press the wall boards against the connecting studs at points along the boundary edge. In the exemplary embodiments of the invention as shown and described below, the clamping elements have the form of elongate strips of aluminium, which are formed with a clamping portion abutting against the outside of the wall boards and a web portion extending perpendicular inwards from the clamping portion and adapted to be inserted into and engage in a groove in the connecting stud, either in the form of a groove-forming element, for instance of aluminium, which is milled in a connecting stud of wood, or as grooves formed directly in the connecting stud. The clamping element could, however, also be a strip of wood, which is nailed or screwed to the connecting stud in the area outside the wall boards and, thus, presses the wall boards against the connecting stud. In the shown and described embodiments, the connecting stud is formed with a recess, in which the edges of the wall boards are placed so that the outsides of the wall boards will be substantially aligned with the outermost sides of the connecting studs. However, the connecting stud could also be without such recesses if, for example, the web portion of the shown clamping element is made sufficiently long to extend beyond the thickness of the wall boards and engage in the groove of the connecting stud. The connecting studs can be optionally made of wood, extruded aluminium or sheet metal.
To facilitate the movements due to moisture of the wall boards in the clamping joints against the connecting studs, it may be convenient to place a thin slide-promoting layer, of plastic for instance, in the joint, either on both sides of the wall board or on one side only if, for example, clamping elements of aluminium are used which can be imagined to result in a sufficiently low friction.
The invention makes it possible to quickly and easily build walls of very different types, such as room-separating walls which extend between floor and ceiling, in which case a connecting stud can suitably be fixed to the ceiling, or a wall which does not extend all the way up to the ceiling but is open at the top, in which case an upper connecting stud is not fixed to the ceiling, or screen walls and walls comprising window portions. In the shown and described embodiments of the invention, the wall is in the form of a non- bearing, room-separating inner wall. However, it should be understood that the wall could also be a load-bearing wall by selecting a suitable material, for instance if a sufficient number of vertical studs of sufficient strength is arranged between the wall boards, and the wall could also function as an outer wall by selecting a suitable weather-resistant outer coating. If the wall is used as an outer wall, the further advantage of the wall providing an excellent heat-insulating capacity is obtained since the amount of thermal bridges, in the form of studs, can be made very small and the wall can instead contain a larger amount of heat-insulating material.
The wall board used may conveniently be a particle board or fibreboard with a decorative surface layer of veneer for instance, but also other types of boards may be used, for instance of homogeneous wood. It is usually preferred that the board joints be arranged vertically in the wall, but it is also possible to arrange them horizontally. In such cases, also the terminal edges of the wall boards should be provided with fitted profiled edges.
Brief Description of the Drawings
Exemplary embodiments of the invention will now be described with reference to the drawings, in which
Fig. 1 is a cut perspective view of part of a wall according to a first embodiment of the invention;
Fig. 2 is a horizontal longitudinal section of a somewhat larger part of the wall according to Fig. 1 ;
Fig. 3 is an enlarged longitudinal section of the board joint in Figs 1 and 2;
Fig. 4 shows an alternative embodiment of a board joint for the embodiment in Figs 1-3;
Fig. 5 is a view of a wall according to a second embodiment of the invention;
Fig. 6 is a schematic, partially exploded longitudinal section illustrating the fundamental composition of a wall according to the second embodiment of the invention;
Fig. 7 is a longitudinal section along the line VII-VII in Fig. 5; and
Fig. 8 is a cross-section along the line VIII-VlII in Fig. 5.
Detailed Description of Embodiments of the Invention
Figs 1 and 2 illustrate the construction of an inventive wall in more detail. The wall consists of a first and a second board layer 1 , 2, which each are made up of two or more separate wall boards 3 which are connected edge-to edge in board joints 4.
According to the invention, first connecting studs 5 are fixed to walls, floor and/or ceiling or around windows and doors to which the wall is to be connected. In Fig. 2, the wall according to the invention is connected to a wall 6, which for instance can be a load-bearing inner or outer wall, and the wall according to the invention is further provided with a door 7, which is pivotally connected to a connecting stud 5' by a hinge 8. The shown connecting studs 51 around the door differ from the connecting stud 5 fixed to the wall 6 by being slightly thicker and provided with stop strips 9 for the door leaf. The connecting studs 5 and 5' are formed with recesses 10 in which terminal edges of the wallboards 3 are placed. The edges of the wall boards are pressed against the connecting stud by means of clamping elements or clamping strips 11. In the embodiment illustrated, this is achieved by the clamping strip having a clamping portion 12, which is adapted to be made to abut the outside of the wall board, and a web portion 13, which is adapted to be inserted in a groove 14 formed in the connecting stud and engage the groove. The detailed design of such connections are well known in the art and therefore need not be described in more detail.
To facilitate a certain degree of movement, caused by moisture, of the wall boards relative to the connecting studs, slide-promoting strips 15 are placed between the wall board and the connecting stud and the clamping element respectively. For reasons of appearance, also architrave strips 16 (however, excluded in some places for the sake of clarity) are in the illustrated embodiment arranged on the outside of the clamping strips. They are suitably nailed or screwed to the wall boards.
The oppositely facing edges of the wall boards 3 in the joints 4 are matchingly profiled in such a manner that, once the boards are tightly put together, the boards are in the same plane and prevented from being moved relative to each other perpendicular to their plane. Moreover, the profile shape is designed so that, with maximally put-together wall boards, the joint 4 will be substantially tight on the outside while a small gap 17 remains on the inside, as is best seen in Figs 3 and 4. This design makes it possible to arrange a bent longitudinal edge 18 of a coupling element 19 made of a thin metal sheet. The coupling element 19 has correspondingly bent longitudinal edges 18 along opposite sides and the bent longitudinal edges 18 further have the same profile shape as the inner portion of each joint 4. By ensuring, when building the wall, that board joints 4 of the two board layers 1 and 2 are placed substantially opposite each other, the bent longitudinal edges 18 of the coupling element can thus be connected to the respective board layers 1 and 2 by means of the joints 4 in the same so that the board layers will cooperate and provide increased stability to the wall.
It will be preferred that, during mounting of a coupling element, this is fixed to the profiled longitudinal edge of one wall board, after which the next wall board is moved with its profiled longitudinal edge into engagement with the other wall board. As a result, the coupling element will be clamped in the joint without requiring further fixing of the same. For this condition to remain, the boards must, however, be connected to each other to prevent them from sliding apart along their planes. In the embodiment according to Figs 1-3, the boards are adapted to be glued together in the joints. This method of connecting suffers, however, from the drawback that, if the wall is to be torn down and moved, the wall boards usually cannot be reused.
Fig. 4 illustrates an alternative method of connecting the wall boards to each other. Here, one wall board is provided with a projecting flange 20, for example of extruded aluminium, which is milled in one board edge and which can be moved into and engage a milled groove-forming means 21 , preferably also of extruded aluminium, in the other board edge. The connection is only schematically shown, but such mechanical, and in the completed wall invisible, assembly fittings of many types are well known in the art and can be made demountable so that the wall boards can be detached without being damaged so as to make reuse possible.
Reference is now made to Figs 5-8, which illustrate a wall according to a second embodiment of the invention. Also in this embodiment, connecting studs 5" are fixed to connecting walls, roof and ceiling. In this embodiment, however, the connecting studs 5" are made of extruded aluminium. The connecting studs 5" are formed with a body portion 22, which on a first side has a recess 23 and on a second side flange portions which protrude from the respective longitudinal edges of the body portion. Each of the flange portions is formed with a recess in the form of an angled portion 24 comprising a flange 25 extending parallel to the plane of the wall, and an engagement groove 26. The flange 25 of the angled portion is adapted to receive an edge portion of a wall board 3, while the engagement groove 26 is adapted to receive and lock a flange 27 of a clamping strip 28 for pressing the wall boards 3 against the flange 25 of the angled portion. The clamping strip 28 is provided with a slide-promoting strip 15 to allow moisture-related movements of the wall boards.
The recess 23 is adapted to be connected to different types of assembly components. More specifically, when the connecting studs 5" are to be mounted onto connecting walls, floor and sealing, a sealing strip 30, suitably of plastic or rubber, is arranged in the recess 23. The sealing strip serves to seal against the connecting wall, floor or ceiling surface since, as a rule, this is not perfectly smooth. In this way, sound can be prevented from passing from one side of the wall to the other. However, when the connecting stud 5" is to be used to connect to and hold a door 7, a stop strip 31 is pressed into and fixed to the recess 23.
The wall boards 3, and in particular the joints 4 between adjoining wall boards, are in this embodiment designed in a manner different from the previously described embodiment. More specifically, locking between the wall boards occurs both in the plane of the boards and perpendicular to the plane of the boards, merely by locking in a form-fit manner. As is best seen in Figs 6 and 7, the boards have along their longitudinal edges overlapping portions in such a manner that the right board in Figs 6 and 7 has an inner overlapping portion 32, while the left board has an outer overlapping portion 33. The inner overlapping portion 32 has a ridge 34 at its outermost edge, an intermediate groove 35 and a tongue 36 adjacent the transition towards the outer surface of the board. The outer overlapping portion 33 has a tongue 37 at its outermost edge adjacent the transition towards the outer surface of the board, an intermediate ridge 38 and a groove 39 adjacent the transition towards the inner surface of the board. When connecting two adjoining wall boards 5" to each other, first the inner overlapping portions 32 of the respective board layers are connected by nails or screws 40 to a coupling element 19'. After that the board with the outer overlapping portion 33 is slightly inclined relative to the other board so that the tongue 37 of the outer overlapping portion can be inserted into the groove 36 of the inner overlapping portion. Subsequently the board with the outer overlapping portion can be pivoted so that the walls will be located in the same plane. The boards are then locked relative to each other by the ridge 34 and the groove 39 engaging with each other and preventing movement of the boards relative to each other in the plane of the boards, while the groove 36 and the tongue 37 prevent movement of the boards relative to each other perpendicular to the plane of the boards. In the interconnected state, a small space remains between the respective intermediate groove 35 and the ridge 38 and results in the head of the screw not preventing the interconnection. Due to the arrangement of the screw, it will further be completely concealed in the completed wall. The coupling element is schematically shown as a block-like stud, for instance of wood, but may suitably be a sheet metal section bent in the shape of a Z or U.
The cross-section of the wall in Fig. 8 shows the corresponding connection of the wall boards 3 to floor and ceiling. Preferably, only one coupling element 19' is arranged between the board layers 1 and 2 approximately in the centre of the height of the wall.
The wall according to the invention as shown in Figs 5-8 provides an aesthetically pleasing wall surface without well visible board joints and without visible nail or screw heads. The design of the wall allows the wall boards to move and slide between the clamping strip 28 and the flange 25 which is parallel to the plane of the wall boards, due to a varying degree of moisture, without the boards risking to warp or visible gaps occurring between adjoining wall boards.

Claims

1. A wall system for building a wall, comprising first (1 ) and second (2) board layers on opposite sides of the wall, which each are made up of wall boards (3) which are mounted edge-to-edge and which are adapted to be placed with their board joints opposite each other, wall boards completely put together edge-to-edge resulting in the forming of board joints (4) between the wall boards substantially tight on an outside of the respective board layers (1 , 2), connecting studs (5, 5', 5") for connecting the wall boards at boundary edges of the wall to connecting walls (6), floor, window portions, doors (7) and/or ceiling, and coupling elements (19, 19'), which each are exteriorly invisibly connectable to each of the insides of the first and second board layers in the area of a board joint to ensure cooperation between the board layers and, thus, stabilisation of the wall, characterised in that the wall boards (3), at least along the edges that are to be mounted adjacent to each other, are exteriorly invisibly connectable to each other to provide locking of the wall boards relative to each other in respect of forces acting both in the plane of the wall boards and perpendicular to the plane of the wall boards, and that the wall system further comprises clamping elements (11 , 28) which are mountable on the connecting studs (5, 5', 5") for pressing the wall boards against the connecting studs to provide a movable connection of the wall boards to the connecting studs.
2. A wall system as claimed in claim 1 , characterised in that the coupling elements (19, 19') have a maximum length of 500 mm.
3. A wall system as claimed in claim 1 or2, characterised in that the connecting studs (5, 5', 5") have recesses (10, 24) for receiving edge portions of the wall boards (3).
4. A wall system as claimed in any one of the preceding claims, characterised in that the clamping element is an elongate clamping strip (11,28).
5. A wall system as claimed in any one of the preceding claims, characterised in that a slide-promoting layer (15) is arranged between the wall boards (3) and the connecting stud (5, 5', 5") and/or between the wall boards and the clamping element (11 , 28).
6. A wall system as claimed in claim 4, characterised in that the clamping strip (11 , 28) engages in a groove (14, 26) formed in the connecting stud (5, 5', 5").
7. A wall system as claimed in any one of the preceding claims, characterised in that the coupling element (19, 19') is made of bent sheet metal.
8. A wall system as claimed in any one of the preceding claims, characterised in that the wall boards (3) have assembly fittings (20, 21 ) to allow adhesive-free connection of the wall boards to each other, the assembly fittings being exteriorly invisible in the completed wall.
9. A wall system as claimed in any one of claims 1-7, characterised in that the wall boards (3) are adapted to be locked to each other in a form-fit manner, the profiled edges of the wall boards being designed in such a manner that the wall boards are moved to be put together, inclined relative to each other, after which they are pivotable to the same plane, in which position they are locked relative to each other in respect of forces acting both in the plane of the wall boards and perpendicular to the plane of the wall boards.
10. A wall board for building a wall, a plurality of such wall boards (3) being adapted to be mounted edge-to-edge on opposite sides of connecting studs (5, 5', 5") fixed to connecting walls, floor, window portions, doors and/or ceiling at boundary edges of the wall to form first (1) and second (2) opposite board layers, comprising at least two opposite edges which are designed in such a manner that wall boards (3) adjoining each other edge-to-edge form an exteriorly substantially tight joint (4), the wall boards of opposite wall layers being exteriorly invisibly connectable to coupling elements in the area of a board joint to ensure cooperation between the board layers and, thus, stabilisation of the wall, characterised in that the wall along two opposite edges has a cross-sectional profile in such a manner that wall boards (3) adjoining each other are exteriorly invisibly connectable to each other to provide locking of the wall boards relative to each other in respect of forces acting both in the plane of the wall boards and perpendicular to the plane of the wall boards.
11. A wall board as claimed in claim 10, c h a r a c t e r i s e d in that it comprises assembly fittings (20, 21 ) for adhesive-free connection to adjoining wall boards (3), the assembly fittings being exteriorly invisible in the completed wall.
12. A wall board as claimed in claim 10, c h a r a c t e r i s e d in that the wall boards (3) are adapted to be locked to each other in a form-fit manner, the profiled edges of the wall boards being designed in such a manner that the wall boards are adapted to be put together, inclined relative to each other, after which they are pivotable to the same plane, in which position they are locked to each other in respect of forces acting both in the plane of the wall boards and perpendicular to the plane of the wall boards.
13. A method of building a wall, comprising first (1 ) and second (2) board layers which are made up of wall boards (3) mounted edge-to-edge, and connecting studs (5, 5', 5") for connecting the wall boards at boundary edges of the wall to connecting walls, floor, window portions, doors and/or ceiling, comprising the steps of providing wall boards (3), which at least at the edges that are to be mounted against each other are exteriorly invisibly connectable to each other in respect of forces acting both in the plane of the wall boards and perpendicular to the plane of the wall boards; fixing connecting studs (5, 5', 5") at boundary edges of the wall to connecting walls, floor, window portions, doors and/or ceiling; mounting the wall boards on each side of the connecting studs in such a manner that board joints (4) of first and second board layers are placed substantially opposite each other; providing coupling elements (19, 19'), which each are exteriorly invisibly connectable to the wall boards of opposite board layers in the area of their board joints; mounting the wall boards onto the connecting studs and edge-to-edge to each other and exteriorly invisibly connecting the wall boards to each other in respect of forces acting both in the plane of the wall boards and perpendicular to the plane of the wall boards; and mounting clamping elements (11 , 28) which press the wall boards against the connecting studs.
14. A method as claimed in claim 13, comprising the step of connecting adjoining wall boards (3) by means of exteriorly invisible assembly fittings (20, 21 ).
15. A method as claimed in claim 13, c h a r a c t e r i s e d by connecting the wall boards (3) to each other by locking in a form-fit manner in such a manner that the profiled edges of the wall boards are designed in such a manner that the wall boards are first put together, inclined relative to each other, and after that the wall boards are pivoted to the same plane, in which position they are locked to each other in respect of forces acting both in the plane of the wall boards and perpendicular to the plane of the wall boards.
PCT/SE2007/001026 2006-11-17 2007-11-19 A wall system as well as a wall board and a method for building a wall WO2008060230A1 (en)

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SE0602468A SE0602468L (en) 2006-11-17 2006-11-17 Wall system and wall board and method of building a wall
SE0602468-1 2006-11-17

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EP2089587A4 (en) 2014-10-22
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