AU688753B2 - Plasterboard support and cavity spacer - Google Patents

Description

-1I-

AUSTRALIA

Patents Act 1990

S

S S *5 S. 55 4 S

S

S.

56 555 5555 5555 *5 S S 5*S* HANFORD PTY LIMITED

ORIGINAL

COMPLETE SPECIFICATION STANDARD PATENT

*SSS

S.

VS S 0

S

5555 *5 S *5 555055

S

Invention Title: Plasterboard Support and Cavity Spacer The following statement is a full description of this invention including the best method of performing it known to us:- 2 PLASTERBOARD SUPPORT CAVITY SPACER The present invention relates to a structural support for plasterboard or similar internal lining material used to supply a finish to the interior surface of concrete or masonty walling. Plasterboard and other lining materials are normally between 4mm 16 mm thick and are manufactured in a variety of sheet sizes. The term "plaster board" as used in this specification is to be taken to include any type of sheet lining material for buildings.

Plasterboard sheets when used for wall lining are designed to be fixed to a structural framework constructed of timber or metal. The plasterboard fixing to the framework is accomplished by mechanical means such as 15 nails for timber frames and "self tapping" screws for *9g9 metal frames or a combination of either nails or screws and a suitable type of adhesive. In most cases the mechanical fixing means is used to hold the plasterboard sheeting in position temporarily until the adhesive sets.

20 Of the two mechanical fixing methods the nailing technique is by far the most popular and cheapest method as it requires no special screws or screw guns and eeoc therefore is easier and faster.

In some applications plasterboard sheets are fixed 25 onto a masonry wall to give it a satisfactory surface finish instead of the usual surface application of 0 Portland cement iR-jrtar render. There are two common methods used to fix the plasterboard sheet to masonry walls, the sheets being glued or bonded directly to the masonry wall or fixed to a light or sub framework such as timber or metal battens. These battens are usually mechanically fixed onto the masonry wall prior to the plasterboard sheet fixing operation which is both difficult and expensive, requiring special masonry fixings and equipment.

Because batten sections are much smaller than normal walling studs they are usually made from metal, as timber, in these small sections, is unstable at lengths longer than one metre. Being metal makes it unpopular with plasterboard fixers as the plasterboard sheeting has to be screwed to the sub framing instead of the simpler nailing method. Similarly wheni the plaster board is bonded directly onto the masonry wall temporary props have to be deployed to support the plasterboard sheets -until the bonding glue sets.

In many cases a plasterboard lining is required onl the inside of anl external masonry wall which is subjected to moisture penetration onl its external surface from weather elements. As plasterboard is easily damaged by water it is necessary in this case to create a cavity or air space between the masonry wall and the plasterboard sheeting.

The present invention consists in a composite laniniated lath for fixing plasterboards, comprising a first elongated element having at least four sides and composed of a compressive lightweight resilient material selected from the group consisting of a rigid material and a semii-rigid material and a second elongated element overlying said first elongated element and composed of a material which is denser than a material of said first elongated element and which is penetrable by at least one fixing element selected from the group consisting of screws and nails and also is hard, dense and resilient enough to hold onto the fixing element after penetration, said first and second elongated elements having interlocking shapes so that in anl assembled condition these elements are held together because of said interlocking shapes.

In a further aspect the present invention consists in a Plasterboard assembly comprising a plasterboard sheet and a plurality of spacing elements connecting said plasterboard sheet with a framework and spaced from one another in a transverse direction, each of said spacing elements including a first elonigated element consisting of a compressive lightweight resilient material selected from the group consisting of a ripjO material and a semiirigid material, and a second elongated element overlaying said first elongated element and composed of a material which is denser than a material of said first elongated element and which is penetrable by at least one fixing element selected from the group consisting of screws and nails av,.A also is hard, dense and resilient enough to hold onto the fixing element after penetration, said first and second elongated elements having mechanically interlocking shapes so that in an assembled condition these elements are held together because of said interlocking shapes.

A composite laminated lath for fixing plasterboard substantially as hereinbefore described with reference to any one of figures 1 to 5 of the accompanying drawings.

The invention described herein provides a new type of composite laminated batten that is simple to fix to masonry walling, can receive nails or screws and is inexpensive. It consists of a lightweight, rigid resilient material in a batten form that is very light, relatively soft, will bond easily, requiring no temporary support and because it is relatively pliable will generally conform to the deformations and contours of the masonry wall.

Attached to one side of the softer resilient material is a layer of more dense material which is attached by shape. The two layered laminated 4batten is bonded or mechanically fixed to the masonry wall with the interface of the masonry wall and the softer resilient material being the surfaces bonded together.

When used together in this way the lamination provides a batten that is easily bonded to the irregular surfaced masonry wall having a dense harder surface on the other side to which a suitable lining material sheeting can be easily nailed.

The softer resilient material absorbs and transfers to the masonry wall the shock of the hammer force as the nail is being driven home. The denser harder layer that is being nailed to holds or anchors the nail in that position which in turn holds the plasterboard sheet and 9 allows the adhesive to set, bonding the plasterboard to the batten.

9999 The properties of the resilient material are important, and in comparison with timber or metal is relatively soft, offering almost no resistance to nail penetration. It must however have sufficient compressive 20 resistance and resilience to spread forces or compressive .9 9 loadings evenly over the irregular surface of the masonry wall that occur during it's installation and serviceable 9*9* lifetime.

In this sense it performs in an absorbing and 25 elastomeric fashion, locally deforming to the irregular masonry surface when loadings or forces are applied and a returning generally to it's original shape. This action is most pronounced during the nailing operation described above, the force of the hammer blow needed for the nail to penetrate the harder and denser layer causes the material to deform to the irregular contours of the masonry wall surface and in doing so absorbs and spreads the shock, transferring the balance of it onto the masonry wall which has the necessary mass to absorb easily.

An important feature of this resilient material is 5 that it absorbs, deforms and evenly spreads the shock forces and that it does not rebound quickly or violently and break the bonding to the masonry wall, however it's resilience will allow it to slowly recover mostly to it's original shape.

The harder and denser layer requires suitable properties for a nail to be driven into or through it and hold the nail firmly, alternatively if a screw is used it must also hold that firmly. Being a much denser material it will transfer most of the shock to the softer resilient layer.

Fig. 1 is an exploded view showing the two components of a batten according to the invention, separated, Fig. 2 is also an isometric view showing the two 15 elements secured together, 9 Fig. 3 is a sectional plan view of a section of walling showing plasterboard secured to a masonry wall by battens according to the invention, Fig. 4 is a view similar to Fig. 3 showing an 20 alternative form of construction, Fig. 5 is a similar view showing a batten according to the invention arranged adjacent a window opening, Fig.

6 is an elevation of a section of a wall showing lengths 9* of batten bonded to masonry, 25 Fig. 7 is a plan view similar to Fig. 3 showing an alternative form of construction, and Fig. 8 is an isometic view of the form of construction shown in Fig. 7.

Fig. 1 shows a length of compressibly resilient material 1 and a length of metal 2. The metal portion 2 is attached to the compressive material 1 by reason of its dovetailed shape enabling it to fit snugly over the dovetail shape of the compressive material which prevents the two from direct horizontal separation. An adhesive 6 may be used to bond the materials together if considered necessary.

In Fig. 2 the two elements 1 and 2 are shown secured together to form a batten according to the invention.

Fig. 3 is a plan view of two battens each made up of a compressively resilient part 1 and a metal portion 2, in position, bonded by adhesive 8 to a masonry wall creating a cavity 6. The plasterboard or lining material 3 is bonded to the metal portions 2 of the battens by an adhesive layer 7.

Fig. 4 is a view similar to that of Fig. 3 showing the use of an enlarged element 1 of the batten which *e* provides an air space 6 and permits the installation of insulation 4.

15 Fig. 5 is again a view in plan similar to Figure 3 but showing a batten of somewhat different cross-sectional shape secured to a masonry wall by an adhesive 8. A layer of insulating material is interposed between the fibrous plaster sheets 3 and the metal element 2 of the batten. A 20 window opening is indicated at 9.

Fig. 6 shows an elevation of a section of a wall incorporating a window 9 and a door opening 10, Lengths of batten 12 are shown bonded to a masonry wall 5 ready to receive a covering layer of fibrous plaster. A stud wall 25 intersection is in dicated at 11.

A suitable softer resilient material would be semi rigid polystyrene foam, dense enough to absorb and transfer shock but flexible enough to follow the general contours of the masonry wall surface. Many other types of foam materials would also be suitable provided their properties were able to perform the same function. The density for this resilient layer would range from slightly less than 10 kgs/m3 to 70 kgs/m3. Polystyrene foam would also be suitable for some applications.

7 The density and the type of the foam would vary depending on the degree of irregularities on the masonry surface. It is also preferred that the foam material not transmit moisture from the wall to the hard skin and if it is absorbent, as many are, that it be not prone to rot.

A commercially available material suitable for use for the purposes of the invention is manufactured and sold under the registered trade mark "ISOLITE" by Rmax, a division of Olympic General Products Pty Ltd. This is a block moulded flame retardant modified grade of EPS (expanded polystyrene). This material is sold in various classes of which class L and SL are the most suitable for purposes of the present invention. Full details of the physical and mechanical properties of this material are 15 available from the manufacturers.

S. A suitable very dense hard thin skin layer would be metal of approximately .4mm 2 mm thick ranging between 2,650 kgs/m3 to 7,800 kgs/m3, the material must be hard, dense and resilient enough to hold onto a driven nail or 20 screw after penetration. The nail can have small serrations on it's shank to assist performance if required. The hard layer's sectional design can vary considerably and must enable it to flex readily so that it too can conform to the overall full height contour, if 25 that is required, of the masonry wall.

Another suitable dense but thicker material would be timber of 10 mm to 50 mm thick with a density of 300 kgs/m3 to 1000 kgs/m3 which also would have to hold onto a driven nail or screw. In larger thicknesses and higher densities difficulty will be experienced with s'raightness and stability of the timber.

The softer resilient material can be altered in section size and shape to allow a cavity of varying width to be formed between the plasterboard and the masonry wall, either to be used as an air space or to position Y' I 8 insulation (FIG vapour barriers or moisture barriers.

Although the two components work exceptionally well together the softer resilient material need not necessarily be continuous. This however depends on the sectional stiffness of the hard dense layer and the nailing spacings require to fix or hold the plasterboard sheet.

In a preferred application the batten is not continuous and is just a series of short pieces spaced apart to suit the spanning ability of the lining material as is shown in FIG 6. The batten can also be used to be fixed horizontally for other fixing applications or to **assist in attaching service conduits.

The softer resilient material can be bonded to the 15 masonry wall with a variety of adhesives, if the masonry Swall has an exposed external surface both the softer resilient material and the adhesive must not be able to be damaged by moisture. If a moisture barrier is required there are several types of adhesives that also act as a 20 moisture barrier to prevent any absorption of moisture, this is one of several solutions to this potential problem.

Another example of the application of this invention is shown in Fig. 7 and Fig. 8 in which the external wall requires the lining 3 to be insulated with a similar 25 polystyrene or polyurethane material 4 as is being used as the resilient material in the laminated batten. In this case the softer resilient material and the wall insulation material are made of the same material and therefore can be made in one piece and incorporated in sheet form.

Fig. 7 is a plan view similar to Fig. 3 but instead showing the batten system where the soft resilient material 1 is incorporated into the insulation material 4 in a sheet form, The sheet insulation material 4 is bonded to the masonry wall 5 or mechanically fived through 9 the hard dense skin 2 into the masonry wall 5. The performance of this type of batten system would be similar to all other types described herein and similarly the hard dense skin 2 need not be continuous -nd could be installed vertically or horizontally.

The laminated batten in this form of contribution, has become an integral part of the insulation sheet material, this can only occur when the properties of the insulation material and the softer resilient material are identical.

Fig. 8 is an isometric view showing how the insulation sheet material 4 can be slotted or grooved to allow the hard dense material 2 to mechanically lock onto it.

15 This is achieved by forming or cutting twin parallel angled slots into one face of the sheet insulation material to form the dovetail outline so as to allow the dense hard material 2 to fit into and lock onto the dovetail section so formed on the face of the sheet 0** 20 Insulation material.

It will be appreciated by persons skilled in the art that numerous variations and/or modifications may be made to the invention as shown in the specific embodiments without departing from the spirit or scope of the 25 invention as broadly described. The present embodiments are, therefore, to be copsidered in all respects as illustrative and not restrictive.

Claims (6)

1. A composite laminated lath for fixing plasterboards, comprising a first elongated element having at least four sides and composed of a compressive lightweight resilient material selected from the group consisting of a rigid material and a semi-rigid material and a second elongated element overlying said first elongated element and composed of a material which is denser than a material of said first elongated element and which is penetrable by at least one fixing element selected from the group consisting of screws and nails and also is hard, dense and resilient enough to hold onto the fixing element after penetration, said first and second elongated elements having interlocking shapes so that in an assembled condition these elements are held together because of said interlocking shapes.

2. A composite Inminated lath as claimed in claim 1. in which the second elongated eleient is channel-shaped.

3. A composite laminated lath as claimed in claim 1 or claim 2, in which the first elongated element has a first dovetail formation while the second elongated element has a second dovetail formation engaging with said first dovetail formation, said formations comprising the interlocking shapes.

4. A composite laminated lath a, claimed in clai;ii 1 or claim 2, in which the first elongated element has a dovetail section while the second element is formed as a sheet provided with a dovetail portion engaging in said dovetail section of said first element, aid dovetail portion and section comprising the interlocking shapes. A plasterboard assembly comprising a plasterboard sheet and a plurality of spacing elements connecting said plasterboard sheet with a framework and spaced from one another in a transverse direction, each of said spacing elements including a first elongated element consisting of a compressive lightweight resilient material selected from the group consisting of a rigid material and a semi-rigid material, and a second elongated element overlaying said first elongated elemnst and composed of a material which is denser than a material of said first elongated element and which is penetrable by at least one fixing element selected from the group consisting of screws and nails and also is hard, dense and resilient enough to hold onto the fixing element after penetration, said first and second elongated elements having mechanically interlocking shapes so that in an assembled condition these elements are held together because of said interlocking shapes.

M

6. A composite laminated lath for fixing plasterboard substantially as hereinbefore described with reference to any one of figures 1 to 5 of the accom, aying drawings, i 12 ABS2TRAC T A composite laminated batten for fixing plasterboard, the batten consisting of a length of lightweight rigid or semi-rigid resilient material. overlaid by a layer of denser material penetrable by screws or nails and secured to said resilient material. 9 too*. 0 9