These and other features and advantages of the invention will become apparent from the following detailed description of preferred embodiments, in which:
FIG. 1 is a cross-sectional view of a partition wall and showing a cross-section of an abutment for providing a flat fair end to the partition wall;
FIG. 2 is a cross-sectional view of a partition wall and showing a cross-section of an abutment for providing a radius end for the partition wall;
FIG. 3 is a cross-sectional view of two partition walls running at right-angles to each other and showing a cross-sectional view of an abutment joint which provides a right-angled join between the two partition walls on an inside surface and which provides a curved join on an outside surface;
FIG. 4 is a cross-sectional view illustrating a cross-sectional view of an abutment for providing a join between a window mullion and a partition wall;
FIG. 5 is a cross-sectional view of an abutment that provides a join between a partition wall and another wall running at ninety degrees to the partition wall;
FIG. 6 is a cross-sectional view illustrating an abutment which can be used at the end of a partition wall to provide a join with a glass partition which runs at ninety degrees to the partition wall;
FIG. 7 is a cross-sectional view illustrating an alternative abutment which can be used to define a fair end for a partition wall;
FIG. 8 schematically illustrates the abutment shown in FIG. 1 when used with plasterboards having a tapered end at the join with the abutment;
FIG. 9 is a flow chart illustrating one method that can be used to make the elongate plaster abutments illustrated in cross-section in FIGS. 1 to 8; and
FIG. 10 is a flow chart illustrating another method that can be used to make the elongate plaster abutments illustrated in cross-section in FIGS. 1 to 8.
EMBODIMENTS
FIG. 1 is a cross-sectional view (in a horizontal plane) illustrating the end of a plasterboard partition wall 1. As is well known the partition wall 1 is defined by a central framework of vertical studs (which may be wood or metal), one of which is shown in FIG. 1 and referenced 3. The outer surfaces of the partition wall 1 are defined by two parallel runs of plasterboard 5-1 and 5-2, which are attached to the stud work 3 (usually by fixing screws, not shown). FIG. 1 also illustrates the cross-sectional view of an elongate abutment member 7-1 which typically runs vertically, from floor to ceiling. In this embodiment, the abutment member 7-1 provides a fair end 9 to the partition wall 1 and is preformed as a fibre and plaster moulding. Typically, the abutment member 7 will be moulded in lengths of 3 (or more) metres and then cut to size to fit between the ceiling and floor. As illustrated in FIG. 1, the abutment 7-1 also includes one or more wood laths 111 that extend along the length of the abutment member 7-1 adjacent the surface 13 which abuts against the end of the partition wall 1. The wood laths act as a fixing substrate, for allowing the abutment member 7-1 to be fixed to the stud 3 by appropriate fixing screws (not shown). The wood laths also provide strength to the abutment member 7-1.
FIG. 1 also shows that, in this embodiment, the abutment member 7-1 has tapered sides 15-1 and 15-2, which extend between the abutment surface 13 and two side walls 16-1 and 16-2. As illustrated in FIG. 1, the width (W) of the main part of the abutment member 7-1 is chosen so that the two side walls 16-1 and 6-2 lie in the same planes as the respective outer surfaces of the plasterboards 5-1 and 5-2. As a result of the tapering sides 15-1 and 15-2, spaces 17-1 and 17-2 are provided that facilitate the application of a skim of plaster in this join region to provide a “seamless” join between the abutment member 7-1 and the plasterboards 5-1 and 5-2. Further, as the abutment member 7-1 is formed from a plaster material, there is no need to pre-treat the abutment member 7 before applying the plaster skim.
In an alternative embodiment in addition to the application of a skim of plaster in the join region a skim of plaster is applied on the partition wall. Alternatively a wall covering, such as wallpaper, is applied to the partition wall and abutment depending on the desired finish.
As those skilled in the art will appreciate, partition walls 1 come in various different standard thicknesses depending on the width of the stud 3 and the plasterboards 5. Therefore, in this embodiment, abutment members 7-1 having different widths (W) are provided. Standard stud widths for use in the UK include 50 mm, 75 mm, 100 mm and 145 mm. For other countries similar standard widths would be provided depending on the standard widths of partition walls used in those countries. Further, the thickness (Th) of the abutment member 7-1 can also be varied depending on the application. In the embodiment illustrated in FIG. 1, the thickness is approximately 30 mm, with the tapered sides 15-1 and 15-2 starting 5 mm below the fair end surface 9. The angle of the taper can also vary, depending on the application. In this embodiment, the angle is chosen so that the abutment member 7-1 provides a recess of 3 mm at the abutment surface 13 on each side of the partition wall 1, but a figure of between 1.5 mm and 6 mm is practicable. Recesses of this size provide adequate space to allow the plaster skim to be applied and “keyed” into the join, but are not too large to cause the plaster skim to crack when dry.
In an alternative embodiment in which a plaster skim is applied to the partition wall as well as the recess the width of the abutment will be such that it will be the same thickness as the partition wall and the plaster skim combined. Alternatively, and depending on the application, the abutment will be the same width as the thickness of the partition wall without the plaster skim and as such the abutment will also receive a covering skim of plaster. In this alternative the thickness of the plaster skim may be tapered down to the abutment in the region of the recess.
When assembling the partition wall, the abutment member 7-1 may be prefixed to the stud 3 before the plasterboards 5-1 and 5-2 are attached. This offers the advantage that the abutment member 7-1 can be attached to the stud by inserting screws through the stud 3 into the wood lath 11. This is advantageous, because the fair surface 9 of the abutment member 7-1 does not have to be damaged by insertion of screws and then filled using an appropriate filler. Once the abutment member 7-1 is attached to the stud 3, the plasterboards 5-1 and 5-2 can then be fixed to the stud 3 in a conventional manner. The spaces 17-1 and 17-2 defined by the tapered sides 15-1 and 15-2 of the abutment member 7-1 can then be filled with an appropriate skim of plaster leaving a seamless join between the plasterboards 5-1 and 5-2 and the abutment member 7-1.
Alternatively, the abutment member 7-1 can be fixed to the end of the partition wall 1 after the plasterboards 5-1 and 5-2 have been secured to the stud 3. In this case, however, the abutment member 7-1 has to be secured to the stud 3 by drilling holes through the fair surface 9 of the abutment member 7-1 or has to be glued to the partition wall.
The abutment member 7-1 illustrated in FIG. 1 offers a number of advantages over the traditional techniques for providing similar fair end posts at the end of a partition wall. These advantages include:
(i) As the abutment member 7-1 is formed as a fibre and plaster moulding, accurate fabrication is possible. This means, for example, that the abutments can be made completely straight along its length which makes it easier for the builder to ensure that the partition wall is also vertical. Further, as the abutment is made of plaster, a skim of plaster can be directly applied to the surface of the abutment without pre-treatment.
(ii) As no metal angles or plasterboards need to be cut and taped and jointed to form the end post, the time taken to erect the partition wall is reduced, thereby making it cheaper to erect such partition walls.
In the embodiment shown in FIG. 1, the abutment member 7-1 has a flat fair end 9. FIG. 2 illustrates an alternative cross-section of an elongate abutment member 7-2 which provides a radius or curved fair end 21. The remaining features of the abutment member 7-2 are the same as those of the abutment member 7-1 shown in FIG. 1 and will not be described again.
In addition to providing end posts, the abutment member 7 may be used for joining two partition walls which run at angles to each other. FIG. 3 illustrates the cross-section of an elongate abutment member 7-3 which can be used for connecting two stud walls 1-1 and 1-2, which run perpendicular to each other. As illustrated in FIG. 3, the abutment member 7-3 in this embodiment includes four tapered sides 15-1, 15-2, 15-3 and 15-4 and is arranged to provide a curved outer surface 31 in the join between the two partition walls 1-1 and 1-2 and to provide a right-angled join 33 on the inside surface of the partition walls 1-1 an 1-2.
As those skilled in the art will appreciate, other types of abutment members 7 can be provided for connecting partition walls 1 which run at different angles (not necessary at right-angles). Further, the abutment member 7 may also be modified to provide a right-angled edge on the outer surface 31 as well as the right-angled edge 33 on the inner surface. Similarly, the inner surface 33 may also be curved to provide a curved inner join between the two partition walls 1-1 and 1-2.
In addition to providing end posts for a partition wall 1 or for providing a join between two partition walls 1-1 and 1-2, the abutment member 7 can also be used as the join between the start of a partition wall and an existing design detail within the building. FIG. 4 illustrates an example of this. In particular, FIG. 4 illustrates the cross-section of a window mullion 35 having a radius (curved) end face 37. FIG. 4 also illustrates a cross-sectional view of a plaster moulded abutment member 7-4 that has been moulded to have a curved inner surface 39 matching the curved profile of the mullion 35. FIG. 4 also illustrates that the abutment member 7-4 abuts against the partition wall 1 in the same way as in the embodiment described with reference to FIG. 1. As illustrated by the dashed lines 41 and 43, tapered sides may also be provided at the join between the mullion 35 and the abutment member 7-4. As before, these tapered sides provide space to allow a skim of plaster to be provided in the region of the join between the mullion 35 and the abutment member 7-4 to make a seamless joint between the two.
FIG. 5 is a cross-sectional view illustrating the form of another elongate abutment member 7-5 that can be used to define the start of a partition wall 1 from an existing wall 51 running perpendicular to the partition wall 1. Wall 51 may also be a partition wall or it maybe a brick wall or the like. As shown in FIG. 5, the abutment member 7-5 includes the same two tapered sides 15-1 and 15-2 adjacent the join with the partition wall 1. The abutment member 7-5 also includes tapered sides 15-3 and 15-4 around the join with the wall 51. As before, the tapered sides 15-3 and 15-4 provide a space for a skim of plaster to be provided in the join area, thereby allowing a seamless join with the wall 51. As illustrated in FIG. 5, the abutment member 7-5 also includes a second wood lath 11-2 adjacent the second abutment surface 55, for allowing the abutment member 7-5 to be secured to the wall 51 using suitable fixing screws (not shown). Instead of or in addition to such fixing screws, cement or glue can be provided in the boundary between the wall 51 and the second abutment surface 55 for securing the abutment member 7 to the wall 51.
In addition to providing a join between two partition walls running in different directions, the moulded abutment 7 can also be used to provide a join between a run of partition wall 1 and a glass partition. The cross-section of an appropriate elongate abutment member 7-6 for this purpose is illustrated in FIG. 6. As shown, the abutment member 7-6 includes a U-shaped recess 56 into which the end of a glass partition 57 can fit. FIG. 6 also shows that the abutment member 7-6 includes a second abutment surface 58 which is for abutment against the right hand plasterboard 5-2. The remaining components of the abutments member 7-6 are the same as those shown in FIG. 1 and will be not, therefore, be described again.
In the above embodiments, the abutment member 7 was arranged to have one or more tapered sides 15 near the join with the plasterboard 5. As those skilled in the art will appreciate, it is not essential to have such tapered sides. Instead, an abutment member 7 may be provided with sides that are designed to lie flush with the outer surface of the plasterboard 5. In this case, tape or other filler could be used to cover the join between the abutment member 7 and the plasterboard 5. In a further alternative, as illustrated in FIG. 7, the abutment member 7-7 may be arranged to have stepped recesses 59-1 and 59-2 near the join with the plasterboards 5, to allow space for a skim of plaster to be applied to each recess to provide a seamless join between the abutment member 7-7 and the plasterboards 5.
In all of the embodiments described above, standard square edge plasterboard 5 has been used. In an alternative embodiment, as illustrated in FIG. 8, plasterboards 5 having a tapered edge 61-1 and 61-2 may also be used to provide larger areas around the joins between the abutment member 7-1 and the plasterboards 5 into which a skim of plaster can be made to provide a seamless join.
In the above embodiment, one or more wood laths were cast within and along the length of the elongate abutment members 7. The wood lath provided a fixing substrate for allowing the abutment member 7 to be fixed to the stud 3 of the partition wall 1 using fixing screws. As those skilled in the art will appreciate, other fixing substrates could be used to achieve this purpose. For example, one or more laths may be made out of metal (such as ferous metal or aluminium) or out of any other rigid product. In addition to providing a fixing substrate, the laths also act to strengthen the elongate abutment members 7. In addition to providing the laths, a separate metal, wood or rope core may be cast within the elongate abutment member 7 for providing further strength.
A number of different elongate plaster abutments 7 have been described above. These abutments 7 can be formed either by cutting wet plaster from an elongate rectangular block of plaster or by moulding the plaster using a suitable mould formed from one or more mould pieces. A description will now be given of the way in which a prototype abutment 7 was made by cutting plaster from an elongate block. A description will then be given as to how this prototype can be used to form a latex moulding which can then be used to make a number of similarly profiled abutment members 7.
FIG. 9 is a flow chart illustrating the steps performed to make a prototype abutment member 7. As shown, in step s1, a zinc profile for the required shape of abutment is cut. A smooth plaster mix is then made by mixing 20 litres of water with due proportion of herculite and kermicast. In step s3, a layer of this plaster mix is applied to an elongate rectangular bench mould and a 300 mm width by 3 m jute scrim is incorporated into this layer of plaster. In step s5, four laths are incorporated into the plaster for flat fixing with the stud 3 and two laths are incorporated into the plaster for providing strength to the edge of the abutment member 7. In step s7, a rope scrim is added to the centre of the plaster and the remaining plaster mix is added. Finally, in step s9, the zinc profile is run over the wet plaster until the required shape is cut out and the abutment member 7 is formed.
As those skilled in the art will appreciate, all of the abutment members 7 described upon may be manufactured using this technique. However, for ease and efficiency of manufacture, the abutment members 7 are preferably formed from a suitably shaped mould. FIG. 10 is a flow chart illustrating the main steps for a production process for making the above described abutment members. As shown, in step s13, the prototype abutment member made in the manner described above is used to make a latex mould. This involves placing the prototype abutment member 7 within an open top watertight container which is wider than and as deep as the prototype abutment. Latex rubber is then poured over the model and is prevented from leaking by the container. Once the rubber has set, it is peeled off the prototype abutment and is ready for use as the mould for production.
In step s15, the thus formed latex mould is part filled with a base of plaster with GRG matting (200 mm wide by 3 m long) inserted into the plaster together with 2 laths for fixing. GRG matting is formed from fibres similar to those used to make fibre glass boats. Then, in step s17, after the base of plaster has hardened the main plaster mix is added to fill the latex mould. In step s19, once all plaster and reinforcements have been incorporated into the mould, a recess is made along the length of the top of the plaster mould for studding purposes. Finally, once the plaster has hardened, the moulded abutment member 7 is removed from the mould. The mould can then be used again to make another abutment member 7 of the same profile.
It will be understood that the present invention has been described above purely by way of example, and modifications of details can be made within the scope of the invention.
Patent Application
20070245654
