Patent Publication Number: US-4221093-A

Title: Sheet metal wall module and wall formed therewith

Description:
FIELD OF THE INVENTION 
     This invention relates to an improved preformed module for forming a wall. 
     SUMMARY OF THE INVENTION 
     It has previously been proposed to provide preformed metal wall modules, as in the patents to Griebsch, U.S. Pat. No. 2,158,234 and Lamel, U.S. Pat. No. 2,256,394, and Scott, U.S. Pat. No. 2,268,907. However, these known modules were structurally complex, difficult to use, and costly to manufacture and install. These known modules also were generally incapable of providing adequate thermal insulation. 
     Accordingly, this invention relates to an improved wall module which is continuous and of light weight. This sheet metal module coacts with upper and lower 2×4 plates, with angled inner flanges on the module and 1×2 furring strips on the flanges in load supporting relation between the plates, and with the furring strips flush with the inner sides of the plates so that inner panels can easily be nailed to the plates and the furring strips. The provision of end tabs and end flanges on the side flanges of the module provide additional areas for nailing connections and strengthen the connection without interferring with economical roll forming of the module from flat stock. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The drawings, of which there are two sheets, show a preferred form of the wall module of the invention, and two alternative ways for incorporating it in a wall structure. 
     FIG. 1 is a fragmentary inside perspective view of the module as it will coact with upper and lower plate members, the plate members being shown in dotted lines. 
     FIG. 2 is a fragmentary outside perspective view of three of the modules in erected position on a lower plate member. 
     FIG. 3 is a fragmentary vertical cross sectional view taken along the plane of the line III--III in FIG. 4. 
     FIG. 4 is a fragmentary horizontal cross sectional view taken along the plane of the line IV--IV in FIG. 3. 
     FIG. 5 is a fragmentary vertical cross sectional view through a modified form of the module and wall and the eaves portion of a coacting roof. 
    
    
     DETAILED DESCRIPTION 
     The module unit indicated generally by the numeral 10 is designed to be erected in multiples in coacting relation with lower plate members 12 and upper plate members 14 to form a wall indicated generally at 16. Th plate members are standard wood stock commonly known as a 2×4, and the modules are made from thin aluminum stock of the order of 1/64 of an inch thick. The stock is shaped as by cutting and slitting and bending or rolling to provide a flat center portion 18 with rearwardly or inwardly extending side flanges 20 on each side and narrower return flanges 22 on the free edges of the side flanges. Slits at the upper and lower ends of the side flanges 20 permit the ends of the return flanges 22 to be bent inwardly toward the center portion 18 so as to form tabs 24, while the ends of the side flanges are bent over to form end flanges 26 in lapped relation to the tabs 24. Turning or bending over of the end flanges leaves a flat upper nailing strip 28 and a flat lower nailing strip 30 on the ends of the center portion 18. Desirably, the vertical height of the lower nailing strip 30 is slightly greater than the height of the lower plate member 12 to leave a lip or drip edge 32 on the module below the lower plate. The upper nailing strip 28 may be slightly shorter as it is usually protected by the eaves of a building. 
     After a section of the wall is erected, by nailing the nailing flanges 28-30 of adjacent modules to the plate members as at 34 in FIG. 2, conventional wood furring strips 36 are secured as by adhesive along and against each pair of adjacent return flanges 22. Desirably, the width of the side flanges 20 is about an inch less than the width of the plate member 12 and 14 so that a standard 1×2 furring strip may extend in abutting relation between the opposed horizontal surfaces of the plate members 12 and 14, and in flush relation to their inner vertical faces. An inner panel 38, such as dry wall or the like, is then secured by suitable means such as adhesive (not illustrated) across the inner surfaces of the plate members 12-14 and several of the furring strips 36. Especially when the panel 38 has load carrying properties, it coacts with the furring strips and the flanges of the modules in supporting the upper plate members 14. When the inner panels 38 have unfinished inner surfaces which are expected to be finished later or covered, holes 40 may be formed through the panels near their upper ends so that insulating material 42 may be introduced into the hollow space between the panels 38 and the modules 10 by blowing or flowing, after the entire wall has been erected. 
     The modified form of the module and wall shown in FIG. 5 utilizes essentially the same construction as the preferred form of the invention, except that the inner panel 38b has a finished surface and it would be undesirable to form an opening therethrough. In order to provide access to the interiors of the modules for the introduction of insulating materials, a hole or opening 40b is formed in each of the center portions 18b near its upper end. In this position the opening is sheltered under the eaves of the roof 44 and may further be protected by a soffet shown by the dotted lines at 46. 
     Desirably, the width of the module is slightly less than twelve inches. This leaves room for thin layers 48 of a caulking mastic or an adhesive between the side flanges 20 of the several modules 10, so that a standard building panel four feet wide will coact with four modules on twelve inch centers. With these and the other dimensions given, the modules provide adequate support for upper plate members, while eliminating the need for conventional studs and outer sheathing and siding. 
     A furring strip 50 (FIG. 2) may be attached to the adjacent edges of each pair of adjacent modules 10, to cover the joint therebetween, by means of screws or special nails 52 which extend into and are firmly held by the caulking 48 between the adjacent flanges 20 on two adjacent modules. This treatment gives the total an external appearance like barn siding. 
     Various changes may be made in the size and arrangement of parts of the module and wall without departing from the spirit and scope of the invention as defined in the following claims.