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Publication numberUS1874922 A
Publication typeGrant
Publication dateAug 30, 1932
Filing dateJul 10, 1929
Priority dateJul 10, 1929
Publication numberUS 1874922 A, US 1874922A, US-A-1874922, US1874922 A, US1874922A
InventorsTrust Co Union Bank
Original AssigneeTrust Co Union Bank
Export CitationBiBTeX, EndNote, RefMan
External Links: USPTO, USPTO Assignment, Espacenet
Building material
US 1874922 A
Abstract  available in
Previous page
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Claims  available in
Description  (OCR text may contain errors)

Aug. 30, 1932. J. H. DELANEY 1,374,922 I BUILDING MATERIAL I I Filed July 10, 1929 2 Sheets-Sheet 1 w g/4 w INVENTOR.




This invention relatesto building material, and especially to foldable boards that can be utilized to form cellular compartments, or hollow blocks, for walls, ceilings,

floors or the like.

. object, I provide a novel process whereby creases can be 'formed in plaster board to enable columnar or cellular shapes or blocks to be'formed. Thus a knock down block is formed, easy to ship, inexpensive to manufacture, and highly practical in use.

It is. another object of my invention to provide a convenient building unit that canv be. readily attached to the beams .or studdings that support the walls or ceilings or floors;

2 and especially by the aid of overlapping or extending edges of the unitsfwhereby wall or fldor or ceiling structures can be constructed in avariety of ways, depending upon the manner in which the. units are assembled.

7 My invention possesses many other advantages, and has other objects which may be made more easily apparent frolnja consideration of a few embodiments of my invention. For this purpose I have shown several forms $0 inthe drawings accompanying and forming part of the present specification. I shall now proceed to describe these forms in detail, which illustrate the general princlples of my invention; but it is to be understood that 1 .this detailed description is not to'be taken 1 in. a limiting sense, since the scope of my invention is best defined by thej'appended -c1aims. a

Referring to the drawings:

Figure 1 is a diagrammaticplan view of a machine arranged to form the novel plaster Fig. 2 is a side elevation thereof v F 3 and 4 are perspective'views of two forms of laster board made in accordance with my invention; Fi 5 is an end view showing how plaster boar constructed in accordance with Fig. 3

can be formed into a hollow block;

5 Fig. 6 is a view similar to'Fig. 1'5, but show-,

1929, Serial 110. 877,207.

ing how the plaster board of Fig. 4 can used to form a hollow block or conduit- Fig. 7 is a sectional view of a wall, ceillng, or floor structure utilizing my invention Fig. 8 shows a modified form of my invention, utilized in connection with a floor structure;

Fig. 9 is a perspective view-f a ioldable l plaster board that is a modification of the form shown in Fig. 3;

Fig. 10 is a plan view of the board shown 1 in Fig. 9, in folded position ,1

Fig. 11 'ndicates'how o'e' variety ofthe I .board can be used to form a wall or partition 'insuch a way as completely to encompass or I modification of the foldable board.

. Theapparatus for making the plaster board can in general be similar to that disclosed in my prior application, Serial No.

278,537, entitled Wall covering and method of making same, and filed on May 17,1928.

The machine is shown, therefore, merely diagrammatlcally. It can be made so that the board is manufactured first in a continuous length, cut later'oninto standard widths and lengths; or else the board can be manufactured in predetermined sizes. In the form shown in Figs. 1 and 2, the process of manufacturing is shown as carried, on to form-a continuous length of plaster board, the plastlc-filling being accommodated between a air of paper or cardboard-backin 11 an 12,

taken from supply rolls not s own. These backings form relatively flexible supports for the filler material.

The bottom backing 11 is shown as fed over a guide roll 13 and a table 14. :Above the table is ositioned'a hopper 15 into which the plasticler material can be placed for deositing it onto the backing 11. This plastic ling, as disclosed in my prior application,

can be an effervescent gypsum mixture, to form cells and voids in the finishing filling;

- or else there can be added a large percentage;

of zonolite, pumice, or other porous materi or mixtures thereof. Optionally, such poros- The material 16 delivered from opper onto the moving backin'g'material 11 is spread to form a substantially uniform and a relatively thick layer by the aid of the stationary shown, spaced apart uniformly. This is the bars 17 placed transversely above table 14.

The upper backing material 12'is fed over a roller. 18 and onto the material 17. One or more rolls 19 serve to form the three-layer material to definite thickness.

As thus far described, the. apparatus is in no wise materially different from that disclosed in my prior application. Before continuing with the description of the apparatus,

. attention is invited to the form of the product creases, such as 2 24, 25, are provided, so-

that the plaster board can be folded on the creases to form a hollow conduit or block,

or to facilitate placing the board to form angles at the creases. Thesecreases as indicated in Fig. 3, can be made'in both the top and bottom, so that the backings 21, 22, nearly touch at or near a point intermediate between the two main surfaces of theboard- In Fig. 4, a form of board is shown' that has but one backing 26. The filling 27 is, however, creased as indicated at 28, 29, 30, to permit folding at these lines. Filling 20, 27 can be solid or porous, as hereinbefore mentioned. The single backing form of Fig. 4can be made by leaving oil the top backing material 12 while the machine of Figs. 1 and 2 operates.

In the form of the machine disclosed, the creases are formed longitudinally of the backing materials by the aid of driven creasing rolls 31, 32 disposed either on top, or both on top and bottom of the plaster board as'it leaves the rolls 19, and while the filling therein is still plastic. Greases 33, 34, 35 can thus be formed. The creaser shoulders '36 on rollers 31, 32 can be arranged thereon in such a way as to secure the desired spacing and number of the creases; and it is intended that there'be supplied a number of sets of creaser rollers with, different spacings and arrangement of the creasing shoulders thereon,

After the board passes the creasing rollers 31, 32, it may be preferable to subject it to another set of smoothing or pressure rolls 36.

Thence the material can be cut and dried in any well understood manner. I

The uses of the .creased material are many and varied. For example, hollow conduits resisting material. Any form of column can be thus covered, by using appropriately proportioned creased boards.

As an example of the mode in which the creased board can be utilized to form insulating partitions, attention is called to Fig. 7. In this instance, wood studdings 40 are usual form of wall supports for houses. Between the studdings are'pla'ced the rectangular hollow blocks 41, of the general. form shown in Fig. 5. The short side 42 can first be nailed to the inner face of a studding, in such a way that its top edge is flush with the end surface ofthe studding. Thenthe opposite side 43'can be correspondingly nailed onto the contiguous studding face, and the long, upper side 44 can be folded over to complete the block, the extending edge'45 covering the edge of the studding, andnailed thereon. The space between the studdings can thus be completely covered.

Since the top sides 44. of 3.11 the blocks thus formed provide a substantially continuous surface, and since the material from which the hollow block is made is non-inflammable,

the efiect is that a partition of substantially fire proof'character is provided. Ordinarily,

a single layer of such hollow blocks is sufl'i-v sulating or sound deadening material, such as hair felt, pumice, or the like The blocks can be used not only for wall partitions, but for many other purposes, such as ceilings and floors. In Fig. 8, I show a :floor structure utilizing my new materiaL' Upon a supporting'member 47 are fastened as by nailing, series of hollow blocks 48, filled if desired with fireproofing or heat insulating or sound deadening material. The blocks in this instanceare shown as trapezoidal in form, and as having extending edges- 49,.

whereby grooves such as 50 can be formed between the blocks.' Into these grooves and above the blocks can be placed material 51" such as concrete or the like. to form the floor surface. The trapezoidal form of the blocks 48 provides a rigid supporting structure for material 51.

It is sometimes unnecessary that all four sides of the hollow block be of the same thick-- ness;- as for example, in Fig. 7, the external faces of the block only, need to be strong so as to support the finish layers, such as smooth plaster or stucco. In the form of block illustrated in Figs. 9 and 10, only the top side 52 is heavy, the other sides 53, 54, 55 thin.

. This effect can obviously be secured by the aid of rollers acting on the material in the course of manufacture, and while the plastic material is still pliant.

In Fig. 11 I show a scheme whereby the i studding fora partition can be entirely encompassed by the blocks. In this instance, in stead of wood studdings, I show evenly spaced structural iron columns 56. Around each column a block 57 is placed, the block being long enough to fillall the intervening distance from column to column. The columns are thus located next to a short side of the block, which can be filled in with heat insulating or fire proof or sound absorbing material 58. To hold the blocks to the columns, clips 59, struck up from the columns, can be used. Furthermore, to prevent slipping between the blocks where they abut, av projection 60 can be provided on one side of each block, fitting into a corresponding roove in the contiguous face of the adjacent lock. Thus a keying effect is provided.

It is of course understood that as many courses of the blocks shown in Figs. 7, 8 and 11- are used as necessary to complete the desired partition, wall, ceiling or floor. Thus in effeet I provide a knock down building block that is easy to ship,1ight in weight, and inexpensive to manufacture. It furthermore has highly desirable fireproofing and sound absorption qualities.

'In Fig-.12, the hollow blocks 61 are shown as supported similarly to those of Fig. 7 but there are added the metal rest bars 62 to provide strength, as for a flooring.

In Fig. 13, I show a creased board 63 in which the creases 64 in each backing 65 extend substantially as deeply as the thickness of the board, the sides 0 the opposite creases be 40 ing in contact. In this way, the bending of the board 63 in either direction is facilitated, the bend being accomplished at either of the I two creases.

I claim:

1. Building material havin a relatively thin flexible backing, and a ller layer attached to the backing, said filler layer having parallel creases across it, said creases being substantially V-shaped, the apex of the creases being close to the backing, and the filler material betweensome of the creases being thinner than between other creases. 1

2. Building material having a pairof relatlvely thin flexible backin and a filler layer between the backings am f attached thereto, said material having a plurality of parallel creases across it, said creases being substantially V-shaped the apex of the creases bein close to the backing opposite the creases, and

the' filler material between some of the creases being thinner than between other creases.

In testimony whereof, I have hereunto set my hand.


Referenced by
Citing PatentFiling datePublication dateApplicantTitle
US2523861 *Apr 2, 1946Sep 26, 1950Buttress George AMethod of finishing end edges of plasterboard
US2712169 *Aug 3, 1951Jul 5, 1955Buttress George AMachine for severing a ribbon of plasterboard to form plasterboard panels and finishing the ends of the panels
US3079289 *Nov 1, 1955Feb 26, 1963Lockheed Aircraft CorpHigh dielectric constant material and method of making same
US3903663 *Jun 3, 1971Sep 9, 1975Winnebago Ind IncPick-up cover
US3909995 *Aug 19, 1971Oct 7, 1975Winnebago Ind IncPick-up cover
US4781558 *Sep 26, 1986Nov 1, 1988The Celotex CorporationApparatus for making an embossed gypsum panel
US4842786 *Oct 3, 1988Jun 27, 1989The Celotex CorporationMethod for producing an embossed gypsum panel
US5840392 *Sep 4, 1997Nov 24, 1998Clark; Kevin H.Self-adhering duct insulation board
U.S. Classification428/162, 428/163
International ClassificationE04C2/40
Cooperative ClassificationE04C2/405
European ClassificationE04C2/40B