US 1959766 A
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Description (OCR text may contain errors)
May'ZZ, 1934. J. E. D. SAYLER WALL STRUCTURE.
Filed Ma 4, 1932 WFM J 3 Sheets-Sheet I mvgm'on May 22, 1934. J. E. D. SAYLER WALL STRUCTURE Filed May 4, 1932 s Shets-Sheet 2 INVENIII'OR May 22, 1934.
J. E. D. SAYLER WALL STRUCTURE Filed May 4, 1932 3 Sheets-Sheet 3 Patented May 22, 1934 1,959,766 WALL STRUCTURE John Elliott Daniel Sayler, Pittsburgh, Pa., as-
signor to Blaw-Knox Company, Pittsburgh, Pa., a corporation of Pennsylvania Application May 4, 1932, Serial No. 609,052
This invention relates to an improved wall unit and the wall constructed therefrom.-
The wall units may comprise an outer sheet, an inner sheet, and filler material interposed between the sheets. The outer sheet which comes in contact with the elements, and is, therefore, most likely to become corroded, is, in accordance with my invention, imperforate. The inner sheet is held to the outer sheet in a manner which will be clearly pointed out in the ensuing description and set forth in the appended claims. In the drawings, in which certain modifications of my invention are shown,
Fig. 1 is a horizontal sectional view, the section 'being taken through a wall constructed in accordance with my invention;
Fig. 2 is a plan view of the inner sheetof a wall unit to be made in accordance with my invention;
Fig. 3 is a sectional view through an inner' sheet of a .wall unit with the edge portions bent to enclose the filler material;
Fig. 4 is a sectional view at right angles to Fig. 3;
Fig. 5 is a horizontal sectional view on an enlarged scale of the wall construction shown in Fig. 1, this figure showing details of the invention;
Fig. 6 is a vertical section on line VI-VI of Fig. 5;
Fig. 7 is'a vertical sectional view through the sill of a wall comprising a unit constructed in' accordance with my invention;
Fig. 8 is a view .similar to Fig. '7 showing a modified arrangement for securing a wall. unit to the sill; Fig. 9 is a verticalsectional view illustrating the eave construction of a building, together with a modified construction for securing a unit to the sill of the building;
Fig. 10 is a detail sectional view showing a unit reinforced by a longitudinal girt;
Fig. 11 is a horizontal section illustrating a construction similar to that shown in Fig. 10 but having a screw projecting through the filler ma terial; and I Fig. 12 is a schematic sectional view illustrating the manner of anchoring a unit to the sill of the building. This view is taken on line XII-XII of Fig. 9 with the grouting removed.
In employing the term wall in the present application, this term is used broadly to include side or top walls; as my improved unit may be employed for any wall of a building, including the roof or ceiling. The unit is, as has been previously stated, made up of two sheets 'with a filler between the same. In Fig. 2, I have illustrated'the inner sheet 15 as it is stamped out of a sheet of metal. The corners are indented, as show: at 16, so that the edge portions may be 60 bent outwardly to form the box-like container shown in Figs. 3 and 4. 'I'he'longer edge por-. tions 1'7 are directed outwardly at right angles to the sheet, while the end portions 18 are first bent outwardly andthen into parallelism with the main portion of the sheet 15 6 Into this box-like container is inserted filler material 20, which may be in the form of a panel, such as a sheet or the like. This material is preferably heat insulating in its efiect, so that heat is not readily transferred through the unit. This filler material may be a felted sheet of fibrous material, or may be loose material packed within the box-like container shown empty in Figs. 3 and 4.
The outer metal sheet 21 is, as has been previously mentioned, imperforate. One or more corrugations 22 is formed in the sheet 21, but one corrugation being shownin the embodiment illustrated in Fig. 5, althoughit will be understood that a plurality of such corrugations may 30 be provided. These corrugations have vas their function not only to stiffen the outer metal sheet 21, but also to permit a screw 24 to be passed through the inner sheet and the filler material 20, the. corrugation 22 enclosing a space into 5 which the tip of the screw 24 will project.
As has been above mentioned, the filler material 20 may be of various types; and with some types, the panel of material will be strong enough to hold the threads on the screw 24. With other types of material, Ihave found it expedient to place a bridge member 26 over the corrugation, in the manner illustrated in Fig. 5. These bridge members may extend the entire length of the corrugation, or may be suflicient in extent only to make provision for receiving the screws 24. If desired, this member 26 may also be of metal, and may be soldered to the sheet 21. The screw 24 may pass through the member 26, as shown in. Fig. 5, or may stop short thereof in the manner 1 0 shown in Fig. 10.
The holes for receiving the screws or other securing means may be drilled at anytime that this is found convenient; but I prefer that the holes be drilled through the inner sheet and the 5 panel of filler material after the assembling of the parts. The screw may then be inserted and tightened up to clamp the sheets to the filler material.
The edge portions of the sheet 21 at the sides 1 I of the unit are curled over or rolled, as shown at 28. A coupling 30 is used to connect adjacent units, this coupling 30 having inwardly curled or rolled portions 31 which interlock with the rolled edge portions 28 of adjacent units. It will be apparent, therefore, that my improved unit is standard; and that by means of the couplings 30, as many units as desired may be secured together to form a wall of the desired length.
It is desirable, although not necessary, that ner and outer sheets firmly assembled with the the parts of my improved wall unit be assembled at the factory, the filler material 20 being inserted in the receptacle-like inner sheet 15, and the outer sheet 21 being inserted within the edge portions 17 of the inner sheet. To prevent displacing of (the outer sheet 21 and to hold the infiller material interposed between the same, I have provided means for securing the edge portion 17 to the curled edge portions 28 of the outer sheet 21. The securing of the edge portions 17 may be effected in various ways, but for simplicity and excellence of product, I prefer to crimp the edges 17 in the manner illustrated in Figs. 5 and 9. When the inner and outer sheets have been assembled, the edge portions 17 may be hammered over so as to somewhat clamp around the curled edge portions 28. The entire edge portions 17 may be hammered over, if this is found suitable to the particular need; but for most purposes, I prefer to hammer over the edge portions 17 only at intervals, as illustrated in Fig. 9. Such crimping of the edge portions 17 holds the inner and outer sheets firmly assembled with the filler material; and when a unit is erected as a part of a building, the flanges are so clamped in position as to additionally secure the outer and inner sheets together. If it is desired that the outer and inner sheets be even more securely held together, the flanges 18 may be soldered to the opposite sheet of the unit.
The edge portions 18 are adapted to engage the foundation of the building, and may also be connected to the eave construction thereof. The customary wall height of small buildings does not exceed twelve feet; and it is convenient to make units in accordance with my invention so that they are of the full wall height. If, however, the wall height of the building is to he, say, eighteen feet, it would usually be found preferable to make the units of such size that two units would be erected in superposed relation to form the wall.
As illustrated in Fig. 7, the foundation includes a sill angle iron mounted on cement work 36 by means of grouting 37. v A bolt 38 passes through the angle 35, was to clamp thereto the edge portion 18 of the wall unit. A strap may be employed in cooperation with adjacent units to secure the same to the foundation 36. In Fig. 8, this strap 39 is long enough merely to be connected to the sill angle iron 35. In the form illustrated in Fig. 9, the corresponding strap 40 is long enough so that it may be secured to-the angle iron 35, and may also be secured to a bolt 41 embedded in the foundation 36. As shown in Fig. 12, the straps 39 and 40 are notched at 44 and 45 on opposed sides thereof, so as to receive the adjacentedges of the adjoining wall units. Where, as shown in Fig. 12, the adjacent edges of the units are rounded, these notches 44 and 45 will 1 be rounded.
of the adjoining units. In the embodiment shown in Fig. 8, the strap 39 is fastened by a screw 47 with but the angle iron 35. In the embodiment shown in Fig. 9, the strap 40 is first directed downwardly along the angle iron 35, 8 and is then directed horizontally across the foundation 36. A screw 47 secures the strap 40 to the angle iron 35, and a nut 48 secures the strap to the bolt 41 embedded in the foundation 36. In certain instances, it may be found desirable to further stiffen the wall units longitudinally;
- and in such cases, I provide a girt 49 in the form of a. structural steel angle held to the sheet 15 by screws 24.
The eave construction shown in Fig. 9 includes the usual eave struts 51, as well as the usual eave fiashings 52 and sheet fiashings 53.
My improved wall unit is assembled without extending securing means of any type through the outer sheet of the building. Perforations in metal sheets, for the sake of bolting or otherwise securing the parts together, are liable to rust at the point where the perforation is made. Leakage ensues, and the life of the structure is accordingly shortened. The corrugated outer sheet, 13. which is exposed to the weather, is imperforate, and, therefore, the several parts of the wall unit, including the screw, are protected, and the danger of corrosion is materially lessened.
Soldering of the bridge members to the outer sheets adds considerably to the stiffness of the outer sheets. These bridge members permit clamping of the inner sheet to the filler material; and where the bridge members are soldered to the outer sheet, these members permit the inner and outer sheets to be secured together in this fashion. 1
While I have illustrated and described certain preferred embodiments of my invention, it will be understood, however, that it is not limited to the form shown, but may be otherwise embodied within the scope of the following claims.
I claim: e
1. A wall unit comprising filler material inter posed between an imperforate outer metal sheet and an inner metal sheet, the outer metal sheet having a corrugation, and securing means extending through the inner metal sheet and embedded in the filler material, the corrugation of the outer metal sheet overlying the extremity of said securing means.
2. A wall unit comprising filler material interposed between an inner metal sheet and an outer metal sheet, the" outer metal sheet having a corrugation, a member within the outer sheet bridging the corrugation, and means passing through the filler material for securing said inner metal sheet to said member.
3. A wall unit comprising filler material interposed between metal sheets and a threaded element for uniting one of said sheets with the filler material, the other metal sheet having a corrugation overlying the end of the threaded element.
4. A wall unit comprising filler material interposed between an inner metal sheet and an outer metal sheet, the outer metal sheet having a corrugation, a strip within the outer sheet bridging