HK1023165B - Composite structural member and wall assembly method - Google Patents

Description

Composite structural member and wall assembly method

Technical Field

The present invention relates to a structural element primarily for use in houses and other building structures.

Background

A typical building, such as a house, includes various structural or framing members. Including, for example, wall chaplets, floor and ceiling grids, roof rafters, partition chaplets, and the like. Although sheet metal chaplets have been increasingly used in recent years, these components are often made of wood.

Although wood works well, it has many disadvantages, such as increasing supply shortfalls and resulting higher prices, as well as being vulnerable to fire, insects and corrosion. On the other hand, sheet metal structural members conduct heat (or cold) through the wall when exposed to high temperatures, and some metal structural members also experience warping. In addition, many builders are unfamiliar with the techniques required to construct with metal components.

Us patent No.1,559,134 describes a wall structure incorporating structural members constructed of reinforced gypsum bonded with a fibrous covering. The wall structure comprises a plurality of structural elements fixed in a wall frame according to usual building techniques, also covered in a conventional manner with plasterboard

Disclosure of Invention

The primary object of the present invention is to overcome the above-mentioned disadvantages by providing a low cost and low thermal conductivity member and wall assembly.

To achieve the above object, the present invention proposes a structural member for supporting at least one panel, comprising a non-thermally conductive load-bearing core member having first and second spaced-apart side surfaces, first and second spaced-apart edge surfaces, and first and second end surfaces, the first and second side surfaces and the first and second edge surfaces each terminating in the first and second end surfaces, the spacing between the first and second edge surfaces being at least as large as the spacing between the first and second side surfaces, characterized in that: first and second reinforcing edge strips are engaged with the first and second edge surfaces, respectively, the edge strips being separated and spaced apart from the core member, the edge strips including extensions extending beyond the first and second end surfaces of the core member, the edge strips preventing the core member from bending when subjected to a load in a direction perpendicular to the edge strips, the first edge strips being completely covered by a cover sheet having a first overlapping portion covering at least a portion of the first side surface and a second overlapping portion covering at least a portion of the second side surface.

The invention also provides a wall structure having two generally parallel wall panels, said panels being spaced apart from one another and defining a wall space therebetween, and said panels being made of gypsum board, at least one core being disposed in said wall space, said core comprising a core formed at least in part of the gypsum, and fastening means for fastening said core to said gypsum board, said fastening means comprising an adhesive, said core of said core having first and second spaced apart sides, first and second spaced apart edge surfaces, and first and second end surfaces, said first and second sides and said first and second edge surfaces each terminating at said first and second end surfaces, each of said edge surfaces facing one of the wall panels, characterized in that: first and second reinforcing edge strips respectively engaging one of said first and second edge surfaces, said edge strips being separated or spaced apart from said core, said edge strips including extensions extending beyond said first and second end surfaces of said core, said edge strips inhibiting bending of the core under loads perpendicular to the direction of the edge strips, said first edge strips being completely covered by a cover sheet having a first overlapping portion covering at least a portion of said first side and a second overlapping portion covering at least a portion of said second side, said cover sheet contacting at least one wall panel.

The invention also provides a method for manufacturing the combined wall chaplet, which comprises the following steps:

(a) casting a core member of a low thermal conductivity material having first and second spaced apart side surfaces, first and second spaced apart edge surfaces, and first and second end surfaces, said first and second side surfaces and said first and second edge surfaces terminating at said first and second end surfaces,

(b) contacting first and second reinforcing edge strips with first and second edge surfaces, respectively, said edge strips including extensions extending beyond said first and second end surfaces, and

(c) the cover panel is folded about the first reinforcing bead, the first side, and the second reinforcing bead to secure the cover panel to at least a portion of the second side.

The present invention also provides a structural member for supporting at least one panel, comprising a thermally non-conductive core member having first and second spaced apart side surfaces and first and second spaced apart edge surfaces, the spacing between the first and second edge surfaces being greater than or equal to the spacing between the first and second side surfaces, characterized in that: first and second reinforcing edge strips are respectively engaged with said first and second edge surfaces, said edge strips being separated and spaced apart by said core member, each of said edge strips being completely covered by a cover sheet, said cover sheet having a first overlapping portion covering at least a portion of said first side and a second overlapping portion covering at least a portion of said second side, the engagement of said edge strips and cover sheet preventing the core member from bending when subjected to a load in a direction perpendicular to the edge surfaces when the structural member is attached to at least one panel with said cover sheet in contact with the panel.

The present invention also provides a structural member for supporting at least one panel, comprising a thermally non-conductive core component, said core component comprising a matrix material and a filler material, and having first and second spaced apart side surfaces and first and second spaced apart edge surfaces, the spacing between said first and second edge surfaces being at least as large as the spacing between said first and second side surfaces, characterized in that: first and second reinforcing edge strips engage and completely cover the first and second edge surfaces, respectively, the edge strips being separated and spaced apart by the core member, the edge strips inhibiting bending of the core member when subjected to loads in a direction perpendicular to the edge surfaces when the structural member is attached to at least one panel.

The invention also provides a wall structure comprising two generally parallel wall panels, said panels being spaced apart from one another to define a wall space therebetween, and said panels being formed of plasterboard, at least one chaplet being provided in said wall space.

Drawings

The invention will be better understood from the following detailed description taken in conjunction with the accompanying drawings. Wherein:

FIG. 1 is a partial perspective view of a wall incorporating structural members constructed in accordance with the teachings of the present invention;

FIG. 2 is an end view of the wall shown in FIG. 1;

FIG. 3 is an enlarged, fragmentary, cross-sectional view taken on line 3-3 of FIG. 2;

FIG. 4 is another enlarged cross-sectional view of the structural member shown in FIG. 3;

FIG. 5 is a view similar to FIG. 4 but showing an alternative construction;

FIG. 6 is a perspective view further illustrating the structural member shown in FIG. 4;

FIGS. 7, 8 and 9 are partial sectional views showing alternative constructions of structural members;

FIG. 10 is a partial cross-sectional view showing another form of the invention;

FIG. 11 is a view showing a production process of the member shown in FIG. 10;

FIGS. 12 and 13 are views similar to FIGS. 10 and 11 but showing another form of the invention;

FIGS. 14 and 15 are views showing a production process of another embodiment of the present invention;

FIG. 16 is a view showing another embodiment of the present invention;

FIGS. 17, 18 and 19 show production steps for another embodiment of the present invention;

FIG. 20 is a view showing a portion of the structural member of FIGS. 17-19;

FIG. 21 is a view of another embodiment of the present invention;

FIG. 22 is a cross-sectional view of another embodiment of the present invention;

FIG. 23 is a schematic view of a building incorporating the elements of the present invention;

FIG. 24 is a view of a truss constructed in accordance with the present invention;

figure 25 is a cross-sectional view of another building incorporating structural members according to the present invention;

FIG. 26 is a view of another structural member according to the present invention;

FIG. 27 is a perspective view of another structural member according to the present invention;

FIG. 28 is a view similar to FIG. 27 showing some of the components of the construct of FIG. 27 in a different position;

FIG. 29 is a cross-sectional view taken along line 29-29 of FIG. 28;

FIG. 30 shows an assembly comprising the components shown in FIG. 27;

FIG. 31 is a cross-sectional view taken along line 31-31 of FIG. 30;

FIG. 32 is a view similar to FIG. 31 showing a modified assembly;

FIGS. 33 and 34 are perspective views showing another embodiment of a structural member;

FIG. 35 is a perspective view of a wall assembly incorporating the structural members of the present invention;

FIG. 36 is a cross-sectional view taken along line 36-36 of FIG. 35;

FIGS. 37, 38, 39 and 40 are cross-sectional views of another embodiment of a structural member;

FIG. 41 is a cross-sectional view of another wall assembly of the present invention; and

FIG. 42 is a view similar to FIG. 41 showing another embodiment of a wall assembly.

Detailed Description

Referring first to fig. 1-3, the wall assembly 30 shown therein may be, for example, a partition wall of a house or other building. The wall assembly 30 includes a plurality of vertically extending composite chaplets 31 constructed in accordance with the present invention, the chaplets 31 being spaced horizontally from one another. In this embodiment, the lower ends of the jammers 31 are mounted in the C-shaped metal bottom plate recesses 32 and their upper ends are mounted in the C-shaped metal top plate recesses 33. The channels and chaplets 31 are covered on one side by a panel 34 which is a wall panel and on their other side by another panel 35 which is a wall panel, forming a hollow wall because the chaplets both separate the two wall panels and support them. In this particular embodiment of the invention, the two panels 34 and 35 are gypsum wallboard. The ends of the vertical jammers 31 extend between the flanges of the grooves 32 and 33. The wall assembly 30 is secured together by threaded fasteners which secure the plates 34 and 35 to the edges of the chaplet 31 and to the flanges of the grooves 32 and 33.

With particular reference to fig. 3 and 4, there is shown a chaplet 31, the chaplet 31 including a body 41 and two edge strips 42 and 43. The body 41 includes a core 44 preferably made of a mixture containing gypsum and cover or back sheets 45 and 46 secured to both sides of the core 44. The body 41 also comprises two edges 47 covered by the edge strips 42 and 43. In this embodiment of the invention the edge strips 42 and 43 are relatively hard and may be made of sheet metal, for example. In the embodiment of the invention shown in fig. 1-4, two edge strips 42 and 43 cover the edge 47 and each have a hem 48 that is folded over or extends to the back panels 45 and 46. The edge strips 42 and 43 are fixedly secured to the body 41 and the plate members 34 and 35 are secured to the jammer 31 by threaded fasteners 49. Fasteners 49 extend through plates 34 and 35 and are threaded through edge strips 42 and 43 to securely fasten plates 34 and 35 to the edge strips. Since the edge strips are themselves fixed to the body 41, the plates 34 and 35 can be spaced apart by the edge strips and fixed to the chaplet 31.

As one particular embodiment of the invention shown in fig. 1-4, the core 44 is made from a mixture of gypsum and conventional additives. The mixture can be the same as a conventional gypsum wallboard or core. The sides are covered by back panels 45 and 46 which are typically used to cover conventional wall panels. The depth of the chaplet 31, or in other words the distance between adjacent sides of the plate members 34 and 35, is substantially equal to 92mm (3-5/8 "), and the thickness of the chaplet (the distance between the back plates 45 and 46) is substantially 32mm (1-1/4"). These dimensions are the most common dimensions for conventional wall chapters. The edge strips 42 and 43 are preferably made from sheet metal having a thickness of 0.3mm to 0.5mm (0.012 inches to 0.020 inches), while the length of the flange 48 is about 6mm (1/4'). The edge strips 42 and 43 are located on the surface of the core at a maximum distance apart (i.e., greater than the distance between the sides of the core) and the edge strips 42 and 43 cover the entire edge surface of the core.

The chaplet 31 constructed in accordance with the present invention has many advantages. The cost is significantly lower than a wood or metal chaplet of similar size. The body 41 is relatively flame retardant and does not conduct heat rapidly between the two plates 34 and 35. The metal strips 42 and 43 cover and protect the end faces of the core 44 and they also form a part which can firmly hold a threaded fastener. The chaplets may have the size and feel of wooden chaplets and may be laid using the same construction techniques as wooden chaplets.

The wall assembly 30 incorporating the chaplets of the present invention also has good transverse strength, i.e., strength in the direction perpendicular to the wall panels. The edge strips 42 and 43 form reinforcing strips which are spaced further apart from each other under transverse loading relative to the bending axis of the chaplet. Further, the planes of the back plates 45 and 46 on the side of the chaplet are parallel to the direction of the lateral load. The core functions to hold the back plates 45 and 46 in these planes and the back plates have greater strength against loads in the direction of these planes.

The chaplet structure shown in fig. 3 and 4 includes a body formed from a single gypsum removable liner. The thickness of the body is typically about 25mm (1 "). With the additional flanges 48, the overall thickness of this chaplet is approximately 36mm (1-1/32'). The core shown in figures 3 and 4 may also be replaced by a single core having the standard core thickness dimensions of 31mm (1-1/4 ") and a width of 92mm (3-5/8").

In figure 5 there is shown a construction in which the body 51 of the core is formed from two layers of plasterboard 52 and 53, for example 16mm (5/8 "). Each of the two sheets 52 and 53 is covered on both sides by a backing 54 and its edges are covered by a bead 55 spanning the two layers. Adjacent backing sheets 54 of the two layers 52 and 53 may be secured together by adhesive and the edge strips 55 may be secured to the two layers 52 and 53 by adhesive.

Fig. 6-13 illustrate different methods of securing the rigid edge strips to the body. In each embodiment, the body may be formed from a single layer of core material and a backing sheet as shown in FIG. 4 or a two layer structure as shown in FIG. 5.

Referring to fig. 6, there is shown a structural member 60 comprising a body 61 and two edge strips 62. Each edge strip 62 includes a flange 63 as described above and the flange 63 is secured to the body 61 by a bead or groove provided at spaced apart locations along the length of the structural member 60. The provision of beads or indentations 64 may be used instead of or in addition to the provision of adhesive between the beads and core and back of the body 61.

Fig. 7 shows a structural member comprising a core 66 and edge strips 67 (only one shown), wherein the flanges 68 of the edge strips 67 are fixed to the body 66 by means of piles indicated by reference numeral 69, which are arranged at a distance from each other in the length direction of the structural member.

Fig. 8 shows a structural member 71 similar to the member 60 shown in fig. 6. However, the structure is formed of two layers 72 and 73 rather than a single layer, with the structural members having a rigid edge strip 74. The edge strips 74 are secured to the two-ply members 72 and 73 by flanges 75 of similar construction to that shown in figure 6. Preferably, the two-ply members 72 and 73 are bonded together and may be secured to the edge strip 74 with an adhesive.

Fig. 9 shows a structural member 77 comprising a main body 78 and two edge strips 79. Each edge strip 79 comprises two flanges 80 which are pressed into the sides of the body 78 by applying pressure against each other, thereby securing the edge strips to the body.

Referring now to fig. 10 and 11, two edge strips 82 (only one shown in fig. 10 and 11) are secured to the body 83. Each edge strip 82 has two flanges 84 and is provided with a preformed pointed tip 85 at a distance from each flange. The prongs 85 may be preformed by a stamping operation. To assemble the edge strip 82 and body 83 together, the middle portion of the edge strip 82 is positioned relative to the edge of the body, and the edge strip 84 is bent downwardly and inwardly to bring the prongs 85 into the body 83 to secure the edge strip to the body 83, as shown in fig. 11.

Referring to fig. 12 and 13, the body 88 is provided with a bead 89. Each edge strip 89 includes a flange 90 and has an edge portion that is bent inwardly to form a flange projection 91. The body 88 has a channel 92 formed along a side 93 adjacent the edge of the body and the flange 90 is preferably bent inwardly into the shape shown in figure 13 to allow the flange lip 91 to fold into the channel 92. It is preferable that the flange 91 extends at substantially right angles to the flange 90 of the adjacent portion and that the guide groove 92 is shaped to engage with the flange 91. Thus, each channel 92 has a surface 94 at right angles to the side 93 and engaging the flange 91 and a further surface 95 which is inclined or angled to provide clearance to accommodate the flange 91 when the flange 90 is bent inwardly.

Fig. 14 and 15 show a structure for fixing the reinforcing edge strip to the body by covering the edge strip with an additional plate such as a plate on the side of the core. The structural member 101 is made up of two sheet layers 102 (although one thicker layer may suffice) each having a backing sheet 103 on both sides. A flat edge stiffener 104 is positioned relative to the edges 105 of the body 101 (preferably along the entire length of each edge), with the width of the edge stiffener 104 being substantially equal to the overall width of the body 101. The cover strip 106 is positioned over the edge strip 104, the cover strip 106 having a width such that it can be folded over the edge of the edge strip 104 and outside the layer 102. The folded-over portion 107 is firmly fixed to the back plate 103 with an adhesive, thereby fixing the edge band 104 to the main body 101. As described above, the edge strip 104 and the cover strip 106 are provided along each edge of the main body 101. The cover strip 106 may be made of backing paper or other sheet-like material.

The edge strips 104 may be made of various reinforcing materials such as metal (as described above), paper, cardboard, non-woven fabric, and the like.

Figure 16 shows a structural member comprising a body 111 and edge strips 112 secured to opposite edges of the body. In this embodiment, two plies 113 are secured together to form a body. Each edge strip 112 includes a bent down flange 114 and an adhesive layer 115 secures the flange 114 to the outer back of the layer 113. In this embodiment, the middle of each edge strip (i.e., the edge strip portion between the two flanges 114) may not be secured to the body 111.

In the above-described embodiments of the invention, the edge strips are secured to one or more layers of core material after the core material is formed. The layers are typically cut or formed into strips. In the embodiment shown in fig. 17-22, the core material of the body may be made by extrusion or cast-in-place and secured to the back plate and edge strip prior to installation. Referring to fig. 17-19, the structural member 120 is formed from a core 121, two back plates 122 and 123, and two edge strips 124 associated with the edge strip 104 described in connection with fig. 14 and 15. The core 121 is made of, for example, gypsum and may be cast in place or extruded into the shape shown in fig. 17. After core 121 is formed from gypsum slurry and before the gypsum board is subjected to the drying stage, two edge strips 124 are secured to edge surface 126, and back sheet 122 is then flexed to cover one side 127 of the core, the two edge strips 124, and at least a portion of the other side 128 of the core. A second back panel 123 is then secured to side 128 and overlaid on the folded portion of panel 122. After the components are assembled and in the condition shown in fig. 19, the assembly is passed through a drying oven to form the final structural member. The back plate 122 may be made wide enough to completely wrap the core 121, thus eliminating the need for the second plate 123.

Referring to FIG. 20, the edge banding 124 may include a plurality of holes 129 therethrough. The holes 129 allow the slurry forming the core 121 to pass through and engage the back plate 122 during the process described above in connection with fig. 17-19 to achieve a better connection with the back plate at the edges of the structural member.

Fig. 21 and 22 also show two embodiments in which the back sheet and edge strips are secured to the core body and back sheet before the core slurry is finally set. In fig. 21, a core 135, such as gypsum slurry, is made and a backing plate 136 is flexed around one side, edge, and a portion of the other side. A second back plate 137 is then placed over the other side of the core. Of course, the backing plate is similar to those shown in fig. 17-19. Extending along the edges of the core are two edge strips 141 (preferably made of a rigid material such as metal or plastic) having flanges 142. The flanges 142 are angled inwardly and into the grooves 143 of the core 135 and back plate 136, thereby forming a secure connection between the edge strips 141 and the core 135. The flanges 142 may be angled inwardly as shown in fig. 21 before the core slurry is injected into the backing paper or the flanges may be bent inwardly and formed into the grooves 143 after the core slurry is injected. Instead of using two backing sheets 136 and 137, a single sheet may be provided having a width wide enough to overlap the edges and form a cladding around the core. In this embodiment, the portion of plate 136 that extends across the edge of core 135 also forms a reinforcing bead.

Fig. 22 shows a structural member similar to that shown in fig. 21, including a core 146 having backing plates 147 disposed along opposite sides and edge strips 148 disposed along opposite edges. Of course, the structural member shown in fig. 22 is the same as the structural member shown in fig. 21, except that the backing sheet does not extend over the edge of the core and underlie the edge strips 141.

Figures 23, 24 and 25 show another structural member in connection with the present invention. With respect to fig. 23, a cross-sectional view of a house mounted to a foundation 154 is shown. The house includes load bearing floor beams 156, ceiling beams 157, wall bracing 158, rafters 159, and chaplets 160 that form the internal partition walls. All of these components 156 and 160 may be constructed by combining structural members as described herein. The floor and ceiling stringers and the rafters 159 preferably have an increased cross-sectional dimension sufficient to resist structural forces applied thereto.

Fig. 24 shows a truss 166 which is particularly effective when building a building such as a house. The truss 166 is constructed of a single sheet forming a body 167 as shown in fig. 3. The periphery of the body 167 has an edge strip 168 secured thereto, which is preferably a rigid material so that other portions of the structure can be secured to the truss 166 with threaded fasteners. Although the body 167 is shown as being imperforate, holes may be provided in the body to facilitate routing of tubing and wiring. It should be noted that the wall chapters and other structural members described herein may have preformed openings through the body for receiving wires and the like.

Fig. 25 shows a cross-section of a relatively large building comprising uprights 171 and horizontal floor 172 and ceiling 173. Retaining wall 174 is installed on the outside of the building. Reference numerals 175 and 176 denote partition walls including wall braces 177 constructed in the manner described herein. Since the walls 175 and 176 serve to separate or space the interior space above the floor of the building and do not carry load, the core of the structural member can be made of a lighter material such as lightweight gypsum. Load bearing refers to a load parallel to the length direction of the chaplet; such chaplets are typically subjected to lateral loads, i.e., loads that are substantially perpendicular to the length of the chaplet. Retaining wall 174 is also not load bearing and can be made in the manner of the present invention.

In the above-described embodiments of the invention, the body of the structural member comprises a core at least partially covered by at least one backing sheet. Figure 26 shows an embodiment of the invention in which the core 181 forming the body has sufficient structural integrity that it does not require an external backing plate. For example, the core may be made from a gypsum-cement mixture, or from gypsum with a fibrous filler or binder. In fig. 26, numeral 182 represents individual fibers, such as paper fibers typically used in the above-described backsheets. In this embodiment, the body contains a backing sheet, but it is in the form of fibers mixed with the core material. The core 181 is fixed to a rim 183 made of, for example, a metal plate. The edge strip 183 includes a folded edge 184 that is angled inwardly. The component shown in fig. 26 is preferably constructed by casting the core 181 in place between the flanges 184.

Fig. 27-28 and 29 illustrate another structural member 200 (e.g., a chaplet) according to another embodiment of the present invention. It will be understood that the drawings are diagrammatic and not to precise scale, but rather that they show the thickness of the components with particular fidelity. This structure comprises a body 201 with a core 202 made of a gypsum mixture, the core 202 being covered on opposite sides by fibreboard, e.g. paper. The core 202 is rectangular and has a size of a standard size of a wooden chaplet used in constructing homes and houses, for example. The core 202 has two opposite edges 204 (fig. 29) which are covered by a reinforcing insert 206 made of a relatively strong material, such as metal. The reinforcing inserts 206 extend along diametrically opposed end edges 204 of the core 202, and the inserts 206 include extensions 207 that extend beyond the ends of the core 202 (see FIG. 27). Extensions 207 may be provided on both or one end of the core 202 and preferably an extension 207 is provided on each edge 204.

The structural member 200 further includes a cover 208 (e.g., made of paper) that extends over the reinforced insert along each core edge 204. The cover 208 includes a flange portion 209 that is folded over along the sides of the core and covers the edges of the side cover 203. The cover plate 208 is secured to the plate 203 by applying adhesive between the flange 209 and the side plate 203.

Fig. 30 and 31 illustrate a method of assembling a wall body including vertical chaplets having the structure shown in fig. 27-29 and a wooden frame member 211. The frame member 211 is secured to the floor section in a suitable manner (as indicated by reference numeral 212 in fig. 31) and the chaplet extends vertically upward from the horizontal frame member 211. The jammer 200 is secured by two extensions 207 that extend down past the front and rear sides 214 and 214, positioning the ends of the body member 201 on the upper side 216 and extending upward from the frame member 211. The two extensions 207 are then secured to the sides 213 and 214 by suitable fasteners such as staples, nails or screws, which are designated by reference numeral 217 in fig. 30 and 31. In this configuration, the cover sheets (not shown) of gypsum wallboard are positioned on opposite sides of the framing members 211 and the chaplet 200 and secured between the wallboard and the chaplet 200 with, for example, metal fasteners and/or adhesives. The reinforcing inserts 206 constitute a reinforcing profile along the edges of the chaplet and function as screw-type fasteners that can be secured to the chaplet and as fasteners that can secure the chaplet 200 to the frame member 211 in the case of reinforcing inserts made of a strong material of higher strength, such as metal.

Referring to fig. 28, the projections 207 extend parallel to the edges 204 of the core, and they may also be folded relative to the edges 204 of the core, as shown in phantom. The folded position of the extensions shown in solid lines in figure 28 facilitates transport and storage of the cores and allows them to be folded outwardly when in use to the position shown in phantom lines in figure 28 and in solid lines in figure 27.

Referring to fig. 32, the core 200 is provided with an extension 207 that is folded relative to the bottom end of the core 202. The core may be secured to the frame member 211 by folding the extension 207 directly outward as shown in phantom in fig. 28 to secure it to the frame member 211 in the manner shown in fig. 31, or by securing the jammer 200 to the frame member 211 as shown in fig. 32, with the threaded fastener 218 passing vertically through the frame member 211 and through the extension 207 and into the core 202.

Fig. 34 shows a chaplet 220 similar to chaplet 200. The jammer 220 includes a gypsum core 221 covered on both sides by cardboard 222. Extending along the edges of core 221 are strakes of reinforcing inserts 223 (best seen in fig. 33), the structure of reinforcing inserts 223 being similar to reinforcing inserts 206 shown in fig. 27-29. The reinforcing inserts 223 protrude beyond the ends of the core 221 and the entire length of each reinforcing insert 223 is covered by a cover plate 224. While in fig. 27 the cover plate 208 terminates at the end surface of the core 202, in the embodiment shown in fig. 33 and 34 the cover plate extends beyond the end surface of the core 221 and to the ends of the two projections 223. In order to fold the core extension 223 and the paper cover portion back up as shown in fig. 32 for storage or mounting on the frame member, it is preferred to cut the flanges 226 of the two covers 224 along lines 227 as shown in fig. 33 to allow the cover-bearing extension to be smoothly folded over the end face of the core 221 as shown in fig. 34. The reinforcing insert 223 may be made of a rigid material (e.g., metal) with screws or other high strength material such as paper, cardboard, scrim, etc., while the cover 224 may be made of a high strength backing paper.

Fig. 35 and 36 illustrate a portion of a wall assembly or structure including a plurality of chaplets 231. Extending along the bottom end of the jammer 231 is a C-shaped metal channel 232 having a horizontal web 233 and a vertical rim 234. Another channel (not shown) similar to the C-channel 232 is preferably provided along the upper end of the chaplet and secured to the ceiling, which is not shown in the figures since the ceiling and upper channel are of conventional type.

Referring to fig. 36, each chaplet 231 comprises a gypsum core 237 covered on both sides by panels 238 (fig. 35) such as shown in fig. 27. Reinforcing inserts 241 are mounted along the front and rear edges of the core 237 and are secured to the core 237 and the plate 238 by adhesive.

To secure the jammers 231 to the channels 232 (see fig. 36), the lower end of each jammer 231 is positioned between the flanges 234 and against the web 233 of the channel 232. The width of each jammer 231 is dimensioned so that it corresponds to the distance between the flanges 234 so as to form a tight fit between the flanges 234 and the reinforcing inserts 241. The components are then secured together by extending a screw-shaped fastener (not shown) over the flange 234 and through the reinforcing insert and into the gypsum core 237, or by staking the components together in the area indicated by 244 in fig. 36. Staking may be accomplished with a tool, such as a punch, that is driven through the flange 234 and through the reinforcing insert 241 and into the core, thereby deflecting the flange 234 into the opening 244 of the reinforcing insert 241. As previously mentioned, the components may be secured together by screws instead of being staked.

Fig. 38 and 39 show a wall assembly particularly useful in the building construction industry, and fig. 37 shows a core support included in the wall assembly of fig. 38 and 39. Referring to fig. 37, there is shown a cross-sectional view through a chaplet 251 comprising a core 252 made of gypsum, the core 252 being partially surrounded or encased by a paperboard 253 typically used to cover the sides of gypsum wallboard. The fourth side of the core 252 is covered by a separate plate 254 which covers the fourth side and overlaps the adjacent edge portion of the plate 253 at 255. Thus, the core 252 is completely surrounded or wrapped with paper except for the end of the jammer. However, it is also possible to wrap the core 252 with a single piece of cardboard.

Referring to fig. 38, the wall assembly 261 includes a plurality of chaplets 251, the chaplets 251 extending vertically and being spaced apart from each other in a horizontal direction. Formed on one side of the wall assembly 261 is a panel 262 of gypsum wallboard, and extending across the other side of the wall assembly 261 are two other panels 263 and 264 of gypsum wallboard, which form another panel. The two plates 263 and 264 are parallel to each other and rest against each other at a joint line 266, and one vertical edge 267 of the jammer 251 is at the joint line 266 between the two plates 263 and 264. The plate 262 is spaced from the two plates 263 and 264 so that the chaplet 251 is on the joint or joint line 266 on only one side of the wall and the other edge 268 of the chaplet 251 is in the middle of the vertical side edges of the plate 262. Adhesive 269 is applied between the vertical edges 267, 268 of the chaplet 251 and the adjacent surfaces of the wall panels 261, 263 and 264, the adhesive 269 securing the components together. After the adhesive is applied, fasteners such as staples are placed between the wall panel and the chaplet in order to maintain the relative position of the components.

FIG. 39 shows a wall assembly 275 similar to wall assembly 261, including structural members such as chaplets 251 and wall panels 276 and 278. Instead of adhesive 269 securing the components together, a foamed adhesive 279 may be used to secure the components as in fig. 39.

Referring to fig. 41, an alternative core support structure is provided which is cut from the broad face of the gypsum board and the structure shown in fig. 37 may be molded into the shape shown in fig. 37. The chaplet of fig. 41 comprises a gypsum core 281 covered by side panels 282, 283 and a paper top cover 284 covering the cut edge 285 of the core.

Fig. 40 shows a chaplet similar to that of fig. 37, but with reinforcing strips 248 disposed along the edges of the core 287 and the lower surface of the cover 291.

In fig. 42, the core 293 of the core stay 294 is covered with paper 296. The core 293 may have regions of different composition, such as low density gypsum 297 and high density gypsum 280 disposed along the edges of the chaplet. If desired, the core may also be made of other materials, for example, having very high strength or being fire-resistant or moisture-proof, to meet different environmental requirements.

The core of the structural member embodying features of the invention may be made of a variety of different materials other than gypsum, for example, a gypsum-cement mixture, standard weight or light weight gypsum, recycled gypsum, moisture resistant gypsum core, or a combination of these mixtures may be used. In addition, various fillers may be included, such as wood chips and/or volcanic materials. The backing sheet can also be made of a variety of different materials, including, for example, paper, or moisture-proofed paper, woven fiberboard, etc., as long as the material has good shear resistance. The reinforcing strip can be made of various materials such as paper, non-woven fabric (scrim) or woven fabric, metal, etc.

In experiments conducted on constructions comprising the chaplets of the present invention and prior art chaplet constructions, the chaplets of the present invention are comparable or better than prior art chaplets; however, the cost of the structure and chaplet manufactured in the manner of the present invention is lower than the cost of the prior art structures.

The following are the results obtained from the combustion experiments carried out on different structures:

combustion experiment

Experiment number	Core support	Wall board	Over-standard sustained improvement (over time) experiments
				1.	11/4″×35/8"25 ga. HDGL steel chaplet	5/8Type FSW	Standard-1 hour module
2.	11/4″×35/8Gypsum chaplet with metal top cover	5/8Type FSW	+4.5 minutes
				3.	1″×35/8Gypsum chaplet with paper top cover	5/8Type FSW	+13.75 minutes
4.	11/4″×35/8"25 ga. HDGL steel chaplet	1/2Type FSW-B	Standard-3/4 hours
				5.	11/4″×35/8Gypsum chaplet with metal top cover	1/2Type FSW-B	+2 minutes
6.	1″×35/8Gypsum chaplet with paper top cover	1/2Type FSW-B	8.5 minutes

Experiments 1 and 4 relate to a standard 1 hour module and a standard 0.75 hour module, respectively. Experiment 1 was performed on a typical 1.0 hour standard wall comprising 16mm (5/8 ") type X wallboard and 92mm (3-5/8") thread-fastened chaplets; experiment 4 was conducted on an 3/4 hour standard wall comprising 12.5mm (1/2 ") type X wallboard and 92mm (3-5/8") thread-lock chaplets. Experiments 2 and 3 show the improvement over time compared to experiment 1 and experiments 5 and 6 show the improvement over time compared to experiment 4. In the above-mentioned combustion experiments 1 to 6, the chaplet had a length of 3m (10'); in experiments 1, 2, 4 and 5, the spacing between the centers of the chaplets was 0.6m (24 "); in experiments 3 and 6, the spacing between the centers of the chaplets was 0.4m (16 "); fixing gypsum boards to opposite edges of the chaplets to form a hollow wall; in experiments 3 and 6, the plates were stapled to the chaplets, while in the other four experiments 25mm (1 ") S-shaped screws were used. A heat source is placed on one side of the hollow wall and a temperature sensor (thermocouple) is placed on the other side of the wall. Each of the experiments listed in the figure, relative to the "duration improvement" column, is the time elapsed from the start of the combustion experiment until the temperature at any thermocouple location on the other side of the wall rose to 325F (162 c) above ambient temperature (see ASTM E119). In experiments 1 and 4, the hot-galvanized steel chaplet is a typical thread-fixing type chaplet wall type; it has a disadvantage of being deformed by heat. In experiments 2 and 5, the structure of the "metal dome" is shown in fig. 6 of the drawings. In experiments 3 and 6, the structure of the "paper top cover" is as shown in fig. 41, but a paper top cover 284 is provided along each edge of the chaplet. Furthermore, the combustion experiments showed that although the chaplets were of different design, such as the design in fig. 15 with metal reinforcing strips, they had similar heat conduction (at the location of the chaplets) as the third experiment.

The following experiments 7-15 relate to the pulling force (in pounds) required to pull the fastener from the edge of the chaplet. The values listed in the rightmost column are the average of multiple experiments. The flag n/a means not applicable; in other words, no experiments were conducted on specially designed chaplet and anchor types.

Pulling force of fixer

Experiment number	Structural member	Reinforcing material	Covering material	Average ultimate tension (pound) ' M ' U-shaped nail 1 ' S-shaped screw
						7	1″×21/2Gypsum core support	018 "MR paper	018 "MR paper	39.5	n/a
8	1″×21/2Gypsum core support	012 "steel	018 "MR paper	31.7	93.5
						9	1″×21/2Gypsum core support	015' steel	018 "MR paper	38.3	84.7
10	1″×21/2Gypsum core support	Using PVA glue only	Is free of	21.2	n/a
						11	1″×21/2Gypsum core support	Is free of	Is free of	30.3	35.5
12	1″×21/2Gypsum core support	Paper board	018 "MR paper	43.5	n/a
						13	2 '. times.3' wooden chaplet	n/a	n/a	307.3	255.3
14	11/4″×35/8Metal chaplet	n/a	n/a	n/a	174.7
						15	1″×21/2Gypsum core support	Is free of	018 "MR paper	46.0	n/a

The experiments with the K-shaped staple showed that the pull-out force used was slightly lower than the M-shaped staple in the table above. In experiments 8 and 9 using screw fasteners, the pull out forces of 415N (93.5 pounds) and 377N (84.7 pounds) were not the forces at which the screws were pulled loose from the steel reinforcing bars; in these experiments, there occurred a phenomenon in which the paper cover sheet material was torn and the reinforcing material was pulled out of the gypsum core before the threaded fasteners were pulled out of the steel bars. Steel bars with slightly greater thickness from 0.45mm to 0.5mm (0.179 to 0.20 inch) have better holding power and lower cost than those listed in experiments 8 and 9. Furthermore, a covering material paper with a thickness of more than 0.45mm (0.018 ") gives a better pulling effect. The standard nail pull force (the force before pulling the anchor out of the gypsum wallboard) was 355N (80 pounds). In the perspective view, a force exceeding this amount is sufficient to pull any securing member from the chaplet. The fixing of staples to wood is almost exclusively used for building houses, and usually also an additional PVA type adhesive is used. The pull-out force of the U-shaped fastener in the above experiment was only applied for the initial period of time with the adhesive applied.

The following experiments relate to the inclination of hollow walls under lateral loads. Each wall bagComprising two panels made of gypsum wallboard, spaced apart from each other, and a vertical chaplet between and secured to the wallboard. The upper and lower ends of the chaplet are retained by guide rails or guide grooves. A horizontal load or force perpendicular to the wall panel is applied to one side of the wall. In experiments 18, 19 and 20, the gypsum wallboard was 8mm (5/16 ") symmetric, and in experiments 16, 17 and 21-30, the wallboard was 12.5mm (1/2") symmetric. Lines with the designation "Tilt" indicate that a wall having a height of 2.4m (8 feet) is at 239.4Pa (5 pounds per foot)²) The amount of tilt under load. The line labeled "Limited height" represents the maximum allowable wall height, when using the quarter span load method as described in ASTM-E72, at 239.4Pa (5 pounds per foot)²) Will experience an acceptable amount of tilt under lateral loading.

Transverse load

	Experiment 16	17	18	19	20
						Structural member	GYP-chaplet	Wooden chaplet	GYP-chaplet	GYP-chaplet	Wooden chaplet
Size of	1″×3-5/8″	2″×4″	1″×2-1/2″	1″×2-1/2″	2″×3
						Cover sheet composition	57# paper top cover	SPF	57# paper top cover	57# paper top cover	SPF
Reinforcing material	n/a	n/a	57# paper	n/a	n/a
						Fixing method	U-shaped nail	U-shaped nail	U-shaped/adhesive	Staple/adhesive	Staple/adhesive
Space of fixer	8″o.c.	8″o.c.	8″o.c.	8″o.c.	8″o.c.
						Calculated limit altitude is at 5PSF, L/240 inclination (feet)	8.52	13.65	11.67	11.75	13.90
Calculated inclination (in inches) at 8 feet height	0.248	0.060	0.097	0.095	0.057
							Experiment 21	22	23	24	25
Structural member	GYP-chaplet	GYP-chaplet	GYP-chaplet	GYP-chaplet	GYP-chaplet
						Size of	1-1/4″×3-5/8″	1-1/4″×3-5/8″	1″×3-5/8″	1-1/4″×3-5/8″	1-1/4″×3-5/8″
Cover sheet composition	57# paper top cover	57# paper top cover	57# paper top cover	57# paper top cover	57# paper top cover
						Reinforcing material	015 steel strip	n/a	n/a	012 steel bar	015 steel strip
Fixing method	1' S-shaped screw	U-shaped nail	Vertical U-shaped nail	1' S-shaped screw	1' S-shaped screw

Transverse load

	TEST 21(CONT’D)	22(CONT’D)	23(CONT’D)	24(CONT’D)	25(CONT’D)
						Structural member	GYP-chaplet	GYP-chaplet	GYP-chaplet	GYP-chaplet	GYP-chaplet
Fixed part interval	12″o.c.	8″o.c.	8″o.c.	12″o.c.	12″o.c.
						Calculated ultimate height is at 5PSF, L/240 inclination (feet)	13.72	9.09	7.29	13.28	13.31
Calculated amount of tilt (in inches) at 8 feet height	0.059	0.204	0.396	0.066	0.065
							TEST 26	27	28	29	30
Structural member	GYP-Stud chaplet	Metal chaplet	Metal chaplet	GYP-chaplet	GYP-chaplet
						Size of	1-1/4″×3-5/8″	1-1/4″×3-5/8″	1-1/4″×3-5/8″	1″×3-5/8″	1″×3-5/8″
Cover sheet composition	25ga. Steel roof cover	20ga. steel	25ga. steel	57# paper top cover	57# paper top cover
						Reinforcing material	n/a	n/a	n/a	n/a	57# paper
Fixing method	1' S-shaped screw	1' S-shaped screw	1' S-shaped screw	Staple/adhesive	U-shaped nail
						Fixed part interval	12″o.c.	12″o.c.	12″o.c.	8″o.c.	8″o.c.
Calculated ultimate height is at 5PSF, L/240 inclination (feet)	13.00	15.69	13.60	13.57	8.31
						Calculated amount of tilt (in inches) at 8 feet height	0.070	0.040	0.061	0.061	0.267

Let us look at the production cost per unit length of residential/commercial room chaplet, which includes raw materials and production processes, the cost of a gypsum chaplet having a core covered with paper and having dimensions of 32mm x 92mm (1-1/4 "x 3-5/8") is reduced by about 53% compared to a standard 50mm x 100mm (2 "x 4") wooden chaplet; the cost of a gypsum core support having dimensions of 32mm by 93mm (1-1/4 "by 3-5/8"), having a gypsum core, having a 0.4mm (0.015 ") thick sheet metal reinforcing strip along the edge, and covered with paper is reduced by about 31%.

In terms of the manufacturing cost (raw materials and production process) of a building chaplet per unit length, the cost of a 32mm by 64mm (1-1/4 "by 2-1/2") gypsum chaplet (containing a gypsum core covered by paper) is approximately 43% less than a standard 50mm by 75mm (2 "by 3") wooden chaplet; the cost of a 32mm by 64mm (1-1/4 '. times.2-1/2') gypsum core support comprised of a gypsum core, paper reinforcing strips disposed along the edges, and a paper cover sheet is reduced by about 38%; and a 32mm by 64mm (1-1/4 "by 2-1/2") gypsum core support made of a gypsum core, a 0.4mm (0.015 ") metal lath disposed along the edge, and a paper cover sheet, reduced by about 20%.

The cost of using a 0.5mm (0.019 ") metal plate is about the same as the 0.4mm (0.015") metal plate used in the two above-mentioned natural paragraphs.

The structural element according to the invention has many advantages. In addition to being less costly, structural members have good thermal or cold conductivity compared to wooden and metal components for comparable size and strength parts. In an embodiment where the edge strip is made of a metal that is a good thermal conductor, the metal strips on opposite edges of the structural member are separated by a low thermal conductivity core, thereby providing a low thermal conductivity. In addition, the core acts to reduce (absorb) heat, and the heat will cause moisture to escape the core material, such as gypsum, thereby dissipating the heat. The metal fasteners used to secure the components together are embedded in the core material of the wall panel and the chaplet, thus preventing overheating.

By combining the core material, the side panels and the edge strips, a structural member having high strength and rigidity can be produced. The core holds the side panels in straight parallel planes, so that the side panels establish the strength and rigidity of the structural member with respect to lateral forces. The edge strips further increase the rigidity and strength. The side panels have the strength necessary to resist lateral forces, i.e. forces parallel to the plane of the side panels.

Because the side boards and rigid strips have some strength, the core can be made of low cost materials such as lightweight gypsum, recycled gypsum, or composites containing low cost fillers.

Because the structural members are relatively stiff and can be secured with metal fasteners, a similar treatment to that of a wood product can be performed. The components may also be secured together with adhesives commonly used in the construction industry.

Claims (53)

1. A structural member (200) for supporting at least one panel, comprising a non-thermally conductive load bearing core member (202), the core member having first and second spaced apart side surfaces, first and second spaced apart edge surfaces (204), and first and second end surfaces, the first and second side surfaces and the first and second edge surfaces each terminating in the first and second end surfaces, the spacing between the first and second edge surfaces (204) being at least as large as the spacing between the first and second side surfaces, characterized in that:

first and second reinforcing edge strips (206) are respectively engaged with the first and second edge surfaces (204), the edge strips (206) being separated and spaced apart from the core member (202), the edge strips (206) including extensions (207) extending beyond the first and second end surfaces of the core member (202), the edge strips (206) preventing the core member (202) from bending when subjected to a load in a direction perpendicular to the edge strips (206), the first edge strip (206) being completely covered by a cover sheet (208), the cover sheet (208) having a first overlapping portion (209) covering at least a portion of the first side surface and a second overlapping portion (209) covering at least a portion of the second side surface.

2. The structural member (200) of claim 1, wherein said core member (202) comprises a mixture including gypsum.

3. The structural member (200) of claim 2, wherein a first portion of said core member has a higher density than a second portion of said core member, said higher density portion being located adjacent said first edge surface.

4. The structural member (200) of claim 1, further comprising a frame member comprising a web disposed between two flanges, the core member (202) being disposed between the two flanges.

5. The structural member (200) of claim 1, further comprising at least one side plate (203) secured to said core member and covering said first side.

6. The structural member (200) of claim 5, wherein said cover panel is disposed adjacent said first side panel (203) and further comprising an adhesive securing said cover panel (208) to said side panel (203).

7. The structural member (200) of claim 1, wherein said cover sheet (208) covers said first side, both sides of the cover sheet are folded over each of said edge strips (206), and an edge portion of the cover sheet (208) is disposed on said second side.

8. The structural member (200) of claim 7, further comprising a side panel (203) disposed on said second side and covering said edge portion.

9. The structural member (200) of claim 1 wherein said edge strip (206) is comprised of sheet metal.

10. The structural member (200) of claim 1 wherein said reinforcing edge strips (206) are made from a material selected from the group consisting of cardboard and scrim.

11. The structural member (200) of claim 1, wherein said cover sheet (208) is made of a material selected from the group consisting of paper and textile fiber.

12. The structural member (200) of claim 1, wherein the core member (202) is made of a cement mixture comprising gypsum.

13. The structural member (200) of claim 1, wherein said core member (202) material further comprises a material selected from the group consisting of recycled gypsum, wood chips, fibers, volcanic filler, and mixtures thereof.

14. The structural member (200) of claim 1, wherein said core member (202) comprises at least one gypsum board formed of a gypsum core and side panels.

15. The structural member (200) of claim 14, wherein said core member (202) comprises two gypsum boards secured together by an adhesive.

16. The structural member (200) of claim 1 wherein said first edge strip (206) is porous.

17. The structural member (200) of claim 1, sized to form a wall stud.

18. The structural member (200) of claim 1, sized to form a grid, roof rafter or truss.

19. The structural member (200) of claim 1 further comprising a threaded fastener (218) extending through and secured to said edge strip.

20. The structural member (200) of claim 1 wherein said edge strip (206) including said extension (207) is made from sheet metal.

21. The structural member (200) of claim 1, further comprising a frame member (211) extending between and secured to said extensions.

22. The structural member (200) of claim 1, wherein one of said extensions (207) is folded over said first end surface.

23. The structural member (200) of claim 1, wherein said cover plate (208) further extends beyond said first and second ends of said core member (202).

24. The structural member (200) of claim 22, wherein said cover sheet (208) further extends beyond said first and second end surfaces and is disposed adjacent said extension (207) which is folded over said first end surface.

25. The structural member (200) of claim 1 wherein said edge strip (206) is made of a rigid material.

26. The structural member (200) of claim 1 wherein said edge strip (206) is made of a nonwoven material.

27. The structural member (200) of claim 26 wherein said material is a paper compound.

28. A wall structure having two generally parallel wall panels, said panels being spaced apart from one another to define a wall space therebetween, and said panels being made of gypsum board, providing at least one chaplet (200) in said wall space, said chaplet (200) comprising a core (202) formed from at least a portion of gypsum, and fastening means for fastening said chaplet (200) to said gypsum board, said fastening means comprising an adhesive, the core (202) of said chaplet having first and second spaced apart sides, first and second spaced apart edge surfaces (204), and first and second end faces, said first and second sides and said first and second edge surfaces (204) each terminating in said first and second end faces, each of said edge surfaces facing one of the wall panels, characterized in that:

first and second reinforcing edge strips (206) respectively engaging one of said first and second edge surfaces (204), said edge strips (206) being separated or spaced apart by said core (202), said edge strips (206) including extensions (207) extending beyond said first and second ends of said core (202), said edge strips (206) inhibiting bending of said core (202) when subjected to a load in a direction perpendicular to said edge strips (206), said first edge strips (206) being completely covered by a cover sheet (208), said cover sheet (208) having a first overlapping portion covering at least a portion of said first side and a second overlapping portion covering at least a portion of said second side, said cover sheet (208) being in contact with at least one wall panel.

29. The wall structure of claim 28, wherein said fastening means further comprises at least one staple.

30. The wall structure of claim 28 wherein said adhesive comprises a foamed adhesive.

31. The wall structure of claim 28 wherein said adhesive comprises a PVA adhesive.

32. The wall structure of claim 28 wherein said cover comprises a single paper cover extending over both of said edge strips.

33. A method of making a composite wall chaplet, the method comprising the steps of:

(a) casting a core member of a low thermal conductivity material having first and second spaced apart side surfaces, first and second spaced apart edge surfaces, and first and second end surfaces, said first and second side surfaces and said first and second edge surfaces terminating at said first and second end surfaces,

(b) contacting first and second reinforcing edge strips with first and second edge surfaces, respectively, said edge strips including extensions extending beyond said first and second end surfaces, and

(c) the cover panel is folded about the first reinforcing bead, the first side, and the second reinforcing bead to secure the cover panel to at least a portion of the second side.

34. A structural member (101) for supporting at least one panel, comprising a thermally non-conductive core component (101 or 121), said core component having first and second spaced apart side surfaces and first and second spaced apart edge surfaces (105 or 126), the spacing between said first and second edge surfaces (105 or 126) being greater than or equal to the spacing between said first and second side surfaces, characterized in that:

first and second reinforcing edge strips (104 or 124) are joined to said first and second edge surfaces (105 or 126), respectively, said edge strips (104 or 124) being separated and spaced apart by said core member (102 or 121), each of said edge strips (104 or 124) being completely covered by a cover sheet (106 or 122), said cover sheet (106 or 122) having a first overlapping portion (107) covering at least a portion of said first side and a second overlapping portion (107) covering at least a portion of said second side, the joining of said edge strips (104 or 124) and cover sheets (106 or 122) preventing the core member (102 or 121) from bending when subjected to a load in a direction perpendicular to the edge surfaces (105 or 126) when the structural member (101) is attached to at least one panel with said cover sheet (106 or 122) in contact with the panel.

35. The structural member of claim 34 wherein said core member (102 or 121) comprises gypsum.

36. The structural member of claim 34 wherein said cover panel (122) covers one of said sides and is folded over said edge strip (104 or 124) and an edge portion of the cover panel is folded over the other of said sides.

37. The structural member of claim 34 wherein said edge strips (104 or 124) are formed from sheet metal.

38. The structural member of claim 34, wherein said core member (102 or 121) comprises at least one gypsum board formed of a gypsum core and a backing sheet.

39. The structural member of claim 38, wherein said core member (102 or 121) comprises two gypsum boards secured together by an adhesive.

40. The structural member of claim 34 wherein said edge strips (104 or 124) are porous.

41. The structural member of claim 34 wherein said cover sheet is made of woven fabric or paper.

42. The structural member of claim 34 wherein said edge strips (104 or 124) are made of plastic.

43. A structural member for supporting at least one panel, comprising thermally non-conductive core components (181) comprising a matrix material and a filler material (182), and having first and second spaced apart side surfaces and first and second spaced apart edge surfaces, the spacing between said first and second edge surfaces being at least as great as the spacing between said first and second side surfaces, characterized in that:

first and second reinforcing edge strips (183) are engaged with and completely cover said first and second edge surfaces, respectively, said edge strips being separated and spaced apart by said core member (181), said edge strips (183) preventing the core member (181) from bending when subjected to a load in a direction perpendicular to the edge surfaces when the structural member (101) is attached to at least one panel.

44. The structural member of claim 43, wherein said core member (181) comprises a mixture including gypsum.

45. The structural member of claim 43, wherein said core member (181) comprises a mixture including gypsum and fiber.

46. The structural member of claim 43, wherein said filler material comprises at least one material selected from the group consisting of paper fibers, synthetic fibers, wood chips, and volcanic materials.

47. The structural member of claim 43 wherein said edge strip (183) is comprised of sheet metal.

48. The structural member of claim 43 wherein said edge strip (183) is made of a rigid material.

49. The structural member of claim 43 wherein said edge strip (183) is formed of a nonwoven material.

50. The structural member of claim 49 wherein said nonwoven material is a paper compound.

51. The structural member of claim 43 wherein said edge strip is formed as a cover plate.

52. The structural member of claim 43 wherein the spacing between said first and second edge surfaces is 1-3 times the spacing between said first and second side surfaces.

53. A wall structure comprising two generally parallel wall panels, said panels being spaced apart from one another to define a wall space therebetween, and said panels being formed of gypsum board, at least one core constructed according to claim 34 or 43 being disposed in said wall space.