Shear wall panel

Abstract

Shear wall panels and methods of manufacturing shear wall panels. Various embodiments comprise wallboard material employed with a sheet stiffener in the form of a plate to form a wall panel that may be used in applications wherein shear panels are desired.

1 . A shear wall panel, comprising: 
 a plate having first and second substantially planar sides and a plurality of holes extending therethrough;    a first flanged portion extending around at least a portion of at least one of said holes and protruding from said first substantially planar side of the plate;    a second flanged portion extending around at least a portion of at least one other of said holes and protruding from said second substantially planar side of the plate; and    wallboard material applied to said first and second sides of said plate.    
   
   
       2 . The shear wall panel of  claim 1  wherein said wallboard material extends through at least some of said holes and at least some of said other of said holes.  
   
   
       3 . The shear wall panel of  claim 1  further comprising: 
 a first backing sheet attached to said wallboard material on said first side of said plate; and    a second backing sheet attached to said wallboard material on said second planar side of said plate.    
   
   
       4 . The shear wall panel of  claim 1  wherein said plate comprises material selected from the group consisting of steel, aluminum, wood, lead and plastic.  
   
   
       5 . The shear wall panel of  claim 1  wherein the wallboard material comprises a material selected from the group consisting of gypsum material and cementitious material.  
   
   
       6 . The shear wall panel of  claim 1  wherein at least some of said holes are round.  
   
   
       7 . The shear wall panel of  claim 1  wherein at least some of said other of said holes are round.  
   
   
       8 . The shear wall panel of  claim 1  wherein at least some of said holes are round and at least some of said other holes are round.  
   
   
       9 . A shear wall panel, comprising: 
 a plate having first and second substantially planar sides, a pair of lateral edges and a pair of end edges;    a plurality of holes extending through said plate;    a flanged portion extending along each said lateral edge and protruding outward from said first planar side of said plate; and    wallboard material applied to said first planar side of said plate.    
   
   
       10 . The shear wall panel of  claim 9  further comprising: 
 a first backing sheet attached to said wallboard material on said first side of said plate; and    a second backing sheet attached to said second planar side of said plate.    
   
   
       11 . The shear wall panel of  claim 9  wherein said plate comprises material selected from the group consisting of steel, aluminum, wood, lead and plastic.  
   
   
       12 . The shear wall panel of  claim 9  wherein the wallboard material comprises a material selected from the group consisting of gypsum material and cementitious material.  
   
   
       13 . The shear wall panel of  claim 9  wherein at least some of said holes are round.  
   
   
       14 . A shear wall panel, comprising: 
 a plate having first and second substantially planar sides, a pair of lateral edges and a pair of end edges;    a plurality of holes extending through said plate;    a flanged portion extending along each said end edge and protruding outward from said first planar side of said plate; and    wallboard material applied to said first planar side of said plate.    
   
   
       15 . The shear wall panel of  claim 14  further comprising: 
 a first backing sheet attached to said wallboard material on said first side of said plate; and    a second backing sheet attached to said second planar side of said plate.    
   
   
       16 . The shear wall panel of  claim 14  wherein said plate comprises material selected from the group consisting of steel, aluminum, wood, lead and plastic.  
   
   
       17 . The shear wall panel of  claim 14  wherein the wallboard material comprises a material selected from the group consisting of gypsum material and cementitious material.  
   
   
       18 . The shear wall panel of  claim 14  wherein at least some of said holes are round.  
   
   
       19 . A shear wall panel, comprising: 
 a plate having first and second substantially planar sides, a pair of lateral edges and a pair of end edges;    a plurality of holes extending through said plate;    a lateral flange extending along each said lateral edge and protruding outward from said first planar side of said plate;    an end flange extending along each said end edge and protruding outward from said first planar side of said plate;    wallboard material applied to said first planar side of said plate.    
   
   
       20 . The shear wall panel of  claim 19  further comprising: 
 a first backing sheet attached to said wallboard material on said first side of said plate; and    a second backing sheet attached to said second planar side of said plate.    
   
   
       21 . The shear wall panel of  claim 19  wherein said plate comprises material selected from the group consisting of steel, aluminum, wood, lead and plastic.  
   
   
       22 . The shear wall panel of  claim 19  wherein the wallboard material comprises a material selected from the group consisting of gypsum material and cementitious material.  
   
   
       23 . The shear wall panel of  claim 19  wherein at least some of said holes are round.  
   
   
       24 . A shear wall panel, comprising: 
 a plate having first and second substantially planar sides, a pair of lateral edges and a pair of end edges;    a plurality of holes extending through said plate;    a flanged portion extending around at least a portion of at least one of said holes and protruding from said first substantially planar side of the plate;    a lateral flange extending along each said lateral edge and protruding outward from said first planar side of said plate; and    wallboard material applied to said first planar side of said plate.    
   
   
       25 . The shear wall panel of  claim 24  wherein each said flanged portion has an end and wherein said wallboard material covers said ends of said flange portions.  
   
   
       26 . The shear wall panel of  claim 25  wherein said lateral flanges protrude from said first planar side a first distance and wherein each said flanged portion protrudes from said first planar side a second distance that is substantially equal to said first distance.  
   
   
       27 . The shear wall panel of  claim 26  wherein said second distance is less than said first distance.  
   
   
       28 . A shear wall panel, comprising: 
 a plate having first and second substantially planar sides, a pair of lateral edges and a pair of end edges;    a plurality of holes extending through said plate;    a first flanged portion extending around at least a portion of at least one of said holes and protruding from said first substantially planar side of the plate;    an end flange extending along each said end edge and protruding outward from said first planar side of said plate; and    wallboard material applied to said first planar side of said plate.    
   
   
       29 . The shear wall panel of  claim 28  wherein each said flanged portion has an end and wherein said wallboard material covers said ends of said flange portions.  
   
   
       30 . The shear wall panel of  claim 29  wherein each said end flange protrudes from said first planar side a first distance and wherein each said flanged portion protrudes from said first planar side a second distance that is substantially equal to said first distance.  
   
   
       31 . The shear wall panel of  claim 30  wherein said second distance is less than said first distance.  
   
   
       32 . A shear wall panel, comprising: 
 a plate having first and second substantially planar sides, a pair of lateral edges and a pair of end edges;    a plurality of holes extending through said plate;    first flanged portion extending around at least a portion of at least one of said holes and protruding from said first substantially planar side of the plate;    a lateral flange extending along each said lateral edge and protruding outward from said first planar side of said plate;    an end flange extending along each said end edge and protruding outward from said first planar side of said plate; and    wallboard material applied to said first planar side of said plate.    
   
   
       33 . The shear wall panel of  claim 32  wherein each said flanged portion has an end and wherein said wallboard material covers said ends of said flange portions.  
   
   
       34 . The shear wall panel of  claim 33  wherein each said lateral flange and each said end flange protrudes from said first planar side a first distance and wherein each said flanged portion protrudes from said first planar side a second distance that is substantially equal to said first distance.  
   
   
       35 . The shear wall panel of  claim 34  wherein said second distance is less than said first distance.  
   
   
       36 . A shear wall panel; comprising: 
 a plate having first and second substantially planar sides and a plurality of holes extending therethrough; and    wallboard material applied to said first and second sides of said plate and extending through said holes therein such that the plate is substantially embedded in said wallboard material.    
   
   
       37 . The shear wall panel of  claim 36  further comprising: 
 a first backing material applied to the wallboard material applied to said first substantially planar side of said plate; and    a second backing material applied to the wallboard material applied to said second substantially planar side of said plate.    
   
   
       38 . The shear wall panel of  claim 36  wherein said plate comprises material selected from the group consisting of steel, aluminum, wood, lead and plastic.  
   
   
       39 . The shear wall panel of  claim 36  wherein the wallboard material comprises a material selected from the group consisting of gypsum material and cementitious material.  
   
   
       40 . The shear wall panel of  claim 36  wherein at least some of said holes are round.  
   
   
       41 . A shear wall panel comprising: 
 a corrugated plate having a first side and a second side and a plurality of holes therethrough; and    wallboard material applied to at least one side of the corrugated plate.    
   
   
       42 . The shear wall panel of  claim 41  wherein said corrugated plate has a plurality of open first troughs on a first side thereof and a plurality of open second troughs on a second side thereof and wherein at least some of said first and second troughs have wallboard material therein.  
   
   
       43 . The shear wall panel of  claim 42  wherein each of said first troughs has a first bottom surface and wherein each of said second troughs has a second bottom surface, said first and second bottom surfaces interconnected by corresponding lateral walls.  
   
   
       44 . The shear wall panel of  claim 43  wherein each of said lateral walls are inclined with respect to said first and second bottom surfaces.  
   
   
       45 . The shear wall panel of  claim 43  wherein each of said lateral walls is substantially perpendicular to said first and second bottom surfaces.  
   
   
       46 . The shear wall panel of  claim 43  wherein said holes extend through at least one of said first and second bottom surfaces.  
   
   
       47 . The shear wall panel of  claim 43  wherein said holes extend through at least one of said lateral walls.  
   
   
       48 . The shear wall panel of  claim 43  wherein said holes extend through said first and second bottom surfaces and said lateral walls.  
   
   
       49 . The shear wall panel of  claim 41  further comprising: 
 a first backing material applied to the first side of the plate; and    a second backing material applied to the second side of the plate.    
   
   
       50 . A method of manufacturing a shear wall panel comprising: 
 forming a series of holes in a plate having substantially planar first and second sides; and    applying wallboard material to the first and second planar sides of the plate such that the wallboard material extends into the holes in the plate to form a panel assembly.    
   
   
       51 . The method of  claim 50  further comprising curing the wallboard material.  
   
   
       52 . The method of  claim 50  wherein said curing comprises placing the panel assembly into an oven.  
   
   
       53 . The method of  claim 52  further comprising applying a first backing material to the wallboard material on the first planar side of the plate.  
   
   
       54 . The method of  claim 52  wherein the first backing material is applied to the wallboard material on the first planar side of the plate prior to said curing.  
   
   
       55 . The method of  claim 54  further comprising applying a second backing material onto the second substantially planar side of the plate.  
   
   
       56 . The method of  claim 55  wherein the first and second backing materials are applied prior to said curing.  
   
   
       57 . The method of  claim 50  further comprising: 
 forming a first flanged portion around at least one hole such that the first flanged portion protrudes from the first substantially planar side; and    forming a second flanged portion around at least one hole such that the second flanged portion protrudes from the second substantially planar side.    
   
   
       58 . A method of fabricating a shear wall panel comprising: 
 forming holes in a plate; and    embedding the plate in a wallboard material such that the wallboard material is received in the holes in the plate.    
   
   
       59 . A method of fabricating a shear wall panel comprising: 
 placing a first backing sheet into a mold cavity;    applying an adhesive to the first backing sheet;    applying a first amount of wallboard material onto the adhesive and first backing sheet;    placing a first side of a plate having a series of holes therethrough onto the wallboard material;    applying pressure to the plate to cause the wallboard material to substantially uniformly disperse along one side of the plate and extend through at least some of the holes in the plate; and    curing the first amount of wallboard material.    
   
   
       60 . The method of  claim 59  further comprising adhering a second backing material onto a second side of the plate  
   
   
       61 . The method of  claim 59  further comprising: 
 applying a second amount of wallboard material onto a second side of the plate;    uniformly dispersing the second amount of wallboard material onto the second side of the plate; and    curing the second amount of wallboard material.    
   
   
       62 . The method of  claim 61  wherein the curing of the first and second amounts of wallboard materials comprises placing the mold containing the plate and first and second amounts of wallboard material into an oven.  
   
   
       63 . The method of  claim 61  further comprising adhering a second backing material onto the second amount of wallboard material.