Leak-proof lead barrier system

[0002] None.

[0003] 1. Field of the Invention

[0004] The present invention is for a leak-proof lead barrier system for use with metal stud framed walls typically installed in X-ray rooms and other areas where radiation protection is needed. The leak-proof lead barrier system utilizes a lead barrier plate secured to the interior of a metal stud before lead-backed gypsum board is installed. The leak-proof lead barrier system can also be adapted for use with header and footer plates.

[0005] 2. Description of the Prior Art

[0006] The current method for creating a leak-proof lead barrier to be used with metal studs and lead laminated gypsum board requires the installer to countersink all the drywall screws into the lead laminated gypsum board when securing the lead laminated gypsum board to metal studs. Once the screws are countersunk, lead screw caps slightly larger than the screw heads are positioned over each and every drywall screw and also countersunk before the seams are taped and finished. In addition to the lead screw caps, a thin strip of sheet lead needs to be installed between the lead portion of the gypsum board and the metal stud where two or more sheets of the lead laminated gypsum board are butted together to prevent leakage at the seam.

[0007] The current method requires extensive, time-consuming labor to install, especially at the joints where two or more sheets of lead laminated gypsum board meet. In addition to the time and labor drawbacks, the integrity of the gypsum in the lead laminated gypsum board is compromised due to countersinking the screws and the use of lead screw caps, which causes the gypsum to crack and crumble.

[0008] The present invention addresses and corrects all of the previously mentioned shortcomings and will be described in detail in the preferred embodiment.

[0009] The general purpose of the present invention is to provide a leak-proof lead barrier system to be used in conjunction with lead laminated gypsum board.

[0010] According to one embodiment of the present invention, there is provided a lead barrier plate, including a mounting portion and a barrier portion, which is appropriately secured to the interior of a metal stud prior to installing lead laminated gypsum board. This lead barrier plate provides a lead barrier where holes are created in the lead backing of the lead laminated gypsum board when it is screwed onto the metal studs and where two or more sheets of the lead laminated gypsum board meet, eliminating the need for lead screw caps and strips of sheet lead at seams.

[0011] One significant aspect and feature of the present invention is an angled lead barrier plate which mounts to the interior of a metal stud.

[0012] Another significant aspect and feature of the present invention is one-step installation of the leak-proof lead barrier plate.

[0013] Still another significant aspect and feature of the present invention is elimination of lead screw caps which compromise the integrity of the gypsum board.

[0014] Yet another significant aspect and feature of the present invention is elimination of lead sheet metal applied to the interior seam of two or more lead laminated gypsum boards.

[0015] A further significant aspect and feature of the present invention is that thickness of the lead barrier plate may be changed to accommodate the needs of the user without affecting form or function.

[0016] Having thus enumerated significant aspects and features of the present invention, it is the principal object of the present invention to provide a leak-proof lead barrier system to be used with lead laminated gypsum board and metal studs.

[0017] One object of the present invention is to provide a leak-proof lead barrier system which can be installed in one step.

[0018] Another object of the present invention is to provide a leak-proof lead barrier system which does not require lead screw caps.

[0019] Yet another object of the present invention is to provide a leak-proof lead barrier system which does not require additional lead sheeting where two or more lead laminated gypsum boards meet.

[0020] Still another object of the present invention is to provide a means of creating a leak-proof lead barrier system which will not compromise the integrity of the lead laminated gypsum board.

[0021] Other objects of the present invention and many of the attendant advantages of the present invention will be readily appreciated as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, in which like reference numerals designate like parts throughout the figures thereof and wherein:

[0022] FIG. 1 illustrates an isometric view of a leak-proof lead barrier system, the present invention;

[0023] FIG. 2 illustrates a top cross-sectional view of the leak-proof lead barrier system; and,

[0024] FIG. 3 illustrates a top cross-sectional view of the prior art method of creating a leak-proof lead barrier system.

[0025] FIG. 1 illustrates an isometric view of a leak-proof lead barrier system 10, the present invention. The leak-proof lead barrier system 10 is created by vertically aligning and securing an angled lead barrier plate 12, having a mounting portion 16 and a barrier portion 14, to the interior of the central planar portion 18 of a metal stud 20. The lead barrier plate 12 is secured to the metal stud 20 by a plurality of sheet metal screws 30a-30nwhich pass through the mounting portion 16 of the lead barrier plate 12 and into the central planar portion 18 of the metal stud 20. It is to be understood that other appropriate means of securement may be used such as, but not limited to, welding, extrusion or metal adhesive. In the illustrated case, the number of sheet metal screws 30a-30nis dependent on the height of the metal stud 20. Each metal stud 20 has a front planar portion 22 and a rear planar portion 24 which extend outwardly from central planar portion 18, and flanges 26 and 28 extend inwardly from the front planar portion 22 and rear planar portion 24, as illustrated.

[0026] The purpose and use of the leak-proof lead barrier system 10 will become visibly apparent when lead laminated gypsum boards are secured to either the front planar portion 22 (FIG. 2), the rear planar portion 24 (not illustrated) or both planar portions 22 and 24 (not illustrated) of the metal stud 20.

[0027] FIG. 2 illustrates a top cross-sectional view of the leak-proof lead barrier system 10. The lead barrier plate 12 is mounted to the metal stud 20 as described in FIG. 1. Illustrated in particular are two lead laminated gypsum boards 32aand 32b, each having a lead portion 34aand 34b, respectively, and oriented in abutting fashion. The juncture where the lead laminated gypsum boards 32aand 32bmeet is centrally aligned along the front planar portion 22 of the metal stud 20 where a plurality of drywall screws 36a-36nsecure the lead laminated gypsum boards 32aand 32bto the metal stud 20. Once again, the number of drywall screws 36a-36nneeded is dependent on the height of the lead laminated gypsum boards 32aand 32band metal stud 20.

[0028] Once the lead laminated gypsum boards 32aand 32bare appropriately secured to the front planar portion 22 of metal stud 20, it becomes apparent that holes 38a-38nare created in the lead portions 34aand 34bof the lead laminated gypsum boards 32aand 32b, creating leaks. Due to the fact that gamma rays, including X-rays, only travel in a straight line, the barrier portion 14 of the lead barrier plate 12 extends beyond flanges 26 and 28, the holes 38a-38n, and the juncture where lead laminated gypsum boards 32aand 32babut. Thus, a leak-proof lead barrier system 10 is created without lead screw caps being installed over each screw or a narrow strip of sheet lead being installed at the seams, as shown in the prior art illustration of FIG. 3.

[0029] FIG. 3 illustrates a top cross-sectional view of the prior art method of creating a leak-proof lead barrier system 100, having lead laminated gypsum boards 104aand 104b, each having a lead portion 105aand 105b, a metal stud 106, and drywall screws 118a-118nidentical to those previously described. The metal stud 106 is comprised of a central planar portion 108, a front planar portion 110, a rear planar portion 112 and two flanges 114 and 116. Illustrated in particular is a sheet lead strip 102 which is positioned between lead portions 105aand 105bof the lead laminated gypsum boards 104aand 104band metal stud 106 and secured in place by drywall screws 118a-118nwhich are countersunk into lead laminated gypsum boards 104aand 104b. The sheet lead strip 102 provides leak protection where lead laminated gypsum boards 104aand 104babut, and lead screw caps 120a-120nare installed over each drywall screw 118a-118nand countersunk to provide leak protection for the holes created by the drywall screws 118a-118n. By countersinking both the drywall screws 118a-118nand the lead screw caps 120a-120n, the gypsum layers of the lead laminated gypsum boards 104aand 104btypically crack and crumble, compromising the integrity of the entire sheets.

[0030] The present invention provides an easy one-step application which is less labor intensive, less time consuming and does not compromise the integrity of the gypsum in the lead laminated gypsum boards.

[0031] Various modifications can be made to the present invention without departing from the apparent scope hereof.