Fire-resistant multiple drywall panel assembly

Abstract

An insulated, fire-resistant pre-fabricated drywall panel assembly is presented. The drywall panel assembly may be assembled from one or more fire-resistant drywall panels, and the panels are designed for seamless installation when placed adjacently. Each drywall panel incorporates a number of layers, including one or more fire-resistant drywall layers, a layer of thermal and acoustic insulation, and sheet metal layers as appropriate. The combination of these layers provides enhanced fire resistance, improved thermal insulation, and reduced sound transmission. When coupled with the seamless installation of adjacent panels, this construction not only improves fire-resistance and minimizes smoke intrusion between sections of a building, but also maintains or enhances the energy efficiency and acoustic performance of the building envelope. The insulation layer may comprise, for example, a flame-retardant polyurethane foam or other suitable insulating material, the selection and thickness of which may be adjusted based on fire-rating, thermal performance, and acoustic requirements.

Description

FIELD OF THE INVENTION

[0001] The present disclosure, in some embodiments, relates to fire-resistant wall construction components for use in building construction.BACKGROUND

[0002] Fire-resistant drywall panels are an essential component of modern building construction. Unlike standard drywall panels, fire-resistant drywall panels include additional fire-resistant materials, offering enhanced protection against fire hazards. These materials may act to slow the spread of a fire by delaying heat penetration and preventing smoke intrusion. Fire-resistant drywall panels are commonly used in residential, commercial, and industrial buildings, particularly in portions of the buildings requiring higher fire safety standards such as stairwells, utility rooms, and walls separating living units.

[0003] In parallel with advances in fire-resistance, drywall panel technology has evolved to incorporate improved insulation characteristics. Modern insulated drywall panels may include integrated thermal and acoustic insulation layers designed to enhance energy efficiency, reduce sound transmission, and improve occupant comfort. These improvements allow insulated wall panels to serve both structural and environmental control functions, reducing the need for separate insulation materials and streamlining wall assembly construction.

[0004] The development of insulated, fire-resistant drywall panels has been driven in part by evolving building codes and safety regulations aimed towards minimizing fire damage while improving energy performance. In addition to increasing fire-resistance and insulation performance, improvements to the structure of these panels have also simplified the installation process, allowing architects and engineers to incorporate insulated, fire-resistant drywall panels into a wider range of building designs and applications, while ensuring labor costs remain low.BRIEF SUMMARY OF THE INVENTION

[0005] Embodiments of the present disclosure present an insulated fire-resistant drywall panel assembly for use in a wide range of building designs and applications. In some embodiments, the insulated, fire-resistant drywall panel is designed to be pre-fabricated prior to installation at a building site. Once transported to the building site, the panels can be attached in succession onto the wall studs of a building frame. According to some embodiments, the successive attachment of the panels to each other simplifies the installation process for the panels over traditional drywall panels.

[0006] In some embodiments, the insulated, fire-resistant drywall panels are designed such that the mounting hardware of one panel is hidden by a portion of the adjacent panel, thereby providing a nearly seamless installation of multiple fire-resistant drywall panels in succession to create a single fire-resistant wall of a building structure. Use of a fire-rated sealant further enhances the fire-resistance of the assembled wall by sealing joints between adjacent panels, limiting the passage of heat, flames, and smoke through panel interfaces while maintaining the structural integrity and aesthetic appearance of the wall assembly.

[0007] According to some embodiments, construction of the panels utilizes an outer sheet metal panel, one or more layers of inner or outer fire-resistant drywall, a flame retardant insulation, one or more layers of inner fire-resistant drywall, and an inner sheet metal panel. This combination of materials results in increased fire and smoke resistance, while ensuring that the wall panel assemblies do not become too heavy for use in building construction. In some embodiments, construction of the fire-resistant drywall panels may result in improved fire-resistance designed to meet or exceed applicable building code requirements, while maintaining or improving the thermal and acoustic insulation performance of the panels as compared to conventional drywall or fire-resistant wall assemblies.

[0008] These and other novel aspects for an insulated, fire-resistant drywall panel assembly will be apparent from the detailed description below. This disclosure including the detailed description should in no way be construed to limit any claimable subject matter regardless of whether the subject matter is presented in claims of the application as it is initially filed or in subsequent claims amended or otherwise presented during prosecution of this disclosure.BRIEF DESCRIPTION OF THE DRAWINGS

[0009] FIG. 1 illustrates a perspective view of an insulated, fire-resistant drywall panel assembly, according to an embodiment.

[0010] FIG. 2 illustrates a side view of an insulated, fire-resistant drywall panel assembly, according to an embodiment.

[0011] FIG. 3 illustrates a side view of the junction point between a first and second insulated, fire-resistant drywall panel, according to an embodiment.

[0012] FIG. 4 illustrates a side view of an insulated, fire-resistant drywall panel assembly rated for 1-hour of fire resistance, according to an embodiment.

[0013] FIG. 5 illustrates a side view of an insulated, fire-resistant drywall panel assembly rated for 2-hour of fire resistance, according to an embodiment.DETAILED DESCRIPTION

[0014] Disclosed herein are several embodiments of an insulated fire-resistant drywall panel assembly for use in building construction. The embodiments disclosed herein are described in the context of use as a wall panel for the interior or exterior of a building. According to certain embodiments, the construction and assembly of the fire-resistant drywall panels are designed to contain the spread of fire and smoke throughout a building.

[0015] In addition to use as interior or exterior wall panels of a building, the insulated, fire-resistant drywall panel assemblies disclosed herein may be used in a variety of other structural and enclosure applications. For example, in some embodiments, the panels may be installed as exterior or interior surfaces of temperature-controlled enclosures, including walk-in refrigerators, freezers, cold storage rooms, or similar insulated compartments. In such applications, the panel assemblies may provide both thermal insulation and fire resistance while meeting sanitation, durability, and safety requirements. The panels may also be used in utility enclosures, equipment rooms, modular structures, or prefabricated assemblies where enhanced fire resistance and insulation performance are desirable.

[0016] As described herein, the insulated fire-resistant drywall panel assembly is designed to replace traditional drywall panels during construction of a building. During traditional building construction, a base framework is built through a method in which concrete is formed in a concrete form or steel beams are installed based on design specifications, and then indoor or outdoor portions such as roofs, ceilings, walls and floors are built and finished. Typically, this base metal or concrete framework incorporates wall studs, which are vertical beams that can sometimes serve as load-bearing elements and onto which the drywall panels are eventually installed. Likewise, exterior wall panels may also be attached directly to wall studs. Once constructed, water, electrical, and insulation is added along and between the studs, and eventually drywall panel assemblies are attached to the studs.

[0017] A well-known point for fire and smoke intrusion between rooms in modern construction buildings is between the gaps formed between adjacent drywall assembly panels. Due to construction and transportation limitations, pre-fabricated drywall panels are typically manufactured in 4′×8′ panels. In order to properly drywall an area larger than 4′×8′, multiple panels of a drywall must be cut and attached to the wall studs adjacently. Attachment to the wall studs is usually facilitated by screws or hex bolts which are drilled through the drywall assembly and directly into the wall stud. As a result of multiple panels being attached adjacently, it is common for small, undesirable gaps to be present between the panels. These gaps have been shown to be a leading factor in smoke and fire intrusion into a building and between sections of a building. Therefore, proper fire-resistance in drywall panel assemblies may be achieved using a combination of fire-resistant materials, and an attachment mechanism between two adjacent panels which reduces or eliminates the gap between the panels. Additionally, in some embodiments a fire-rated sealant may further increase thermal and acoustic insulation between panels.

[0018] FIG. 1 presents, according to some embodiments, a perspective view of an insulated, fire-resistant drywall panel assembly 1. In some embodiments, the drywall panel assembly 1 is formed by one or more drywall panels 1000 which are attached together laterally in succession to form the drywall panel assembly 1. According to some embodiments, the drywall panel may be pre-fabricated in a variety of sizes to accommodate small and large wall constructions.

[0019] Turning now to FIG. 2, a side view of a fire-resistant drywall panel assembly is presented. According to some embodiments, each adjacent drywall panel 1000 has an outer surface 100 and an inner surface 200. The inner surface 200 is the surface which is placed against the wall studs of a building, and is not visible once the panel is installed, while the outer surface 100 is the surface that is visible from the inside of the room, hallway, or staircase in which the drywall panel 1000 is installed. In between the outer surface 100 and inner surface 200 is one or more layers, which together with the outer surface 100 and the inner surface 200 form each drywall panel 1000. In certain embodiments, the drywall panels 1000 may be installed on the exterior of a building, wherein the inner surface 200 is attached to the outside of the wall studs, and the outer surface 100 is exposed to the outside of the building. In other contemplated embodiments, the drywall panels 1000 may be installed on the interior or exterior of a refrigeration section of a building or warehouse. When used in refrigeration, the drywall panels 1000 operate to increase fire resistance, while also providing additional temperature resistance for the building.

[0020] FIG. 3 depicts a side view of the junction point between a first and second drywall panel 1000, according to one embodiment. In certain embodiments, both the outer surface 100 and inner surface 200 of each drywall panel 1000 comprise a layer of sheet metal 101. This sheet metal layer 101 is designed to act as a barrier, providing the initial form of protection to the layers of material forming the drywall panel 1000. This includes protection against moisture and physical contact against the softer, more fragile fire-resistant inner portions of the fire-resistant drywall panel 1000.

[0021] In some embodiments, the sheet metal layer 101 comprises a pre-painted galvanized steel sheet having a thickness in the range of approximately Gauge 22 to Gauge 26. The pre-painted galvanized steel sheet may be provided on both the outer and inner faces of the drywall panel 1000, as depicted in the accompanying drawings. The selected gauge may balance structural rigidity, weight, corrosion resistance, and ease of handling and installation, depending on the intended application. The galvanized steel may further include a factory-applied pre-painted finish, which can improve durability, resistance to environmental exposure, and aesthetic appearance, while reducing the need for on-site finishing. The thickness, coating type, and surface finish of the sheet metal layer 101 may be selected based on intended application requirements, including environmental conditions, fire-rating objectives, and design preferences, without departing from the scope of the disclosed embodiments.

[0022] The drywall panels 1000 may also be coated with a fire-resistant sealant, applied to the sheet metal layer 101 or other surfaces of the panel. This sealant can further enhance the fire resistance of the panel, helping to meet or exceed relevant fire-rating standards while maintaining the panel's structural and aesthetic properties.

[0023] In certain embodiments, beneath the outer sheet metal panel 101(a) is a layer of fire-resistant drywall 102. Depending on the intended duration of fire-resistance, the thickness of the drywall 102 may range from ½″ to 2″. The specific type of drywall 102 used may vary depending on a number of factors including the type of building being built and the climate of the intended building. By way of example, certain types of fire-resistant drywall are better suited for mold-resistance for use in moist or humid climates, while other types of fire-resistant drywall may provide enhanced acoustic performance. In some embodiments, the fire-resistant drywall 102 comprises a fire-rated gypsum board configured to provide at least a one-hour fire-resistance rating. Typical examples of fire-resistant drywall may include, but are not limited to, Type X or Type C drywall.

[0024] Beneath the outer lay of drywall 101(a) is a layer of flame-retardant foam 103. According to some embodiments, the flame-retardant foam 103 may comprise a flame-retardant polyurethane (PU) foam or equivalent type flame-retardant foam, the selection of which will be within the skill of one in the art. Foams other than polyurethane may include polystyrene, polyvinylchloride, polyethylene, polypropylene, acrylonitrile butadiene styrene, polyethylene terephthalate, and cellulose acetate. D. Feldman, Polymeric Foam Materials for Insulation in Buildings, MATERIALS FOR ENERGY EFFICIENCY AND THERMAL COMFORT IN BUILDINGS, 257-273 (2010).

[0025] In certain embodiments, the PU foam exhibits a substantially uniform density across the panel and is of a self-extinguishing type configured to limit flame propagation when exposed to fire. The flame-retardant foam 103 may further be formulated to comply with applicable fire-testing and performance standards, including but not limited to standards governing flame spread, smoke development, and heat release. The use of a flame-retardant foam 103 beneath the outer layer of fire-resistant drywall 102 adds to the overall fire resistance of the drywall panel 1000, while also providing additional acoustic insulation and thermal resistance in the drywall panel 1000. The thickness of the flame-retardant foam 103 may vary depending on a number of factors including the intended duration of fire-resistance, the particular type and formulation of flame-retardant foam used, and the intended thickness of the wall panel assembly 1. For example, the thickness of the flame-retardant foam may be between 1½″ to 8″.

[0026] According to certain embodiments, beneath the flame-retardant foam layer 103 is one or more additional layers of fire-resistant drywall 104(a) &104(b). Similar to the fire-resistant drywall 102 on the other side of the flame-retardant foam 103, the inner layers of fire-resistant drywalls 104(a) &104(b) provide additional fire-resistance for the drywall panel 1000. The number of additional layers of drywall, along with the thickness of the layers of drywall may vary depending on intended fire-resistance duration, weight limitations for the drywall panel assembly 1, and other factors. For example, the thickness of the inner layers of drywall may be ½″ to 2″.

[0027] The layer of inner sheet metal 101(b) attaches directly to these additional layers of fire-resistant drywall 104(a) &104(b), thereby forming a drywall panel 1 with inner and outer sheet metal layers 101(a) &101(b) and layers of fire-resistant drywall 102, 104(a) &104(b) and flame-retardant foam 103 held between.

[0028] As described herein previously, in certain embodiments of the fire-resistant drywall panel assembly 1, each drywall panel 1000 is comprised of a number of layers including the inner and outer sheet metal 101(a) &101(b), fire-resistant drywall 102, 104(a) &104(b), and a layer of flame-retardant foam 103. These materials are layered together to form each pre-assembled fire-resistant drywall panel 1000. In some embodiments, the various layers are held together using mechanical fasteners. This may include one or more screws, bolts, nails, rivets, clamps, pins, threaded inserts, or anchors. Some embodiments may utilize multiple types of mechanical fasteners simultaneously to provide enhanced assembly of the drywall panel 1000.

[0029] In some other assemblies, the various layers of the fire-resistant drywall panel 1000 may be held together by an adhesive. This adhesive may be, for example, an epoxy acrylic adhesive, or other type of adhesive, and is added between each layer to keep the layers bonded together. Certain embodiments may utilize multiple types or layers of adhesive to increase the strength of the bond between each layer. In some embodiments, mechanical fasteners and adhesives are used in combination to further strengthen the bond between each layer of the drywall panel assembly.

[0030] As described herein, the fire-resistant drywall panel assembly 1 is designed to replace traditional drywall panels during construction of a building. Like traditional drywall panels, the pre-fabricated fire-resistant drywall panels 1000 are designed for direct attachment to wall studs. Mechanical fasteners including one or more of screws, bolts, nails, rivets, clamps, pins, threaded inserts, or anchors may be used to attach each fire-resistant drywall panel 1000 to the wall studs. One example of a fastener 106 is a hex bolt, as depicted in FIG. 3.

[0031] According to certain embodiments, the shape of the fire-resistant drywall panel assembly 1 is designed such that adjacent panels 1000 may be securely attached to one another without the use of any mechanical fasteners, and the mechanical fasteners 106 that are used to attach the panel assemblies to the wall studs are completely hidden by each adjacent panel. This provides a smooth and nearly seamless transition between adjacent panels 1000, thereby preventing smoke and fire intrusion through the gaps between panels. Attachment of adjacent panels 1000, as depicted in FIG. 1, is achieved by shaping each wall panel 1000 to have a first edge 300 and a second edge 400, wherein the first edge 300 and second edge 400 are shaped to interlock with the adjacent section (as depicted in FIG. 3). This creates a substantially airtight and secure attachment point between the first edge 300 of a first panel 1000(a) and the second edge 400 of the adjacent panel 1000(b).

[0032] Referring to FIG. 3, in some embodiments, the first edge 300 of the outer side 100 of each drywall panel 1000 includes an outer overhang tab 301, while the second edge 400 of the outer side 100 includes an outer overhang tab insert 401. One or more of the outer drywall layer 102 and the outer sheet metal layer 101(a) form the outer overhang tab 301 which is a portion of the outer drywall layer 102 and the outer sheet metal layer 101(a) that extends beyond the flame-retardant foam 103. On the second edge 400, the outer overhang tab insert 401 is formed by extending the flame-retardant foam 103 outwards beyond the outer drywall layer 102 and the outer sheet metal layer 101(a).

[0033] A similar construction is utilized on the inner surface 200 of the fire-resistant drywall panel 1000. The first edge 300 of the inner surface 200 of the fire-resistant drywall panel 1000 includes an inner overhang tab insert 302, while the second edge 400 forms an inner overhang tab 402. According to some embodiments, one or more of the inner drywall layers 104(a) &104(b) and the inner sheet metal layer 101(b) form the inner overhang tab insert 302 which is a portion of the inner drywall layers 104(a) &104(b) and the inner sheet metal layer 101(b) that extends beyond the flame-retardant foam 103 on the first edge 300 Likewise, on the second edge 400, the flame-retardant foam 103 extends outwards beyond the inner drywall layers 104(a) &104(b) and the inner sheet metal layer 101(b), forming the inner overhang tab 402.

[0034] In certain embodiments, the inner overhang tab insert 02 may have a small cutout 403 with a pre-drilled through-hole. This through-hole may be sized to accommodate whichever mechanical fastener 106 is being used to attach the drywall panel 1000 directly to the studs. Installation of the panels requires a first panel 1000(a) to be directly attached to the stud by a mechanical fastener 106 through the pre-drilled through-hole. Once the first panel 1000(a) is attached to the wall, an adjacent panel 1000(b) may be installed by inserting the outer overhang tab insert 401 of a second panel 1000(b) underneath the outer overhang tab 301 of the first panel 1000(a) and pushing the second panel 1000(b) laterally until the outer overhang tab 301 of the first panel 1000(a) sits flush over the outer overhang tab insert 401 of the second panel 1000(b). Simultaneously, the inner overhang tab 402 of the second panel 1000(b) may be inserted over the inner overhang tab insert 302 of the first panel 1000(a), necessarily also covering the mechanical fastener 106 and cutout 403 of the first panel 1000(a).

[0035] Once fully inserted, the second panel 1000(b) may then be attached to a wall stud using a mechanical fastener 106 through the pre-drilled through-hole located on the cutout 403. This process may be repeated as many times as necessary to fully cover the wall with the pre-assembled wall panels 1000, thereby creating a smooth, flame resistant wall of drywall panels for the interior of a building.

[0036] In certain embodiments, a fire-resistant sealant may be applied between the panels to increase thermal and acoustic insulation. Examples of suitable sealants may include but are not limited to intumescent sealants, silicone-based fire-resistant sealants, acrylic fire-resistant caulks, and epoxy-based fire-resistant coatings, each selected based on the desired level of fire resistance, adhesion, and environmental performance.

[0037] FIG. 4 illustrates a side view of an insulated, fire-resistant drywall panel assembly 1000 rated for approximately one hour of fire resistance, according to one embodiment. In the embodiment depicted in FIG. 4, the panel assembly 1000 includes, in order from an exterior-facing side to an interior-facing side, an outer sheet metal layer 101(a), a layer of flame-retardant polymer foam 103, a single layer of fire-resistant drywall 102, and an inner sheet metal layer 101(b). This configuration provides a balance of fire resistance, thermal insulation, and structural rigidity while minimizing overall panel thickness and weight. In certain embodiments, the materials and thicknesses of the layers are selected such that the panel assembly meets or exceeds applicable one-hour fire-resistance requirements while also providing acoustic and thermal insulation benefits.

[0038] FIG. 5 illustrates a side view of an insulated, fire-resistant drywall panel assembly 1000 rated for approximately one hour of fire resistance, according to another embodiment. In the embodiment depicted in FIG. 5, the panel assembly 1000 includes, in order from an exterior-facing side to an interior-facing side, an outer sheet metal layer 101(a), a layer of flame-retardant polymer foam 103, a first layer of fire-resistant drywall 102, a second layer of fire-resistant drywall 104, and an inner sheet metal layer 101(b). The inclusion of multiple layers of fire-resistant drywall increases the fire-resistance, sound attenuation, and structural integrity of the panel assembly while maintaining insulation performance provided by the flame-retardant foam 103. In some embodiments, this multi-layer drywall configuration may provide enhanced performance margins relative to fire-rating, impact resistance, or acoustic isolation, while remaining compatible with the interlocking edge structures and concealed fastener systems described herein.

[0039] It will be appreciated that the material stack-ups illustrated in FIGS. 4 and 5 are exemplary only, and that other layer configurations and material combinations are contemplated within the scope of the disclosed embodiments. For example, as one skilled in the art would recognize, one or more layers of fire-resistant drywall may be replaced with or supplemented by alternative fire-resistant boards, including cement board, magnesium oxide board, calcium silicate board, fiber-reinforced gypsum board, or other fire-rated panel materials now known or later developed. Likewise, the number, thickness, and arrangement of insulation layers, fire-resistant layers, and sheet metal layers may be varied to achieve different fire-resistance ratings, thermal performance, acoustic properties, structural characteristics, or code compliance requirements, without departing from the principles of the insulated, fire-resistant drywall panel assembly described herein.

[0040] While various embodiments of the present disclosure have been described in detail, it should be apparent that modifications and variations thereto are possible, all of which fall within the true spirit and scope of the disclosure. For example, various other embodiments may utilize different or multiple attachment methods onto the wall studs.

[0041] Additionally, various embodiments may utilize different arrangements of the layers of flame-resistant materials therein, or use multiple layers of the same materials to increase fire resistance. Therefore, the foregoing is intended only to be illustrative of the principles of the disclosure. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not intended to limit the disclosure to the exact construction and operation shown and described. Accordingly, all suitable modifications and equivalents may be included and considered to fall within the scope of the disclosure, defined by the following claim or claims.

[0042] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the disclosure. As used herein, the term “and / or” includes any and all combinations of one or more of the associated listed items. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well as the singular forms, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and / or “comprising” when used in this specification, specify the presence of stated features, steps, orientations, elements, and / or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, components, and / or groups thereof.

[0043] Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one having ordinary skill in the relevant art. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and the present disclosure and will not be interpreted in an idealized or overly formal sense, unless expressly so defined herein.

[0044] It will be understood that a number of techniques and steps relating to the disclosure are presented. Each of these has individual benefits and each can also be used in conjunction with one or more, or in some cases all, of the other disclosed techniques. Accordingly, for the sake of clarity, this description will refrain from repeating every possible combination of the individual steps in an unnecessary fashion. Nevertheless, the specification and claims should be read with the understanding that such combinations are entirely within the scope of the inventions and the claims.

Claims

1. A wall panel assembly for use in building construction comprising:a layer of outer sheet metal;one or more layers of outer drywall;a layer of foam;one or more layers of inner drywall; anda layer of inner sheet metal.

2. The wall panel assembly of claim 1 wherein the outer drywall layer and the inner drywall layer are comprised of fire-resistant drywall.

3. The wall panel assembly of claim 1 wherein the foam is a flame-retardant polyurethane foam.

4. The wall panel assembly of claim 1 wherein the outer sheet metal, outer drywall, foam, inner drywall, and inner sheet metal layers are attached to each other using an adhesive or a first mechanical fastener.

5. The adhesive of claim 4 comprising an epoxy or acrylic adhesive.

6. The first mechanical fastener of claim 4 comprising one or more of a screw, bolt, nail, rivet, clamp, pin, threaded insert, or an anchor.

7. The wall panel assembly of claim 1 wherein one or more of the outer drywall layer and the outer sheet metal layers include an outer overhang tab or an outer overhang tab insert.

8. The wall panel assembly of claim 7 wherein the outer overhang tab of one wall panel assembly overlaps atop of the outer overhang tab insert of another wall panel assembly when two wall panel assemblies are adjacent to one another forming a smooth outer layer.

9. The wall panel assembly of claim 1 wherein one or more of the inner drywall layers and the inner sheet metal layers include an inner overhang tab or an inner overhang tab insert.

10. The wall panel assembly of claim 8 wherein the inner overhang tab of one wall panel assembly partially overlaps atop of the inner overhang tab insert of another wall panel assembly when two wall panel assemblies are adjacent to one another such a portion of the inner overhang tab insert of one of the panels is left partially exposed.

11. The partially exposed inner overhang tab insert of claim 10 forming a surface into which a second mechanical fastener is inserted through.

12. The wall panel assembly of claim 1 wherein a fire-retardant sealant is applied between adjacent wall panels.

13. The wall panel assembly of claim 1 wherein a second mechanical fastener attaches each wall panel to a wall support structure.

14. The wall support structure of claim 13 comprising one or more of wall studs, metal framing members, concrete or masonry substrates, or prefabricated modular support panels.

15. A wall panel assembly for use in building construction comprising:a layer of outer sheet metal;one or more layers of outer drywall;a layer of foam; anda layer of inner sheet metal.

16. The wall panel assembly of claim 15 wherein the layer of foam and the inner sheet metal layer include an inner overhang tab or an inner overhang tab insert.

17. The inner overhang tab insert of claim 16 forming a surface into which a mechanical fastener is inserted.

18. A wall panel assembly for use in building construction comprising:one or more layers of sheet metal;one or more layers of fire-resistant drywall; andone or more layers of fire-resistant foam.

19. The wall panel assembly of claim 18 wherein the sheet metal, fire-resistant drywall, and fire-resistant foam layers are attached to each other using an adhesive or a first mechanical fastener.

20. The wall panel assembly of claim 19 wherein a second mechanical fastener attaches each wall panel to a wall support structure.

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