WO2005031080A1

WO2005031080A1 - An acoustic partition and clip for use in same

Info

Publication number: WO2005031080A1
Application number: PCT/AU2004/001312
Authority: WO
Inventors: Campbell John Seccombe
Original assignee: Bluescope Steel Limited
Priority date: 2003-10-01
Filing date: 2004-09-24
Publication date: 2005-04-07

Abstract

A clip (10) for mounting a building element (50) to an underlying structure has a base (11) and a pair of upstanding legs (12 and 13). Each leg has on its distal end a respective channel (16 and 17) operative to receive the building element so as to support the building element in spaced relationship from the base. The clip is arranged to be used in partition walls with the spacing of the building element from the base enhancing the acoustic performance of the partition. To further inhibit sound transmission between the building element and the clip, a resilient liner may be disposed between the body portion and the building element. A channel shaped clip (30) is also disclosed that incorporates a sound inhibiting liner (32). The clip (30) may be formed by profiling a layered sheet having a metal layer and a layer of resilient material that forms the liner (32).

Description

AN ACOUSTIC PARTITION AND CLIP FOR USE IN SAME

TECHNICAL FIELD

The present invention relates generally to partitions that exhibit enhanced acoustic performance and to clips for use in securing building elements such as battens to an underlying structure for use in such partitions. The invention has particular application to building walls where wall panels are connected to a structural wall through a clip and the invention is herein described in that context. However, it is to be appreciated that the invention has broader application and is not limited to that use. For example, the invention may be utilised in ceilings or floors or the like.

BACKGROUND In recent times there has been an increasing trend to higher density living. Whilst this trend has numerous advantages, it has increased the need to develop wall or flooring systems that will reduce the amount of sound that is transmitted between adjoining properties. The ability to inhibit sound transmission is a major consideration in the design of apartments or other multi dwelling structures. As sound transmits by vibration, it has been recognised that sound often is transmitted through fastening clips that secure paneling to a common structural wall. SUMMARY OF THE INVENTION

In a first aspect, the invention provides a clip for mounting a building element to an underlying structure, the clip comprising a body portion mountable to the underlying structure having a base and a pair of legs upstanding from the base, each leg having a coupling operative to receive an edge region of the building element so as to support the building element in spaced relationship from the base. In a particular embodiment, the clip provides a resilient mount for the building element. By providing a resilient mount, vibration between the building element and the underlying structure can be reduced thereby inhibiting sound transmission through the building wall . In one form, the clip is rigid and the resilience is provided by a liner which is disposed in each coupling. In a particular form, this liner is formed from a resilient material such as a compressible foam. In another form, the legs are able to flex so as to provide at least part, if not all, of the requisite resilience. In one form, only a portion of each leg is operative to flex, and in a particular form, this portion is a distal region of the respective legs which incorporate the couplings. In that form, a proximal portion of the respective legs which are connected to the base are of a greater rigidity. In one form, each coupling is channel shaped so as to retain a portion of the building element in engagement with the clip. In one form, the channels of the respective couplings are in facing relationship. This arrangement has the advantage of facilitating installation of the building element and further reduces the sound transmission through the clip as it obviates the need for separate fastening which may provide a conduit for sound transmission. In a particular embodiment, the body portion of the clip is formed from sheet metal. The clip is simply formed by profiling the sheet metal by folding, pressing, roll forming or punching operation (or combination thereof) . Typically the liner is then inserted into the clip as a separate operation. In the alternative embodiment, the clip may be formed from material other than metal. For example, the clip may be made from plastic that is extruded in lengths or moulded. In a further aspect, the present invention provides a clip for connecting a building element to underlying structure, the clip having a channel shaped body portion mountable to the underlying structure and incorporating a base and side margins that upstand from the base, and a liner formed from resilient material disposed in the channel, wherein the channel is arranged to receive the building element with the liner being arranged to inhibit sound transmission between the body portion and the building element. In a particular embodiment, the channel is shaped so as to retain the building element in engagement with the clip. This arrangement has the advantage of facilitating insulation of the clip and further reduces the sound transmission through the clip as it obviates a need for separate fastening which may provide a conduit for sound. In a particular embodiment, the clip according to the second aspect is formed from layered sheet material having a metal layer and a layer of resilient material. The clip is simply formed by profiling the layered structure by a folding, pressing, roll forming or punching operation (or combination thereof) with the metal layer forming the body portion and the compressive layer forming the liner. In an alternative embodiment, the body portion may be formed from material other than metal. For example, the body portion may be made of plastic that is extruded in length or moulded. In the latter application, the liner may be integrally formed with the body portion or inserted in a separate operation. In one form, the resilient material is able to be compressed. In a particular form, the sound absorbing material is a foam such as a soft closed cell polyethylene . In a particular embodiment, the side margins of the body portion each have a distal lip that projects inwardly over the base portion. In a preferred form, the liner is disposed in the distal lip. In one form, the clip in either aspect described above is operative to be connected to the underlining structure by one or more mechanical fasteners that extent from the base into the underlying structure. In that arrangement, the base may include one or more pre-formed holes to receive the fasteners . Depending on the construction of the underlying structure, the fasteners may be self-tapping screws, anchor bolts, rivets or the like. In one form, the clip is arranged to be used in conjunction with a concrete partition wall such as that disclosed in the applicant's co-pending International application WO2003/046312, the contents of which are herein incorporated by cross reference. The wall according to that application is formed using a modular panel that incorporates stiffening formations on its outer surface. These stiffening formation may be in the form of corrugations, or pleats or the like and are incorporated to improve the strength of the panel so as to be able to resist the hydrostatic pressure induced on filling the panel with concrete. In using the clip in that application, a raised seat may project from the base in a direction opposition to the direction in which the legs extend. The seat is arranged to receive a fastener to secure the clip to the underlying structure. The advantage of using a seat is that it can be designed to inter-fit within adjacent corrugations or ribs of the panel according to the above form. In one form, the seat is profiled so that the clip can locate between the stiffening formation in at least two orientations which are displaced from one another through 90°^■ In one form, the clip further includes engaging elements which extend downwardly from the legs towards the base . These engaging elements are arranged to dig in to an insulation blanket so as to locate the blanket relative to the clip thereby facilitating installation of the blanket . The clip according to the above forms has substantial practical benefit. It can be manufactured simply and inexpensively. It is also ideally suited to be used with conventional metal battens that are of a generally top hat profile having opposing webs which are interconnected at one end, and which incorporate outwardly extending flanges at their other end. The battens can be simply attached to the clip by flexing the batten webs to locate the outwardly extending flanges into engagement with the clip. The webs on being released tend to return to their natural state which biases the flanges into the couplings, or side margins, of the clip thereby effectively retaining the batten in place without necessarily requiring additional fastening. The flanges locate on the liner improving the acoustic performance. In addition, in the arrangement where the clip base is spaced from the batten or building element, the distance between a facing panel which is secured to the batten and the underlying structure is increased without having to use a deeper batten profile. The inventors have found that by increasing this distance provides substantial improvement in the acoustic performance of a wall incorporating the clip. The actual spacing may vary depending on the thickness of the wall, the required acoustic performance and the materials from which the wall is formed. In one form, the inventors have found that spacing the panel from a core in the order of 40 mm to 60 mm, and more particularly in the order of 45 to 55mm provide acceptable acoustic performance in party wall applications where the core of the wall is formed from concrete and the facing panel is plasterboard. A further advantage of the clip in this form is that by spacing the building member from the underlying structure allows adequate clearance to enable cable and pipe services to be installed behind the building element. In a further aspect, the present invention relates to a mounting assembly for mounting a panel to an underlying structure, the assembly comprising a clip according to any form above, and a building element having a mounting surface arranged to be secured to the panel, the building element being retained by the clip. In one embodiment, the building element is in the form of a sheet metal batten. In use, the batten is secured to the structure by a plurality of clips disposed along its length. In yet a further aspect, the invention relates to a method of forming a resilient clip, the method comprising the steps of providing a sheet layered structure having a metal layer and layer of resilient material; profiling the structure so as turn opposite side margins of the structure out of plane of the sheet so as to form a channel having the resilient material on an inner side of the channel relative to the metal layer. In yet a further aspect, the invention relates to a partition comprising a central core, and a facing panel secured to at least one major surface of the core by a mounting assembly according to any form described above.

BRIEF DESCRIPTION OF THE DRAWINGS

It is convenient to hereinafter describe embodiments of the invention with reference to the accompanying drawings. It is to be appreciated that the particularity of the drawings and the related description is to be understood as not superseding the generality of the preceding broad description of the invention. In the drawings : Fig. 1 is a perspective view of an acoustic clip; Fig. 2 is an end view of the clip of Fig. 1; Fig. 3 is a cross sectional plan view of a partition using a clip of Fig. 1; Fig. 4 is a graph comprising the results of acoustic tests on two wall; Fig. 5 is a perspective view of a second embodiment of a acoustic clip; and Fig. 6 is a cross-section elevation of a wall panel secured to a structural wall of a clip of Fig. 5 DETAILED DESCRIPTION OF THE DRAWINGS

Fig. 1 illustrates a clip 10 that is designed for use in securing a batten 50 to an underlying structure 100 (see Fig. 3) . The clip 10 which is manufactured from mild steel by a press forming operation comprises a base 11 have a pair of upstanding legs 12 and 13. Each leg on its distal end 14 and 15 incorporates respective channels 16 and 17. These channels are in opposing relationship and face towards each other and are formed by rolling over the respective distal ends of the legs 12 and 13. Each channel 16 and 17, incorporates a lining 18 which is formed from a compressible foam such as a soft, closed cell polyethylene. One purpose of the lining 18 is to provide some resilience to the clips to act as dampeners to vibration transferred from an underlying structure 100 to a batten 50 (see Fig. 3) . In addition, the respective legs 12, 13 are designed so that the distal end portions of the respective legs, which incorporate the respective channels 16 and 17 are able to flex to provide some additional resilience to the clip so as to further inhibit transmission of vibration through the clip. In contrast, a proximal portion 22 of the respective legs 12, 13 are not as flexible and incorporate gussets 23 which rigidifies that portion of the respective legs. The base 11 includes a pre-formed hole 19 which is arranged to receive a fastener to secure the clip 10 to the underlying structure. The fastener is typically self- tapping but may be of any suitable type. The pre-formed hole 19 is located within a seat 20 which projects from the base 11 in a direction opposite to that in which the legs 12 and 13 extend. The seat 11 is formed as a truncated square pyramid with the aperture 19 located centrally within the seat. The incorporation of the seat 20 allows the clip to be secured to an underlying structure having a corrugated or similarly ribbed profile with the seat locating within the valleys defined between adjacent ribs. Such a structure is used in a concrete wall formed from modular panels as described in international application WO2003/046312 the contents of which are herein incorporated by a cross reference. Each of the legs 12 and 13 further include a locating spike 21 that is operative to be embedded in an acoustic blanket 60 (see Fig. 3) . The spikes 21 project downwards and extend from the respective distal ends 14, 15 of the legs . As indicated above, the clip 10 is designed to secure a batten 50 to an underlying structure. Turning to Fig. 3, a partition 300 is disclosed that uses the clip 10 and batten 50 as its mounting assembly. The batten 50 is of a top hat profile having a pair of webs 51 and 52 that are interconnected at one end by a bridge portion 53 and include outwardly extending flanges 54 and 55 at their other end. Each flange includes a lip 56 at its distal end that is turned out of the plane of the flanges 54 and 55. The partition 300 also includes a structural core 100 and the clip 10 is secured to the core 100 in a regular array of lines 10¹, 10¹¹. The battens 50 are each secured by the clips disposed in a respective one of the lines. More specifically, the flanges 54, 55 of each batten is designed to be located into a respective one of the channels 16, 17 of a clip. Typically, the batten 50 is presented at an angle to the clips so that one of the flanges 54 locates into a respective one of the channels 17 and 18 of the clip 10. The batten is then pivoted around and snapped home with the other flange being caused to flex inwardly so as to be able to pass over the channel of the other leg of the clip and locate into that channel. Once located fully within the channels 16 and 17, the batten is able to return towards its natural state and is thereby captured by the clip. As best seen in Fig. 3, the only contact between the batten 50 and the clip is through the compressive foam layer 18 which provides a barrier to sound transmission through the clip. In addition, because the foam is compressible, it is possible to design the channels 16 and 17 to be slightly undersized compared to the batten profile so that the batten is firmly held within the clip, thereby inhibiting movement of the batten in the respective channels. Also, if the wall 100 is uneven, this can be compensated to some extent by the compressive foam 18 as it provides some play in the exact position of the batten 50 in the channel 16 and 17. The clips 10 also simplify the installation of acoustic blankets 60 against the core 100. As illustrated in Fig. 3, the blankets extend between the clips 10¹, 10¹¹ and are secured by the engaging spikes 21 extending from the outer side of the legs 12 and 13 of the respective clips . Facing panels 70 are mounted on the respective battens and secured in place by fasteners 71 which are typically secured through the bridging portion 53 of the respective battens. These facing panels may be of any suitable construction but are typically formed from fibre cement or plasterboard. As is clearly illustrated in Fig. 3, the battens are spaced a substantial distance from the core 100. This arrangement provides a number of benefits. Firstly, the inventors have found that by increasing the spacing can significantly improve the acoustic performance of the wall. Fig. 4 is a graph of tests conducted by the applicant which compares the performance of a partition wall which incorporates the clip 10. In particular, the graph compares the clip 10 forming a 50mm core to panel gap as compared to a similar structural wall which uses clips that do not allow any significant spacing of the batten 50 from the wall and therefore incorporate a 35mm core to panel gap. In other respects the walls are identical. As can be seen, with the 50 mm gap, the transmission loss at the lower frequency range (such as the 300 to 900 hertz) is significantly greater. A second advantage of spacing the batten 50 from the wall 100 is that it allows access to services and cabling between the batten and the wall 100. Fig. 5 illustrates an alternative clip 40 that is designed to for use in securing a batten 50 to an underlying structure 100 (see Fig. 6) . The clip 40 is more simplified than the clip 10 but still provides a degree of acoustic suppression. The clip 40 is manufactured from sheet laminate material having an outer metal layer 31 and an inner resilient layer 32 which is bonded to the metal layer typically by an adhesive. The metal layer forms a clip body portion 33 designed to provide the structural integrity to the clip and is typically manufactured from mild steel having a thickness of between 0.5 - 1.5 mm. The resilient layer 32 is designed to inhibit transmission of sound through the clip by dampening vibration. In a preferred form, the layer 32 is formed from a compressible foam such as soft, closed cell polyethylene foam. An advantage of using a compressible foam as distinct from other non compressive resilient materials, is that it allows the clip 100 to firmly engage the batten 50, whilst still allowing some "play" in the exact positioning of the batten within the clip as will be discussed in more detail below. The clip is press formed from the laminate material so that the body portion 33 includes a base portion 34 and opposite side margins 35, 36 that extend upwardly from the base portion 34. Each side margin incorporates at its distal end a lip return 37, 38 that extends over the base portion 34. As such, the body portion 33 defines a channel 39 that is lined by the compressive foam 32 and incorporate edge regions 40, 41 that have the compressive foam in facing relation. The clip further includes an aperture 42 arranged to receive a fastener 90 (Fig. 6) to secure the clip to the underlying structure 100. Fig. 6 is a cross sectional view of the clip 30 used in securing a wall panel 101 the to underlying structure 100, which in the illustrated form is a concrete wall. The clip 30 is secured to the wall 100 by the fastener 90 received through the aperture 42. The fastener is typically self tapping but may be of any suitable type. In use, a plurality of clips are secured in lines typically extending down or across the wall, with each line of clips being operative to receive the batten

50. The batten 50 is the same as that described with reference to Fig. 3 and has a pair of webs 51, 52 that are interconnected at one end by a bridge portion 53 and include outwardly extending flanges 54, 55 at their other ends. Each flange includes a lip 56 at its distal end that is turned out of the plane of the flanges 54, 55. The batten 50 is designed to fit into the channels 39 of a line clips 30. The batten 50 is typically presented at an angle to the clips 30 so that one of the flanges 54, 55 locates into a respective one of the edge regions 40, 41 of the channel 39. The batten is then pivoted around and snapped home with the other flange being caused to flex inwardly so as to be able to pass over the lip return of the clip and locate into the other edge region. Once located fully within the channel, the batten is able to return towards its natural state and is thereby captured within the channel 39. As seen in Fig. 6, the only contact between the batten 50 and the clip 30 is through the compressive foam 32. As a result, a barrier to sound transmission through the clip is provided. In addition, because the foam is compressible it is possible to design the channel 39 to be slightly undersized compared to the batten profile so that batten is firmly held within the clip, thereby inhibiting movement of the batten in the channel . Also if the wall 100 is uneven, this can be compensated to some extent by the compressive foam 32 as it provides some play in the exact position of the batten 50 in the channel 39. Once an array of battens is secured to the wall 100 via the clips 30, the wall panel 101 can be installed over the battens 50 and secured thereto by fasteners 91 secured through the panel 101 and into the bridge portion 53 of the respective battens. With this arrangement, the fasteners 91 preferably do not extend into the clips so as to maintain the batten in isolation to the metal body portions 31 of the clips 30. Accordingly, partitions according to the present invention provide a high level of acoustic performance whilst presenting a uniform and serviceable surface. The completed system competes favourably with any competitor solution pre-cast concrete, brick work and the like and is ideally designed for party walls to apartments, hotels and the like. In the claims which follow and in the preceding description of the invention, except where the context requires otherwise due to express language or necessary implication, the word "comprise" or variations such as "comprises" or "comprising" is used in an inclusive sense, i.e. to specify the presence of the stated features but not to preclude the presence or addition of further features in various embodiments of the invention. It will be appreciated that variations and/or modifications may be made to the parts previously described without departing from the spirit or ambit of the invention.

Claims

THE CLAIMS DEFINING THE INVENTION ARE AS FOLLOWS:

1. A clip for mounting a building element to an underlying structure, the clip comprising a body portion mountable to the underlying structure having a base and a pair of legs upstanding from the base, each leg having a coupling operative to receive an edge region of the building element so as to support the building element in spaced relationship from the base.

2. A clip according to claim 1, wherein the clip further comprises a liner disposed in each coupling arranged to inhibit sound transmission between the building element and the clip.

3. A clip according to either claim 1 or 2, wherein each coupling is channel shaped so as to retain a portion of the building element in engagement with the clip.

4. A clip according to claim 3, wherein the channels of the respective couplings are in facing relationship.

5. A clip according to any preceding claim, wherein each leg is operative to flex so as to inhibit the transmission of vibration between the building element and the underlying structure .

6. A clip according to claim 5, wherein a distal portion of each leg is operative to flex so as to inhibit transmission of vibration between the building element and the underlying structure, and wherein a proximal portion, where the leg joins the base, is more rigid than its associated proximal portion.

7. A clip according to claim 6, wherein the distal portion incorporates the respective coupling of that leg.

8. A clip for connecting a building element to underlying structure, the clip having a channel shaped body portion mountable to the underlying structure and incorporating a base and side margins that upstand from the base, and a liner formed from resilient material disposed in the channel, wherein the channel is arranged to receive the building element with the liner being arranged to inhibit sound transmission between the body portion and the building element.

9. A clip according to claim 8, wherein the side margins are shaped so as to retain the building element within the channel .

10. A clip according to either claim 8 or 9 wherein the clip is formed from a layered sheet material having a metal layer and a layer of resilient material, the metal layer being profiled to form the body portion and the resilient material forming the liner.

11. A clip according to any one of claims 8 to 10, wherein the side margins of the body portion each have a distal lip that projects inwardly over the base.

12. A clip according to claim 11, wherein the resilient material is disposed on the distal lip.

13. A clip according to any preceding claim, wherein the body portion is formed from sheet metal.

14. A clip according to any preceding claim, wherein the clip is operative to be connected through the base to the underlying structure by one or more mechanical fasteners that extend from the base into the underlying structure.

15. A clip according to claim 14, wherein the base has one or more pre-formed holes to receive the fastener.

16. A clip according to either claim 14 or 15, further incorporating a seat formed in the base, the seat projecting outwardly from the clip in a direction opposite to that of the legs or side margins and being operative to receive a mechanical fastener to secure the base to the underlying structure.

17. A mounting assembly for mounting a panel to an underlying structure, the assembly comprising a clip according to any preceding claim when dependent on claim 1, and a building element having a mounting surface arranged to be secured to the panel and being locatable in respective ones of the couplings so as to be retained by the clip in spaced relationship to the clip base.

18. A mounting assembly according to claim 17, wherein the building element is in the form of a sheet metal batten having opposite outwardly extending flanges which are operative to locate in respective ones of the couplings of the clip.

19. A mounting assembly for mounting a panel to an underlying structure, the assembly comprising a clip according to any one of claims 8 to 16, when dependent on claim 8, and a building element having a mounting surface arranged to be secured to the panel and opposite outwardly extending flanges, the building element being locatable in the clip channel with the flanges being operative to engage with the side margins so as to be retained within the channel .

20. A mounting assembly according to claim 8, wherein the building element is in the form of a sheet metal batten.

21. A partition comprising a central core, and a facing panel secured to at least one of the major surfaces of the core by a mounting assembly according to any one of claims 17 to 20.

22. A partition according to claim 21, wherein the core is formed from cementitious material.

23. A partition according to either claim 21 or 22, wherein the facing panel is formed from fibre cement or plaster board.

24. A method of forming a resilient clip, the method comprising the steps of: - providing a sheet layered structure having a metal layer and layer of resilient material; profiling the structure so as turn opposite side margins of the structure out of plane of the sheet so as to form a channel having the resilient material on an inner side of the channel relative to the metal layer.