Classifications

• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
  • E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
  • E04B2/74—Removable non-load-bearing partitions; Partitions with a free upper edge
  • E04B2/7407—Removable non-load-bearing partitions; Partitions with a free upper edge assembled using frames with infill panels or coverings only; made-up of panels and a support structure incorporating posts
  • E04B2/7453—Removable non-load-bearing partitions; Partitions with a free upper edge assembled using frames with infill panels or coverings only; made-up of panels and a support structure incorporating posts with panels and support posts, extending from floor to ceiling
  • E04B2/7457—Removable non-load-bearing partitions; Partitions with a free upper edge assembled using frames with infill panels or coverings only; made-up of panels and a support structure incorporating posts with panels and support posts, extending from floor to ceiling with wallboards attached to the outer faces of the posts, parallel to the partition

Definitions

• Oblong metal elements that are used as members for frameworks of drywalls namely the runners - transverse struts - and the studs - vertical struts - can have different cross-sectional shapes, such as U-shape, C-shape or L-shape, for example. In the state of the art, these metal elements are also referred to as ‘profiles’.
• drywalls are erected to clad dead spaces or functional spaces, like service ducts, electrical duct or the like. Especially if these spaces are small, entry ports are not provided. Accordingly, once the wall or parts thereof are erected, there is no possibility to enter or leave this dead room anymore. Consequently, it is not possible to perform any assembly works from the backside of the wall, i.e. from the inner side of such dead rooms.
• shaft drywalls have been mounted by providing floor and ceiling runners essentially parallel to each other.
• U-shaped or C-shaped studs having a base plane - called the web - and a side planes - called the flanges - on opposite sides of the base plane and each arranged vertically to the web, are fixed on the one hand at the top to the ceiling profile and on the other hand at the bottom to the floor profile, to build a stud frame.
• C-shaped studs are preferred over U-shaped studs.
• the studs are arranged so that one flange is aligned parallel to the rear side of the drywall to be built and fixed to the ceiling and the floor profiles.
• the web is aligned vertically to the rear side, being a spacer element between rear side and front side of the wall, and the second side plane is arranged parallel to the rear side of the wall again.
• the front panels can then be attached to theses front flanges of the studs, to build the front cladding of the wall.
• H-shaped studs can be achieved by fixing two U-shaped studs back-side to back-side, or they can be manufactured in one piece.
• Each H-shaped stud has flanges to the right and to the left (whereas a U-shaped stud only has flanges to one side). Drywall panels can now be applied to the inner surfaces of the rear flanges of the studs, for instance adhered.
• C-shaped studs - or double-C-shaped studs - cannot be used, since they have a “flap section” at the end of the flanges, and thus they don’t offer a plane area to fix the panels at the inner rear surface.
• the cladding is fixed to the inside of the rear side flanges with glue, cement or the like.
• claim 1 refers to a drywall, especially a shaft drywall, having a front side and a rear side, wherein the drywall is arranged between two opposing boundary surfaces.
• the drywall comprises a first cladding, also called rear cladding, of one or more drywall panel layers and a second cladding, also called front cladding, of one or more drywall panel layers.
• a runner is provided on each boundary surface, wherein the two runners are essentially arranged parallel to each other.
• Each runner is provided as a single or as multiple runner elements.
• Each runner has a rear section, essentially extending in a first plane, and a front section, essentially extending in a second plane (for clarity, the terms “first plane” and “second plane” here refer to the runners only).
• the drywall comprises a plurality of first construction means.
• Each first construction means has a rear section, essentially extending in a first plane, and a front section, essentially extending in a second plane, the second plane preferably being essentially parallel to the first plane (for clarity, the terms “first plane” and “second plane” here refer to the first construction means only).
• the first construction means are fixed to the rear section - especially the inner surface of the rear section - of the first runner and/or to the rear section of the second runner by their own rear sections.
• the first cladding is fixed to the front sections of the first construction means.
• each second construction means has a rear section, essentially extending in a first plane, and a front section, essentially extending in a second plane, the second plane preferably being essentially parallel to the first plane (for clarity, the terms “first plane” and “second plane” here refer to the second construction means only).
• the second construction means are positioned between the first cladding and the front section of the runners.
• the second construction means are fixed via their front sections to the front section - especially the inner surfaces of the front section - of the first runner and/or to the rear section - especially the inner surfaces of the front section - of the second runner.
• the second cladding is fixed to the front sections of the second construction means.
• the essentially planar front and rear sections of the runners, the first and the second construction means may especially serve to provide connection areas to the respective fixation counterpart.
• the terms “front”, “front side”, or the like, and “rear”, “rear side”, or the like are used to differentiate two opposite directions, namely the side on which the elements under consideration or their respective parts or sections are located, or the direction to which their respective surfaces are facing.
• the term “rear (side)” herein refers to the section, side or surface directed to the shaft (or to the dead space, respectively).
• the term “front (side)” hereinafter shall refer to the section, side or surface directed away from the shaft (or dead space, respectively).
• essentially for instance in essentially parallel, essentially vertical or essentially horizontal etc, means that typical construction-related inaccuracies and deviations shall not be construed to mean that the corresponding embodiments would not be included by the respective specification.
• the terms “essentially extending in a plane” and “essentially (being) planar” assigned to a geometric (areal) element or section means that a specific plane may be assigned to the extension of the respective element or section taken as a whole, but that it is possible that there are some structures, grooves, notches, welts, end lips or the like may be present in the element or section. Likewise, it is not contrary to the term planar if the respective geometric element or section has, perforations, holes, recesses, punchings or the like.
• the two opposite boundary surfaces are the ceiling and the floor of a room, especially a room of a house or another building.
• the two runners are preferably aligned essentially horizontally.
• the drywall according to the invention is erected vertically, which means that preferably, the front side and the back side of the drywall are essentially parallel to each other.
• the drywall according to the invention may be a single drywall, or a part of a drywall system composed of more than one planar drywall.
• a single drywall spans only in one plane.
• a drywall system may be composed of two or more drywalls, each one of them spanning in a plane, adjacent walls being connected by a common edge and being arranged in an angle to each other.
• connection edges to further walls e.g. boundary wall
• the respective wall edge is fixed by studs, too, which may be identical to the studs as used for the wall construction, however, which may also be different studs.
• U-shaped studs may be used here, too.
• a runner is composed of more than one single runner element, these single runner elements are preferably aligned consecutively, in a row.
• the runner elements that build the runner may be U- shaped, for example, i.e. it is necessary that they have at least three essentially planar sections, namely a web and two flanges.
• the web serves to fix the runner to the respective boundary surface, whereas the flanges are used to attach the fixation elements to.
• the flanges are preferably essentially perpendicular to the web. However, if the opposite boundary surfaces are not parallel to each other, or if the drywall shall not be arranged vertically but somewhat inclined, it may be advantageous if the angles between the web and the flanges of the runners of one or of both runners differ from 90°.
• the first and/or the second construction means may be relatively short metal elements.
• Metal elements that are hat-shaped are especially suitable, as they provide essentially planar front and rear sections.
• the drywall comprises at least one stud system. Therefore, preferably the first construction means and/or the second construction means are chosen as studs, extending between the two runners. Preferably the first as well as the second construction means are studs.
• the first construction means are called first studs, and the second fixation elements are called second studs.
• the first studs are positioned essentially perpendicular to the runners.
• the second studs are also positioned essentially perpendicular to the runners, and especially essentially parallel to the first studs.
• the first studs and the second studs both extend essentially vertically between the two runners.
• the first construction means are arranged equidistant to each other, and/or the second studs are arranged equidistant to each other.
• the distance between each two neighboring first studs and/or two neighboring second studs may be 625 mm.
• the number of first studs and the number of second studs are equal.
• other stud arrangements for example non-equidistant first and/or second studs, and/or different numbers of first and second studs, and/or staggered first and second studs (when regarded from the front side of the drywall). It is also possible that some of the first studs are in alignment to some of the second studs, and some are staggered.
• the first studs are hat-shaped (the respective metal elements are also known as hat profiles or hat profile rails).
• a hat-shaped stud has a base section - the web two side sections - the flanges - that each are arranged at an angle to the web, generally essentially perpendicular to the web, and two outward directed sections at the flange edges facing away from the web, being essentially equiplanar to each other and essentially parallel to the web - herein referred to as the ‘brim sections’.
• the web, the flanges and the brim sections each are essentially planar.
• Special embodiments of hat-shaped studs that have a plurality of hole punchings, especially in the flange area, may be chosen as first studs.
• Such studs are also known as “spring rails”.
• the webs of the hat-shaped studs serve as the front sections
• the brim sections serve as the rear sections of the first studs (as introduced above).
• the brim sections of the first studs are attached to the runners - especially, the outermost parts of the brim sections at the two ends of the studs are fastened to the runners, especially to a flange of the runners, at the two boundary surfaces, to fix the studs in their respective position.
• the webs of the first studs are attached to the rear side of the rear cladding.
• all attachments are screw attachments. Due to the special shape of the first studs, both the screwing of the brim sections of the first stud to the runners as well as the screwing of the rear side cladding to the webs of the first studs can be carried out from the front side.
• the hat-shaped studs it is also possible to position the hat-shaped studs the other way round, i.e. in a way that the brim sections are fixed to the rear cladding and the webs are fixed to the runners.
• the first studs may be C-shaped studs, especially so-called CD-studs.
• the C-shaped first studs may be fixed to the runners by suitable fixation clips (“indirect fixation”).
• These C-shaped studs comprise a base section - the web -, two side planes - the flanges - arranged at an angle at both ends of the web, preferably arranged essentially perpendicular to the web, and two inwardly directed sections at the flange edges being opposite the web, herein referred to as the ‘flap sections’.
• Fixation clips for the fixation of CD studs or CD runners to surfaces or to other studs or runners are known in the state of the art.
• the panel layers may be fastened to the first construction means, especially the first studs, by long screws that penetrate all the layers; and/or the first panel layer may be screwed to the first studs, the second panel layer to the first panel layer, and so on; and/or it is possible to have long screws penetrating all panel layers and end in the first studs together with screws only fixing the first panel layer to the second studs and/or only fixing panel layers together.
• the second studs may be U-shaped, however, advantageously, they are C-shaped (including their layouts like CW-studs).
• the flap sections are essentially parallel to the web, and equiplanar to each other.
• the web, the flanges and the flap sections each are essentially planar.
• the fixation of the second studs within the drywall according to the invention may be effected just by the second cladding that is attached to them, and if applicable by clamping the second stud between the first cladding and the front sections of the runners (form-fit).
• the front sections of the second studs are fastened to the front sections of the runners, to enhance stability of the drywall.
• the second studs are attached to the front section of the runners by crimping and/or by screwing.
• the second studs will be adjacent to the first (rear) cladding by their rear sections.
• a sealing is provided at the interfaces between the second studs and the first cladding.
• a sealing tape may be adhered on the outer surface of the rear sections of the second claddings before the installation of these second studs. It is also possible to provide a sealing material only in sections, for example to adhere sealing tape segments in certain distances, having spaces without sealing between. Even if the sealing is not continuous, it causes a good decoupling.
• the second studs are not directly fastened to the first cladding, the decoupling properties are optimized.
• the second studs may be arranged such that all openings of the studs face to the same direction, especially to the left or to the right when looking from the front side of the drywall.
• the panel layers may be fastened to the second studs by long screws that penetrate all the layers; and/or the first panel layer may be screwed to the second studs, the second panel layer to the first panel layer, and so on; and/or it is possible to have long screws penetrating all panel layers and end in the second studs together with screws only fixing the first panel layer to the second studs and/or only fixing panel layers together.
• the first and/or the second studs generally are made of metal, e.g. aluminium, especially preferred they are made of steel.
• Insulating material can be inserted in the interior space between the two claddings; generally this will be done before the front cladding is mounted. Insulation material can be chosen according to its known purposes.
• the process according to the invention comprises the following steps:
• the second construction means are positioned between the first cladding and the front section of the runners.
• the width of the runners is chosen according to the dimensions of the first cladding and the second studs, the second studs may be inserted such that they are held in place by a clamping effect. In cases where an insulating material is inserted into the interior space between the two claddings, this may help to hold the second construction means in place while erecting the drywall.
• step (d2) the second construction means are fastened via their front sections to the front section - especially the inner surfaces of the front section - of the first runner and/or to the rear section - especially the inner surfaces of the front section - of the second runner.
• Step (d2) may be executed simultaneously or subsequently to step (d).
• the process according to the invention allows that all fixations may be executed from the front side direction. Accordingly, at least steps (c) to (e), preferably (b) to (e), are executed from the front side direction. Steps (a) and (b) are not yet hindered by the resulting first cladding, however, it is advantageous if all steps (a) to (e) are executed from the front side direction, i.e. by a person standing on the front side of the drywall in construction. According to the processes as known from the art, it has not been possible to fix all layers and components of such drywalls, like crimping and/or screwing, since there was no more access to this back side during these processes.
• first construction means are first studs and/or the second construction means are second studs, it is preferred if each of these studs extends between the two runners.
• the steps are executed in the order as described above.
• the two opposing boundary surfaces are the ceiling and the floor of a room.
• the drywall as erected by the aforementioned process corresponds to the specifications as given for the drywall and its designs according to the invention, as described before.
• the first cladding is the rear cladding and the second cladding is the front cladding.
• step (c) a sequence of more than one panel layers is attached to the front sections of the first studs, and/or in a further step (c1 ), following step (c), at least one further panel layer is fixed on the panel layer that was attached to the studs in step (c), so that a multi-layer first cladding is obtained.
• step (e) a sequence of more than one panel layers is attached to the front sections of the second studs, and/or in a further step (e1 ), following step (e), at least one further panel layer is fixed on the panel layer that was attached to the studs in step (e), so that a multilayer second cladding is obtained.
• a sealing is provided between the rear section of the second studs and the adjacent surface of the rear cladding.
• this is realized by adhering a sealing tape to the outer surface of the rear sections of the second studs before installing the second studs, i.e. before attaching them to the front sections of the runners in step (d).
• a sealing layer or a sealing tape may also be provided on the respective surfaces of the rear cladding before installing the second studs.
• the runner may be a single metal element (a single runner), or be composed of more than one runner element. If a multitude of elements is used to compose the runner, it is preferred if they are arranged in a row, aligned one after the other. In one way of implementing the runner, adjacent runner elements touch each other via common abutting edges, so that there is at least one continuous attachment area (one of the flanges) for the first studs.
• the term runner shall also comprise runner systems where there is a distance between successive elements, as long as the available flanges allow to fasten all first studs in the desired way. By this, it could be possible to save material.
• the attachment of the first construction means, especially the first studs, to the runner in step (b), or the attachment of the second construction means, especially the second studs, to the runner in step (d2), or both these attachments is/are effected by crimping the parts together (i.e. by crimp connection) and/or by screwing them together (i.e. by screw connection).
• step (d2) which in general means a fixation of the front section of the second construction means to the inner surface of the front section of the runners, crimping is very advantageous as this can be easily performed from the front side of the drywall to be erected.
• the attachment of the panel layer(s) to the first construction means, especially to the first studs, in step (c) and/or step (c1 ), and/or the attachment of the panel layer(s) to the second construction means, especially to the second studs, in step (e) and/or step (e1 ), and/or both these attachments is/are effected by screwing.
• the process allows to erect the drywall by acting from the front side of the resulting drywall, since all steps are executable from this side. Compared to shaft dry walls according to the state of the art, a simple and effective process is provided, allowing safe fixations in all steps. Gluing or the like can be avoided.
• the drywall according to the invention and/or received by the process according to the invention has excellent sound absorption properties, since the second construction means, especially the second studs, are only fixed to the runners, but not to the first cladding. This means that two cladding layers are present, which are essentially acoustically decoupled from each other.
• 1 first construction means especially hat-shaped stud
• Fig. 1 principally illustrates the general design of a hat-shaped stud which can be used as first construction means 1.
• the stud has a base section 12 - the web -, two side sections 13 - the flanges - that each are arranged at an angle to the web, generally essentially perpendicular to the web, and two outwardly directed sections 11 - the brim sections - at the flange edges facing away from the web, being essentially equiplanar to each other and essentially parallel to the web.
• Fig. 2 principally illustrates the general design of a C-shaped stud which can be used as a second construction means 2, comprising a base section 23 - the web -, two side sections 21 , 22 - the flanges - arranged at an angle at both ends of the web, preferably arranged essentially perpendicular to the web, and two inward directed sections 24 - the ‘flap sections’ - at the flange edges being opposite the web.
• Fig. 3a and Fig. 3b principally show runners 3, in the shown example consisting of more than one single runner element 31 , 32, 33 (the figures indicate that more runners could follow).
• the runner 3 is attached to a ceiling 7
• the runner 3 is attached to a floor 8.
• the size relations are not to scale; generally single runner elements will be somewhat longer as shown herein.
• each single runner element 31 , 32, 33 is a U-shaped metal element comprising a web 34 and two flanges 35, 36.
• the single runner elements 31 , 32, 33 are arranged in alignment one after the other, abutting at the abutting edges 37. As already discussed above, alternatively it is possible to leave spaces between the single elements.
• Fig. 4 shows a detailed view of the fixation of hat-shaped stud 1 (first construction means) to a runner 3.
• the brim section 1 1 of the hat-shaped stud 1 may be fixed to the inner side of the rear flange 35 (rear section) of the runner 3 by tapping screws 41 , for example.
• Fig. 4 further illustrates that a certain plane can be assigned to web 34 and flanges 35, 36 of the runner 3 and web 1 1 , flanges 13 and brim section 12 of the hat-shaped stud 1 (also true for the sections of the C-shaped stud; not shown in this figure), irrespective of being somewhat modified by grooves 71 , end lips 72 or the like.
• Fig. 5 and Fig. 6 show cross views of an example of a shaft dry wall according to the invention, wherein the first construction means 1 are studs, namely hat-shaped studs, and the second construction means 2 also are studs, namely C-shaped studs, and wherein the two opposing boundaries are the ceiling 7 and the floor 8 of a room.
• Fig. 5 shows a horizontal cross section through a drywall according to the invention (view from above). In this figure, the rear side (e.g. the shaft side of a shaft drywall) of the drywall lies on the top of the picture, and the front side (e.g. the freely accessible of a shaft drywall) of the drywall lies on the bottom.
• Fig. 5 shows a horizontal cross section through a drywall according to the invention (view from above). In this figure, the rear side (e.g. the shaft side of a shaft drywall) of the drywall lies on the top of the picture, and the front side (e.g. the freely accessible of a shaft
• FIG. 6 shows a vertical cross section (side view) through a drywall according to the invention.
• the rear side e.g. the shaft side of a shaft drywall
• the front side e.g. the freely accessible of a shaft drywall
• a panel layer is fixed to the front sections 12 - the webs - of the first studs 1 by drywall screws 42, to build a first (rear) cladding 4. Accordingly, the rear side of the front cladding 4 is adjacent to the front sections 12 - the webs - of the first studs 1 .
• Second studs 2 are fixed to the front section 36 - front flange - of the runners 3 by crimping 43, precisely the front section 22 - a flange - at both ends of each second stud 2 is crimped to the inner surface of the front section 36 - front flange - of the runners 3.
• the dimension of the web 34 of the runners 3 is chosen such that the rear section 21 - rear flange - of the studs 2 lies adjacent to the front surface of the rear cladding 4.
• a sealing tape 44 is provided at the interfaces between the rear cladding 4 and the rear sections 21 of the second stud 2.
• two panel layers 51 , 52 are attached by drywall screws 42, to build a second (front) cladding 5.
• an insulation 9 is inserted (arranged between the second studs 2 also positioned in this interspace).
• a U-shaped stud 61 which itself is fixed by a wall nail 62, secures the fixation of the drywall to the adjacent walls 6 of the room. Respective sealings 63 are provided at the drywalls ends.
• Fig. 7 shows an example of an intermediate state of the process according to the invention, namely a frame wherein a plurality of first construction means 1 , namely first hat-shaped studs, is attached to two horizontally aligned, parallel runners 3 that are attached to the ceiling 7 and to the floor 8 of a room.
• the first studs 1 are arranged equidistant to each other.
• further studs 61 U-shaped are present for fixation to the adjacent walls 6.
• This frame is ready for the attachment of the first panel layer and the subsequent drywall components and layers.
• Fig. 8 shows a perspective schematic view of a dry wall according to the invention, comprising a plurality of first construction means 1 in form of hat-shaped studs, a plurality of second construction means 2 in form of C-shaped studs, runners 3 on floor and ceiling (latter not shown), a first cladding 4 between the first and the second construction means 1 , 2 and a second cladding 5 fixed on the second construction means 2.
• U-shaped studs 61 are used for side wall mounting.

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• 2022
  • 2022-12-22 JP JP2025536755A patent/JP2025540488A/ja active Pending
  • 2022-12-22 EP EP22843128.4A patent/EP4409079A1/de not_active Withdrawn
  • 2022-12-22 WO PCT/EP2022/025591 patent/WO2024132083A1/en not_active Ceased

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