US20240167281A1 - Gypsum stud wall system with high knock factor - Google Patents
Gypsum stud wall system with high knock factor Download PDFInfo
- Publication number
- US20240167281A1 US20240167281A1 US18/485,005 US202318485005A US2024167281A1 US 20240167281 A1 US20240167281 A1 US 20240167281A1 US 202318485005 A US202318485005 A US 202318485005A US 2024167281 A1 US2024167281 A1 US 2024167281A1
- Authority
- US
- United States
- Prior art keywords
- stud
- wallboard
- gypsum
- panel
- frame
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Pending
Links
- 229910052602 gypsum Inorganic materials 0.000 title claims abstract description 91
- 239000010440 gypsum Substances 0.000 title claims abstract description 91
- 239000002184 metal Substances 0.000 claims description 15
- 238000005096 rolling process Methods 0.000 claims description 13
- 239000000853 adhesive Substances 0.000 claims description 10
- 230000001070 adhesive effect Effects 0.000 claims description 10
- 239000000758 substrate Substances 0.000 claims description 10
- 238000000034 method Methods 0.000 claims description 5
- 238000012360 testing method Methods 0.000 description 32
- 239000000523 sample Substances 0.000 description 29
- 238000010276 construction Methods 0.000 description 15
- 229910000831 Steel Inorganic materials 0.000 description 14
- 239000010959 steel Substances 0.000 description 14
- 239000007787 solid Substances 0.000 description 12
- 230000005540 biological transmission Effects 0.000 description 5
- 239000002023 wood Substances 0.000 description 5
- 238000009432 framing Methods 0.000 description 4
- 238000009413 insulation Methods 0.000 description 4
- 239000000123 paper Substances 0.000 description 4
- 239000011499 joint compound Substances 0.000 description 3
- 238000005259 measurement Methods 0.000 description 3
- 239000000565 sealant Substances 0.000 description 3
- 241000288673 Chiroptera Species 0.000 description 2
- 230000000712 assembly Effects 0.000 description 2
- 238000000429 assembly Methods 0.000 description 2
- 238000005520 cutting process Methods 0.000 description 2
- 239000006260 foam Substances 0.000 description 2
- 229920001821 foam rubber Polymers 0.000 description 2
- 239000000463 material Substances 0.000 description 2
- 150000002825 nitriles Chemical class 0.000 description 2
- 239000004033 plastic Substances 0.000 description 2
- 229920003023 plastic Polymers 0.000 description 2
- 239000000126 substance Substances 0.000 description 2
- PYRKKGOKRMZEIT-UHFFFAOYSA-N 2-[6-(2-cyclopropylethoxy)-9-(2-hydroxy-2-methylpropyl)-1h-phenanthro[9,10-d]imidazol-2-yl]-5-fluorobenzene-1,3-dicarbonitrile Chemical compound C1=C2C3=CC(CC(C)(O)C)=CC=C3C=3NC(C=4C(=CC(F)=CC=4C#N)C#N)=NC=3C2=CC=C1OCCC1CC1 PYRKKGOKRMZEIT-UHFFFAOYSA-N 0.000 description 1
- 229920005830 Polyurethane Foam Polymers 0.000 description 1
- 239000011358 absorbing material Substances 0.000 description 1
- 238000010521 absorption reaction Methods 0.000 description 1
- 230000004323 axial length Effects 0.000 description 1
- 230000006835 compression Effects 0.000 description 1
- 238000007906 compression Methods 0.000 description 1
- 239000013068 control sample Substances 0.000 description 1
- 238000013461 design Methods 0.000 description 1
- 239000004744 fabric Substances 0.000 description 1
- 230000002349 favourable effect Effects 0.000 description 1
- 239000011152 fibreglass Substances 0.000 description 1
- 230000003116 impacting effect Effects 0.000 description 1
- 238000010348 incorporation Methods 0.000 description 1
- 238000003780 insertion Methods 0.000 description 1
- 230000037431 insertion Effects 0.000 description 1
- 238000009434 installation Methods 0.000 description 1
- 239000002655 kraft paper Substances 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 230000003278 mimic effect Effects 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 230000000149 penetrating effect Effects 0.000 description 1
- 238000009428 plumbing Methods 0.000 description 1
- 229920001084 poly(chloroprene) Polymers 0.000 description 1
- 239000011496 polyurethane foam Substances 0.000 description 1
- 238000012797 qualification Methods 0.000 description 1
- 238000000926 separation method Methods 0.000 description 1
- 239000008259 solid foam Substances 0.000 description 1
- 239000001589 sorbitan tristearate Substances 0.000 description 1
- 235000019640 taste Nutrition 0.000 description 1
Images
Classifications
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C3/00—Structural elongated elements designed for load-supporting
- E04C3/30—Columns; Pillars; Struts
- E04C3/34—Columns; Pillars; Struts of concrete other stone-like material, with or without permanent form elements, with or without internal or external reinforcement, e.g. metal coverings
-
- 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
- E04B2/56—Load-bearing walls of framework or pillarwork; Walls incorporating load-bearing elongated members
- E04B2/58—Load-bearing walls of framework or pillarwork; Walls incorporating load-bearing elongated members with elongated members of metal
Landscapes
- Engineering & Computer Science (AREA)
- Architecture (AREA)
- Civil Engineering (AREA)
- Structural Engineering (AREA)
- Building Environments (AREA)
Abstract
An interior wall is provided, including a frame including at least one footer, at least one header, at least one vertical frame member connecting at least one of the at least one footer to at least one of the at least one header, the frame having a first side and a second side, and defining an interior frame space. A first wallboard panel is fastened to the first side of the frame. At least one gypsum wallboard stud is secured in the interior frame space, being fastened to the first wallboard panel and being dimensioned to extend from the first side to the second side. A second wallboard panel is fastened to the second side of the frame and to the at least one gypsum wallboard stud for creating a continuous acoustic connection between the first wallboard panel and the second wallboard panel.
Description
- The present application is a Non-Provisional of, and claims 35 USC 119 priority from, U.S. Provisional Application No. 63/384,365 filed Nov. 18, 2022, the entire contents of which are incorporated by reference herein.
- The present invention relates generally to the construction of interior walls involving the attachment of gypsum wallboard panels to wood or metal framing elements, and more specifically to improved techniques implemented to enhance desired sound transmission through such walls.
- Conventional interior walls are often constructed by attaching gypsum wallboard panels to framing members made of wood or U-shaped steel. The frames include horizontally positioned header (upper) and footer (lower) members, respectively secured to the ceiling and floor. Vertically positioned stud members are secured between the headers and footers using fasteners as is well known in the art. Spaces between opposing wallboard panels are optionally filled with bats of insulation.
- For US-based customers, there is an expectation by customers that the interior wall needs to be sufficiently sturdy to define the room circumscribed by the walls, and that the wall will support shelving or wall hangings as needed to satisfy the customer's decorating preferences.
- Another factor that US-based customers focus on when evaluating interior wall construction is the sound transmission of the wall. In other words, how quiet is the room defined by the interior walls when the doors are closed? An important property of interior walls is the ability of the wall to isolate the individuals within a room defined by the walls from outside noise.
- In technical terms, the sound transmission property of an interior wall is quantified by what is known in the industry as an STC value. STC values for interior wall assemblies made of single sheets of ⅝-inch wallboard secured to metal studs range from 38-40 without insulation and 43-44 with insulation in the form of fiberglass bats or the like. Walls made with metal studs have higher (quieter) STC ratings than walls made with wooden studs. Sound rated floors are typically evaluated by ASTM Standard E492 and are rated as to impact insulation class (IIC). The greater the IIC rating, the less impact noise will be transmitted to the area below. Floors may also be rated as to Sound Transmission Class (STC) per ASTM E90. As is the case with wall assemblies, the greater the STC rating, the less airborne sound will be transmitted to the area below. Sound rated floors typically are specified to have an IIC rating of not less than 50 and an STC rating of not less than 50.
- It is commonplace for customers of residential or commercial construction in Mexico to focus on the stability of the interior construction in a different way compared with US customers. In Mexico, the focus is more on the solid feel of the interior wall, rather than on the resulting quiet character of the room. Mexican customers are more focused on obtaining sturdy interior walls, and consider structural sturdiness more significant than the sound absorbing qualities. To this end, customers in Mexico often knock on the wall with their knuckles to obtain a sense of the solidity of the relevant wall, with a muffled, solid sound being more favorable to a hollow sound.
- Accordingly, there is a need for an interior wall construction system that provides acoustical properties that are acceptable to both US and Mexican customers.
- The above-listed need is met or exceeded by the present interior wall, also referred to as a wall system which features the use of wallboard studs disposed in a wall frame between standard vertical studs. In a preferred embodiment, the wallboard studs are provided in a spacing that enhances a solid feel of the wall when knocked. In a particularly preferred embodiment, the wallboard studs are dimensioned to fill an interior space of the frame defined between first and second wallboard panels. As such, there is a solid connection between the facing wallboard panels and the wallboard studs. In addition, to reduce the transmission of sound through the wall and thus improve the STC values, the present wall system preferably includes at least one sound mat placed between the frame and a substrate. At least a footer of the frame is provided with such a sound mat, however additional frame members, including header and vertical studs are contemplated as being equipped with the sound mat.
- Knock test results on the present wall determined that the present configuration provides enhanced acoustic properties of the type preferred by Mexican customers. Further, the incorporation of the sound mat enhances the disruption of trans-wall acoustic energy and thus provides a more suitable wall to US consumer tastes. In testing the present wall system, a knock test index was developed. In the knock test, an acoustically isolated room is created and a test panel is secured to one wall of the room. The test panel is configured to represent the subject wall, with a spacing and arrangement of wallboard studs as described above. A steel ball encased in plastic is connected to the ceiling using a string having a length dimensioned to allow the ball to swing and contact a desired area of the test panel. A nearby microphone is positioned to record the sound generated by the ball impacting the panel.
- In one embodiment, a wallboard stud is provided that is fabricated from a gypsum wallboard panel that replaces conventional wood or metal studs. During assembly, the panel is scored on at least one face to have a plurality of parallel score cut lines defining segments. A spacing between the score lines determines the width of the segment. In the present panel, the score lines are spaced so that the panel is rolled from an outer edge, which forms a central core, and following segments are dimensioned so that upon completion of the rolling process, a solid roll of interconnected segments is formed. Adhesive is applied as needed during the rolling process to hold the respective segments together. In a preferred embodiment, a thickness of the rolled-up gypsum stud is in the range of 2.5 inches (6.35 cm), or the width of a track of a top or bottom track.
- In an embodiment, the score lines were created by forming 90° V-cuts or score cuts in the conventional wallboard panel, preferably on the “back” or kraft paper face, as opposed to the “front” or finished face. The cuts extend into the board, penetrating and extending through the back face and the core, but leave the face paper intact to enable folding/rolling up. Segments measured in order from the outer edge: 1″ (2.5 cm), 1″ (2.5 cm), 1.5″ (3.8 cm), 1.5″ (3.8 cm), 2.0″ (5.0 cm), 2.0″ (5.0 cm), 2½″ (6.35 cm), 2½″ (6.35 cm), and 2½″ (6.35 cm). Rolling begins at the 1″ edge so that the final, solid rolled stud has a width of 2½″ (6.35 cm).
- In an alternate embodiment, a gypsum rolled stud is formed in two main pieces. The first piece is a small, square-shaped insert stud made of rolled gypsum that fits into a central or axial opening of a larger stud tube also made of rolled, scored gypsum. In an embodiment, the smaller, insert stud is formed from four segments measuring 1.5″ (3.8 cm). Linear 90° V-cuts or score cuts are formed in the back face as in the first embodiment. The outer tube is formed by segments formed by 90° V-cuts or score cuts in the back face of the panel and having dimensions of 2.5″ (6.35 cm). The insert tube is inserted into the central axial opening of the larger stud tube. Adhesive is applied as needed to secure the rolled up components in their designated shapes, both the outer tube and the insert tube and the assembled stud.
- In still another embodiment, multiple components, meaning outer tubes and smaller insert studs are made from a standard 4 foot×8 foot gypsum wallboard panel. Linear score cuts are made on both the back face and the front or finished face. In some cases, the score cuts are formed through the entire panel. In a preferred embodiment, to create the desired gypsum stud components, the score cut lines are formed in both faces of the panel, so that a clean separation is achieved.
- More specifically, an interior wall is provided, including a frame including at least one footer, at least one header, at least one vertical frame member connecting at least one of the at least one footer to at least one of the at least one header, the frame having a first side and a second side, and defining an interior frame space. A first wallboard panel is fastened to the first side of the frame. At least one wallboard stud is secured in the interior frame space, being fastened to the first wallboard panel and being dimensioned to extend from the first side to the second side. A second wallboard panel is fastened to the second side of the frame and to the at least one wallboard stud for creating a continuous acoustic connection between the first wallboard panel and the second wallboard panel.
- In a preferred embodiment, the first and second wallboard panels are fastened directly to the corresponding wallboard studs. Also, the frame is preferably made of one of metal channel and wood.
- In an embodiment where the frame is made of metal channel, the wallboard studs are configured to have a thickness dimensioned to fill a cavity defined by walls of the metal channel. It is especially preferred that the wallboard studs have a thickness of 2.5 inches.
- In an embodiment, the present wall further includes an acoustic mat installed between the frame and a substrate. It is especially preferred that the acoustic mat is disposed between the footer and a substrate. In an embodiment, the acoustic mat is made of polyurethane foam, solid closed cell foam or solid foam rubber.
- In analyzing the acoustic properties of the present interior wall, a knock factor ratio was developed. In an embodiment, the knock factor ratio of the present interior wall is 0.8. In an embodiment, the wallboard studs have an on center spacing of one of 12 and 24 inches.
- In another embodiment, an interior wall is provided, including a frame including at least one footer, at least one header, at least one vertical frame member connecting at least one of the at least one footer to at least one of the at least one header, the frame having a first side and a second side, and defining an interior frame space. A first wallboard panel is fastened to the first side of the frame. At least one wallboard stud is secured in the interior frame space, being fastened to the first wallboard panel and being dimensioned to extend from the first side to the second side. A second wallboard panel is fastened to the frame and to the at least one wallboard stud for creating a continuous acoustic connection between the first wallboard panel and the second wallboard panel. The frame is made of metal channel and the wallboard studs are dimensioned to have a thickness dimensioned to fill a cavity defined by walls of the metal channel. Further, the wall has a knock factor ratio of 0.8.
- In yet another embodiment, a method for constructing an interior wall is provided, including: providing a frame including of at least one footer, at least one header at least one vertical stud connecting the at least one header to the at least one footer, the frame defining a first side, a second side and an interior frame space; attaching at least one wallboard stud in the interior frame space to connect to first and second wallboard panels secured respectively to the first and second sides; measuring a knock factor of the resulting assembled wall; and adjusting at least one of the number and lateral spacing of the at least one wallboard stud in the interior frame space to achieve a knock factor ratio of 0.8.
- More specifically, a gypsum stud is provided, including a gypsum wallboard panel having first and second facing sheets sandwiching a core therebetween, a series of cuts formed on at least one of the first and second facing sheets and extending into the core, retaining intact an opposing one of said first and second facing sheets to form a hinge point, the panel being rolled from a first side to a second side into a rolled condition so that a rolled up stud is formed.
- In an embodiment, a layer of adhesive is applied to at least one of the first and second facing sheets so that the panel is held in the rolled condition. In an embodiment, the cuts are 90° cuts, and preferably the cuts extend vertically up to but not into the opposite facing sheet from where they begin. In an embodiment, the cuts are made in the following sequence: 1″ (2.5 cm), 1″ (2.5 cm), 1.5″ (3.81 cm), 1.5″ (3.81 cm), 2.0″ (5.0 cm), 2.0″ (5.0 cm), 2½″ (6.35 cm), 2½″ (6.35 cm), 2½″ (6.35 cm). In the previous embodiment, the rolling preferably begins at the 1″ end so that the resulting stud has a width of 2½″ (6.35 cm).
- In another embodiment, the wallboard panel is a full-size, standard panel, and said cuts are made into the first and second facing sheets in a specialized pattern to form multiple wallboard studs. In such an embodiment, the cuts are preferably made in multiple groups of the following sequence: 3.8 (1.5 in.), 6.9 (2.7 in.), 3.8 (1.5 in.), 6.9 (2.7 in.), 6.4 (2.5 in.), 6.4 (2.5 in.), 6.4 (2.5 in). In such an embodiment, three gypsum studs, including three tubular outer portions and three insert portions are created from the standard wallboard panel.
- In an embodiment, the stud is made of two portions, an outer portion defining a central opening, and an insert portion dimensioned to fit within the central opening. In such an embodiment, the insert portion is formed by creating the cuts in an alternating fashion on the first and second facing sheets.
- In still another embodiment, a method of making a gypsum stud is provided, including, providing a gypsum wallboard panel having first and second facing sheets sandwiching a core therebetween; generating a series of cuts formed on at least one of the first and second facing sheets and extending into a core located between the sheets, retaining intact an opposing one of the first and second facing sheets to form a hinge point; and rolling the panel from a first side to a second side into a rolled condition so that a rolled up stud is formed.
- In an embodiment, a first spacing of the cuts on the first facing sheet is different from a second spacing of the cuts on the second facing sheet. In an embodiment, the method includes generating the series of cuts to form a first outer portion defining a central opening, and generating the series of cuts to form a second, insert portion dimensioned to fit inside the opening.
-
FIG. 1 is a fragmentary side perspective view of a wall constructed according to the present system; -
FIG. 1A are perspective views of gypsum wallboard studs used in the wall ofFIG. 1 ; -
FIG. 2 is a schematic horizontal cross-section of the wall ofFIG. 1 ; -
FIG. 3 is a side elevation of a wall frame according to the present system; -
FIG. 4 is a side elevation of the frame ofFIG. 3 with wallboard panels secured on one side; -
FIG. 5 is a side elevation of the insertion of multiple wallboard studs and that attachment of a second wallboard panel to the present system; -
FIG. 6 is a side elevation of the present system showing the second wallboard panel being finished by application of wallboard joint compound; -
FIG. 7 is a view of the apparatus used to measure the present wall knock test; -
FIG. 8 is a view of a rear side of one of the panels used inFIG. 7 to measure the wall knock test; -
FIG. 9 is a graph of knock test results for 3 different sample walls, per Table 1; -
FIG. 10 is a graph of knock test results per Table 2; -
FIG. 11 is a top view of the present rolled gypsum stud; -
FIG. 12 is a vertical cross-section of a gypsum panel scored to obtain the rolled gypsum stud ofFIG. 11 ; -
FIG. 13 is a top view of an alternate embodiment of the rolled gypsum stud ofFIG. 11 ; -
FIG. 14 is a vertical cross-section of a gypsum panel scored to obtain the rolled gypsum stud ofFIG. 13 ; -
FIG. 15 is a top view of another alternate embodiment of the present rolled gypsum stud; -
FIG. 16 is a partial exploded view of the rolled gypsum stud ofFIG. 15 ; -
FIG. 17 is a vertical cross-section of the components of the rolled gypsum stud ofFIG. 13 ; -
FIG. 18 is a top view of still another alternate embodiment of the present rolled stud; -
FIG. 19 is a vertical cross-section of a standard gypsum wallboard panel scored to produce multiple studs of the embodiment ofFIG. 15 in a single foldable piece; -
FIG. 20 is a vertical cross-section of a standard gypsum wallboard panel scored to produce multiple studs of the embodiment ofFIGS. 15 and 21 ; and -
FIG. 21 is an exploded view of the present rolled stud ofFIG. 18 . - Referring now to
FIGS. 1, 1A, 2 and 3 , the present wall, also referred to as a wall system, is generally designated 10 and refers to an interior wall in a residential or commercial building that is not load bearing. Thewall 10 is mounted on asubstrate 12 such as a poured concrete floor or the like, and reaches to aceiling 14, which may or may not be finished. - Included in the
wall 10 is aframe 16 including at least one footer orbase member 18 fastened to thesubstrate 12 by specialized fasteners as known in the art. Thefooters 18 usually are installed in 8 foot lengths, and multiple footers are often positioned end-to-end, depending on the size of the wall to be constructed. Also included is at least oneheader 20 defining an upper margin of theframe 16. Similar to thefooter 18, theheader 20 is provided in 8 foot lengths and multiple headers are often installed end-to-end. At least onevertical frame member 22 connects thefooter 18 to the header and themembers - In conventional construction, the
vertical frame members 22 are installed at a predetermined spacing, such as 16-inch on center spacing. In the present application, theframe 16 is provided with afirst side 24 corresponding to an exterior of a room defined by thewall 10, and asecond side 26 corresponding to an interior of the room defined by the wall. Aninterior frame space 28 is defined by theframe members - Referring now to
FIGS. 2 and 4 , afirst wallboard panel 30 is secured to thefirst side 24. Preferably, thepanel 30 is a sheet of gypsum wallboard or the like having a 4 by 8 foot dimension and a thickness of ½ inch, ⅝ inch or even 1 inch depending on the application. Other known construction panels used in interior construction are contemplated as thefirst wallboard panel 30. It will be understood that thefirst wallboard panel 30 represents a plurality of such panels secured to theframe 16 by fasteners to close off thewall 10 as is known in the art. - A feature of the
present wall 10 is that at least onewallboard stud 32 is secured in theinterior frame space 28, and is fastened to theframe 16 and to aninterior surface 34 of thefirst wallboard panel 30 using fasteners such as screws or nails. It is preferred that thewallboard stud 32 is directly secured to the first wallboard panel to create a secure connection. As seen inFIG. 1A , in the present application, thewallboard stud 32 is assembled from a plurality of layers orthicknesses 36 of conventional wallboard that has been cut into appropriate lengths, such as 8 feet long, in similar fashion to thevertical frame members 22. Themultiple layers 36 are secured into a unitary mass using chemical adhesive or the like. Further, in the preferred embodiment, thewallboard studs 32 have a width of 100 mm, about 4 inches and a thickness of 64 mm, about 2.5 inches. In other words, thewallboard stud 32 has a thickness that extends from thefirst frame side 24 to thesecond frame side 26. - While the
frame 16 is contemplated as being made either of wood studs or metal [-shaped channel, in a preferred embodiment the frame is made of metal channel and thefooter 18 defines an upwardly-projecting U-shape defining acavity 38 betweenwalls 40. A feature of thewallboard stud 32 is having a thickness that extends between thewalls 40, or from thefirst side 24 to thesecond side 26, which is considered to be substantially the same dimension. - Referring now to
FIGS. 2 and 5 , once thewallboard studs 32 are secured to thefirst wallboard panel 30, asecond wallboard panel 42 is fastened to the wallboard studs and also to theother frame members first wallboard panel 30. As is the case with thefirst wallboard panel 30, thesecond wallboard panel 42 is a sheet of gypsum wallboard or the like having a 4 by 8 foot dimension and a thickness of ½ inch, ⅝ inch or even 1 inch depending on the application. Other known construction panels used in interior construction are contemplated. It will be understood that thefirst wallboard panel 42 represents a plurality of such panels secured to theframe 16 to close off thewall 10 as is known in the art. - As seen in
FIG. 6 , once thesecond wallboard panel 42 is in place, thewall 10 is finished in a conventional manner, using wallboardjoint compound 44 to fill the seams between adjacent panels. Upon assembly, thesecond wallboard panel 42 creates a continuous acoustic connection between thefirst wallboard panel 30, thewallboard stud 32 and the second wallboard panel. - Referring again to
FIGS. 1 and 3 another feature of thepresent wall 10 is that anacoustic mat 46 is installed between theframe 16 and thesubstrate 12, more specifically between thefooter 18 and the substrate. The purpose of theacoustic mat 46 is to absorb acoustic energy transmitted through thewall 10 by interrupting the flow of sound through the wall. As such, theacoustic mat 46 enhances the STC value of thewall 10. While it is preferred that theacoustic mat 46 is positioned between thefooter 18 and thesubstrate 12, it is also contemplated that theacoustic mat 46 is optionally further be positioned between theframe 16 and theceiling 14, as well as betweenvertical frame members 22 and adjacent walls. - In construction, the
acoustic mat 46 is preferably made of solid or foam rubber, closed cell foam or neoprene. A preferred mat thickness is between ⅛ inch and ½ inch, with a density of 80-120 lb/ft3. Also the presentacoustic mat 46 has a tensile strength of 60 psi minimum, with an elongation of 60% minimum. - Referring now to
FIGS. 7 and 8 , an effort has been made to quantify the acoustic properties of thewall 10 to better design walls for Mexican customers who typically knock on the wall with their knuckles to gauge a wall's solid structure. The test described below is referred to as the Knock Test. Initially, aroom 50 is constructed having a minimum size of 8 ft.×8 ft.×8 ft. Included in theroom 50 is afloor 52 with carpet tile, aceiling 54 made of acoustic tile panels supported by a suitable frame, and a plurality of sound absorptiveacoustic panels 56 disposed on surroundingwalls test sample 62 of thesubject wall 10 is secured to atest wall mount 64, which is mounted on thewall 60, however the particular wall in theroom 50 may vary. Theroom 50 is configured to isolate outside noises, and care is taken to reduce or eliminate other background noise from HVAC, lighting, plumbing and other sources. - A steel ball 66 of preferably 1.12-1.25 inch diameter is preferably encased in plastic in the preferred form of two layers of nitrile gloves, and is secured to a
string 68 mounted to theceiling 54. Thestring 68 is tied to the nitrile material and is long enough so that the ball 66, when released, will strike thesample 62. While other dimensions are contemplated, with thestring 68 mounted to theceiling 54 at a distance of 33 inches from thesupport wall 60, to strike thesample 62, the string has a preferred length of 63 inches. It is contemplated that the string length may vary depending on the application, provided the appropriate location on thetest sample 62 is achieved. Thesample 62 has a height of 48 inches and is centered on thesupport 64, preferably at 27 inches from both thefloor 52 and from theceiling 54. - Further, prior to the test, the ball 66 is held in a suspended position by a
release fixture 70 to provide consistent results. In the preferred embodiment, therelease fixture 70 is a clip connected to one of theceiling 54 and thewall 58 using a string, but other structures are contemplated including fixed stands or racks. Amount 72 such as a tripod, is placed in theroom 50 adjacent thesample 62, and is configured for accommodating a soundlevel meter microphone 74. Preferably, themicrophone 74 has the capability of a Class 1 sound level meter with the ability to measure Leq and Lmax in one-third octave bands and octave bands. -
FIG. 8 depicts a rear view of thetest sample 62 behind thewall 60. This portion of thesample 62 is designed to simulate an adjacent wall to thewall 10 being tested. As such, aframe 76 is constructed of conventional metal channel material, similar to theframe 16.Wallboard panels 78 cover the exterior of theframe 76, and are sealed at joints with acoustical sealant. Preferably, thewallboard panels 78 extend beyond the frame approximately ⅜ to ½ inch to facilitate a snug fit by thesample 62. Theframe 76 is dimensioned to surround the target area receiving the impact of the test ball 66. Also theframe 76 is secured, preferably by acoustical sealant, to abacking wall 80 attached to arear side 82 of thewall 60. Awallboard panel 84 is positioned between theframe 76 and thebacking wall 80. A room 86 serving as the location for the rear of thesample 62 is equipped with sound absorbing materials on thefloor 52,ceiling 54 andpanels 56 similar to theroom 50. - Measurements were taken with the
microphone 74 positioned at 4 locations across the face of the test sample 62: -
- 1. Mic centered at middle of a cavity between
studs 32 of thetest specimen 62; - 2. Mic centered at a middle of the
stud 32; - 3. Mic centered at a middle of the cavity between the
stud 32 and a perimeter frame edge defining thesample 62; and - 4. Mic at 2″ from perimeter frame edge.
- 1. Mic centered at middle of a cavity between
- In the preferred embodiment, all measurement locations are equidistant from the face of the test sample 62 (approximately 12″ from sample).
- Details of the
sample 62 are as follows. Thesample 62 is affixed to thestiff wall 64, and the back of the sample should also be drywall. Also, thesample 62 should be sealed—air compression from inside the sample cannot travel to outside the sample. This is achieved through the use of acoustical sealant and strong cloth tape, cover screws. A minimum sample size: is 24″ wide by 48″ tall. - Further, in the
sample 62, the metal framing is covered with drywall to create a drywall frame around the steel studs to prevent sound energy from breaking into/out of test sample cavity. Screws placement/spacing in thesample 62 should mimic real placement/spacing of screws. A single frame can be used for multiple face samples, but screw holes should not be reused. If asample 62 is overused, a new frame is built. A control sample is created to ensure repeatability between frames. During the test, the steel ball 66 measured impact should be centered in the middle of the sample, betweentest specimen 62 framing members. - Data generated by the tests is processed as follows: Lmax data is recorded in one-third octave bands and full octave bands. Lmax results are averaged from all measurements at each mic location. A Knock Factor Ratio is calculated from averaged Lmax results (low frequency sound level divided by high frequency sound level). A high knock factor (more low frequency energy than high frequency energy) correlates to hollow-sounding walls. In contrast, a low knock factor (more high frequency energy than low frequency energy) correlates to solid-sounding walls.
-
FIG. 9 and Table 1 below contain data for tested knock factors and STC values for three different sample walls, described below: -
- Steel Stud (Control): Wall constructed with 2½″ 25 gauge steel studs spaced 24″ on center and faced with ½″ lightweight gypsum board (fastened to steel studs with screws).
- 2″ Gypsum Stud: Wall constructed with 2″ gypsum studs spaced 12″ on center set in 2½″ perimeter steel track and faced with 1″ gypsum panels. ¼″ thick joint compound applied to both sides of the gypsum studs to make up the ½″ gap between the gypsum studs and 1″ gypsum panels. 1″ gypsum panels fastened to 2″ gypsum studs with screws.
- 2½″ Gypsum Stud:
Wall 10 constructed with 2½″ gypsum studs set in 2½″ perimeter steel track and faced with 1″ gypsum panels. 1″ gypsum panels fastened to 2″ gypsum studs with screws.
-
TABLE 1 Knock Factor Ratio and STC comparison of wall construction Impact Location Knock Factor Ratio STC value Steel Stud (Control) 1.4 33 2 inch Gypsum stud 0.9 39 2.5 inch Gypsum stud 0.8 42 - The Knock Factor Ratio calculated from the knock test data above compares low and high frequency sound levels generated by knocking on the
test specimen 62. A high knock factor ratio indicates that the low frequency sound levels generated by the knock exceed the high frequency sound levels generated by the knock—when this is the case, the wall is perceived as sounding hollow. A low knock factor ratio indicates that the high frequency sound levels generated by the knock exceed the low frequency sound levels generated by the knock—when this is the case, the wall is perceived as sounding more solid. - In the comparison above, conventional steel stud cavity walls, indicated by the Steel Stud (Control) curve on the graph, sound hollow when knocked upon, as indicated by the high Knock Factor Ratio. Both the 2″ and 2½″ gypsum stud walls, indicated by the 2″ Gypsum Stud and 2.5″ Gypsum Stud curves on the graph in Table 1, sound solid when knocked upon, as indicated by their lower Knock Factor Ratios, compared to Steel Stud (Control). The 2½″ gypsum stud wall has a lower Knock Factor Ratio than the 2″ gypsum stud wall, indicating that adjusting the size/profile of the gypsum stud and the method of attaching the face gypsum panels to the gypsum studs can affect the Knock Factor. Also, when STC values are considered, the 2 inch and 2½ inch gypsum stud walls have significantly higher values and as such respectively better sound absorption qualities than the control.
-
FIG. 10 and Table 2 reflect knock test results for 2different sample walls 10. A first wall had 2½″ Gypsum Studs at 12″ on center (o.c.): the wall was constructed with 2½″ gypsum studs spaced 12″ o.c. (on center), set in 2½″ perimeter steel track, and faced with 1″ gypsum panels. The 1″ gypsum panels were fastened to 2½″ gypsum studs with screws. In the other wall tested, 2½″ Gypsum Studs at 24″ on center (o.c.): Wall constructed with 2½″ gypsum studs spaced 24″ o.c., set in 2½″ perimeter steel track, and faced with 1″ gypsum panels. 1″ gypsum panels fastened to 2½″ gypsum studs with screws. -
TABLE 2 Knock Factor Comparison Impact Location Knock Factor Ratio 2.5″ Gypsum Stud @ 12″ o.c. 0.8 2.5″ Gypsum Stud @ 24″ o.c. 0.9 Knock Factor Ratio: ( Avg 50 Hz to 80 Hz)/(Avg 1250 Hz to 2000 Hz) - The Knock Factor Ratio calculated from the knock test data above compares low and high frequency sound levels generated by knocking on the test specimen. A high knock factor ratio indicates that the low frequency sound levels generated by the knock exceed the high frequency sound levels generated by the knock—when this is the case, the wall is perceived as sounding hollow. A low knock factor ratio indicates that the high frequency sound levels generated by the knock exceed the low frequency sound levels generated by the knock—when this is the case, the wall is perceived as sounding more solid.
- In the comparison above, from the data of Table 2, it is noted that the 2½″ gypsum stud wall with the
wallboard studs 32 spaced 12″ o.c. has a lower Knock Factor Ratio than the 2½″ gypsum stud wall withwallboard studs 32 spaced 24″ o.c., indicating that the distance between gypsum studs can affect the Knock Factor Ratio. This result is expected, since a shorter spacing means thatmore wallboard studs 32 are found in thewall 10. - Referring now to
FIGS. 11 and 12 , a first embodiment of an alternate embodiment of thegypsum stud 32 discussed above is generally designated 100. Thestud 100 shares properties with thestud 32 in that it is formed from a standardgypsum wallboard panel 102, or a portion of such a panel. Included on thepanel 102 is afirst facing sheet 104, commonly referred to as the face paper which is finished upon installation in a room, asecond facing sheet 106, commonly referred to as the backing paper, which is made of a relatively coarser grade of paper, and aset gypsum core 108 sandwiched between the facingsheets panel 102 may vary with the application, but standard thicknesses are 0.5 inch (1.27 cm) or ⅝ inch (1.58 cm). Also, a full or standardsized panel 102 has a dimension of 4 feet (1.22M)×8 feet (2.44 M). It is also contemplated that thepresent stud 100 is made either from standard panels, or segments of such panels, also referred to as dunnage. - Generally, the
present gypsum stud 100 is formed in a first embodiment by creating a series ofcuts 110, preferably 90° V-shaped cuts, also referred to as score cuts or linear cuts, on at least one of the first andsecond facing sheets core 108, up to and retaining intact an opposing one of the first and second facing sheets (at the end opposite the direction of the cut) to form a hinge point. Thus, theuncut facing sheet cuts 110 extend a full length of thewallboard panel 102, to provide the resultingstud 100 having a height suitable for use in building frame construction. - Upon forming the
cuts 110, the panel is then rolled from a first side to a second side, or in from a first direction to a second direction, so that the panel is folded upon itself by hinge action at the cuts. The resulting rolledstud 100 is useful for wall construction between opposing wallboard panels, and has a preferred width of 2.5 inches (6.3 cm). This dimension also is configured to suitably fit within a channel formed by conventional steel frame members forming top and bottom tracks in a wall frame. Tests have shown that such wallboard studs are comparable in their load-bearing qualifications to standard wooden or steel studs. - Referring now to
FIG. 12 , thepanel 102 is shown with the cuts marked 110A, 110B, 110C, 110D, 110E, 110F, 110G and 110H. As described above, thecuts 110 are preferably 90° V-shaped, which provides a series of right angle folds upon rolling. Note that thecuts 110A-110H do not extend into the first facingsheet 104. Once thecuts 110A-110H are made, a plurality ofsegments 112, designated 112A-1121 are defined, having axial lengths when viewed from right to left inFIG. 12 of: 1″ (2.5 cm), 1″ (2.5 cm), 1.5″ (3.8 cm), 1.5″ (3.8 cm), 2.0″ (5.0 cm), 2.0″ (5.0 cm), 2½″ (6.3 cm), 2½″ (6.3 cm), and 2½″ (6.3 cm). Preferably a layer ofchemical adhesive 114 is applied to the segments on at least one of the first andsecond facing sheets panel 102 in the rolled up condition. To assemble thegypsum stud 100, the panel inFIG. 12 is rolled from right to left, or smallest segment to largest. Upon assembly, thestud 10 has the appearance as seen inFIG. 11 . - Referring now to
FIGS. 13 and 14 , a modified version of the present gypsum stud is generally designated 120. Features shared with thestud 100 are designated with identical reference numbers. A main difference of thestud 120 is that it has a rectangular profile of 2.0 inches (5.0 cm)×2.5 inches (6.3 cm), while thestud 100 has a profile of 2.5″ (6.3 cm)×2.5″ (6.3 cm) square.Cuts 110A-110G are made as before, while thesegments 122A-122H measure 1″ (2.5 cm), 1″ (2.5 cm), 1.5″ (3.8 cm), 1.5″ (3.8 cm), 2.0″ (5.0 cm), 2.0″ (5.0 cm), 2.5″ (6.3 cm) and 2.0″ (5.0 cm).Adhesive 114 is applied as before, and the direction of rolling is right to left, or starting with the smallest segment to the largest. Upon rolling thestud 120, it has the appearance shown inFIG. 13 . - Referring now to
FIGS. 15-17 , another modified version of the present gypsum stud is generally designated 130. Components shared with thestuds stud 130 it is made of two portions, anouter portion 132 defining acentral opening 134, preferably polygonal in shape, and aninsert portion 136 dimensioned to fit matingly within the central opening. Both theouter portion 132 and theinsert portion 136 are constructed by folding segments of thegypsum panel 102. Preferably, theouter portion 132 has a square shape with 2.5 inch (6.3 cm) sides 138, and theinsert portion 136 is also square, having 1.5 inch (3.8 cm) sides 140. As seen inFIG. 16 , theinsert portion 136 also has anopening 142. - Referring now to
FIG. 17 , thepanels 102 used to make thestud 130 are shown in the cutting position. 90° V-cuts 144A-144C are formed in thepanel 102 forming theouter portion 132, and definesegments 146A-146D of 2.5 inches long. Also, 90° V-cuts 148A-148C in thepanel 102 forming theinsert portion 136 define segments 150 A-D of 1.5 inches long. It will be seen that in thestuds cuts 110, 144 and 148 are all made in the same direction, and the first facingsheet 104 defines the hinge or folding point, which is not cut. Depending on the application, thesecond facing sheet 106 optionally defines the hinge or folding point. Unlike the other embodiments, in this case since the segments 146, 150 are all the same length, the rolling can start in either direction. Also, as needed, the adhesive 114 is applied. Upon completion of the rolling, theouter portion 132 and theinsert portion 136 have the appearance shown inFIG. 16 . Then, as assembled, with theinsert portion 136 inserted into theouter portion 132, the completedstud 130 is shown inFIG. 15 . - Referring now to
FIGS. 18 and 21 , an alternate embodiment to thestud 130 is generally designated 160. Components shared with theprevious embodiments studs insert portion outer portion embodiments insert portion 162 lacks theopening 134. In addition, theinsert portion 162 is created using a “zig-zag” cuttingpattern using cuts 110 alternating on both first andsecond facing sheets outer portion 164 is formed with cuts on only one facingsheet - In a preferred embodiment, the
insert portion 162 hassegments 168A-C of 2.5″ (6.4 cm) formed by cuts 170 A-C (FIG. 19 ) alternating on the first andsecond facing sheets insert portion 162 is inserted into thecentral opening 134 of theouter portion 164.Adhesive 114 is applied as needed to maintain the desired shapes. The entire length (as opposed to the height, which is equal to wall frame height) of thestud 160 is 3.7″ (9.4 cm). - Referring now to
FIGS. 19 and 20 , another feature of the present rolledstud standard wallboard panel 102 dimensioned at 4′×8′ (128 cm×244 cm) depending on the arrangement of thecuts 110. Thecuts 110R located adjacent both the first andsecond facing sheets panel 102, defining threestuds 160 generated from a single panel. Moving from left to right, theinsert segments 168A-C are rolled first, with the zig-zag cuts 170A-C forming the stacked orientation seen inFIG. 18 . Then, as rolling progresses, theouter portion 164 is formed. Thesegments 166A-D and 168 A-C are thus made in multiple groups of the following sequence: 3.8 (1.5 in.), 6.9 (2.7 in.), 3.8 (1.5 in.), 6.9 (2.7 in.), 6.4 (2.5 in.), 6.4 (2.5 in.), 6.4 (2.5 in.). - In
FIG. 19 , eachstud 160 of the three studs formed from thepanel 102 is formed in a single piece, with theinsert portion 162 joined to theouter portion 164. InFIG. 20 , each of the threestuds 160 are created in two pieces, withcuts 110 S cleaving theinsert portion 162 from theouter portion 164. - While a particular embodiment of the present interior wall system with high knock factor has been described herein, it will be appreciated by those skilled in the art that changes and modifications may be made thereto without departing from the invention in its broader aspects and as set forth in the following claims.
Claims (15)
1. An interior wall, comprising:
a frame including at least one footer, at least one header, at least one vertical frame member connecting at least one of said at least one footer to at least one of said at least one header, said frame having a first side and a second side, and defining an interior frame space;
a first wallboard panel fastened to said first side of said frame;
at least one wallboard stud secured in said frame space, being fastened to said first wallboard panel and being dimensioned to extend from said first side to said second side;
a second wallboard panel being fastened to said frame and to said at least one wallboard stud for creating a continuous acoustic connection between said first wallboard panel and said second wallboard panel.
2. The interior wall of claim 1 , wherein said frame is made of metal channel and said wallboard studs are configured to have a thickness dimensioned to fill a cavity defined by walls of said metal channel.
3. The interior wall of claim 1 , further including an acoustic mat installed between said frame and a substrate.
4. The interior wall of claim 3 , wherein said acoustic mat is disposed between said footer and the substrate.
5. The interior wall of claim 1 , wherein said wallboard studs have an on center spacing of one of 12 and 24 inches, and said wall having a knock factor ratio of 0.8.
6. A method for constructing an interior wall as defined in claim 1 comprising:
measuring a knock factor of the assembled wall; and
adjusting at least one of the number and lateral spacing of said at least one wallboard stud in said interior frame space to achieve a knock factor ratio of 0.8.
7. A gypsum stud for use in the wall of claim 1 , comprising:
a gypsum wallboard panel having first and second facing sheets sandwiching a core therebetween;
a series of cuts formed on at least one of said first and second facing sheets and extending into a core located between said sheets, retaining intact an opposing one of said first and second facing sheets to form a hinge point;
said panel being rolled from a first side to a second side into a rolled condition so that a rolled up stud is formed.
8. The gypsum stud of claim 7 further including a layer of adhesive applied to at least one of said first and second facing sheets so that said panel is held in said rolled condition.
9. The gypsum stud of claim 7 wherein said cuts are 90° cut and said cuts extend up to the opposite facing sheet from where they begin.
10. The gypsum stud of claim 7 , wherein said cuts are made in the following sequence: 1″ (2.5 cm), 1″ (2.5 cm), 1.5″ (3.8 cm), 1.5″ (3.8 cm), 2.0″ (5.0 cm), 2.0″ (5.0 cm), 2½″ (6.35 cm), 2½″ (6.35 cm), and 2½″ (6.35 cm) and the rolling begins at the 1″ end so that the resulting stud has a width of 2½″.
11. The gypsum stud of claim 7 , wherein said cuts are made in multiple groups of the following sequence: 3.8 (1.5 in.), 6.9 (2.7 in.), 3.8 (1.5 in.), 6.9 (2.7 in.), 6.4 (2.5 in.), 6.4 (2.5 in.), 6.4 (2.5 in.).
12. The gypsum stud of claim 1 , wherein said gypsum wallboard panel is a full-size, standard panel, and said cuts are made into said first and second facing sheets to form multiple wallboard studs.
13. The gypsum stud of claim 12 , wherein said cuts are made in multiple groups of the following sequence: 3.8 (1.5 in.), 6.9 (2.7 in.), 3.8 (1.5 in.), 6.9 (2.7 in.), 6.4 (2.5 in.), 6.4 (2.5 in.), 6.4 (2.5 in.).
14. The gypsum stud of claim 12 , wherein three said gypsum studs, including three tubular outer portions and three insert portions are created from said panel.
15. The gypsum stud of claim 7 , wherein said stud is made of two portions, an outer portion defining a central opening, and an insert portion dimensioned to fit within said central opening.
Priority Applications (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US18/485,005 US20240167281A1 (en) | 2022-11-18 | 2023-10-11 | Gypsum stud wall system with high knock factor |
PCT/US2023/079506 WO2024107644A2 (en) | 2022-11-18 | 2023-11-13 | Gypsum stud wall system with high knock factor |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US202263384365P | 2022-11-18 | 2022-11-18 | |
US18/485,005 US20240167281A1 (en) | 2022-11-18 | 2023-10-11 | Gypsum stud wall system with high knock factor |
Publications (1)
Publication Number | Publication Date |
---|---|
US20240167281A1 true US20240167281A1 (en) | 2024-05-23 |
Family
ID=91080710
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US18/485,005 Pending US20240167281A1 (en) | 2022-11-18 | 2023-10-11 | Gypsum stud wall system with high knock factor |
Country Status (1)
Country | Link |
---|---|
US (1) | US20240167281A1 (en) |
-
2023
- 2023-10-11 US US18/485,005 patent/US20240167281A1/en active Pending
Similar Documents
Publication | Publication Date | Title |
---|---|---|
US8424251B2 (en) | Sound Proofing material with improved damping and structural integrity | |
US7921965B1 (en) | Soundproof assembly and methods for manufacturing same | |
US7127858B2 (en) | Interior wall and partition construction | |
US7181891B2 (en) | Acoustical sound proofing material and methods for manufacturing same | |
US20100146874A1 (en) | Non load-bearing interior demising wall or partition | |
US20160289961A1 (en) | Structural member comprising sound insulating layer | |
WO2019172040A1 (en) | Partition wall structure and method for constructing same | |
JP2017151325A (en) | Sound insulation panel | |
RU153758U1 (en) | SOUND PROTECTION | |
US20240167281A1 (en) | Gypsum stud wall system with high knock factor | |
US20060179760A1 (en) | Acoustic wall using compressed fiber panels | |
WO2024107644A2 (en) | Gypsum stud wall system with high knock factor | |
CA3129697C (en) | Unitary double stud assembly for sound damping wall | |
RU155097U1 (en) | PROTECTION OF ADDITIONAL SOUND INSULATION | |
US20050066618A1 (en) | Panel and related wall structure | |
Buratti et al. | Impact noise reduction: laboratory and field measurements of different materials performances | |
CN217204858U (en) | Prefabricated house wallboard easy to assemble | |
JP7337400B2 (en) | sound insulation panel | |
JP3233200U (en) | Soundproof structure of the room | |
JP2023140362A (en) | floor structure | |
Stani et al. | Sound insulation of plasterboard walls and airflow resistivity: an empirical examination with respect to practical applications | |
JP2022094741A (en) | Floor structure | |
AU2014201979B2 (en) | Wall structure and method | |
JP3130583U (en) | Interior panel material, interior structure and rib material | |
Brandin et al. | Dynamic response of timber floors–criteria, performance and design for acceptability |
Legal Events
Date | Code | Title | Description |
---|---|---|---|
AS | Assignment |
Owner name: UNITED STATES GYPSUM COMPANY, ILLINOIS Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:HIDALGO, HECTOR NIETO;SCHMIDT, ANDREW L.;PHILLIPS, AUSTIN;AND OTHERS;SIGNING DATES FROM 20240205 TO 20240305;REEL/FRAME:066673/0129 |