WO2013064191A1

WO2013064191A1 - Drywall with improved acoustic properties and channel therefor

Info

Publication number: WO2013064191A1
Application number: PCT/EP2011/069376
Authority: WO
Inventors: Cyrille Demanet; Hye-Mi Lee; Gaël MAILLE; Yong-Sam Park; Julien SOULHAT; Emmanuel Vial
Original assignee: Lafarge Platres
Priority date: 2011-11-03
Filing date: 2011-11-03
Publication date: 2013-05-10
Also published as: PL2773821T3; EP2773821A1; ES2625820T3; EP2773821B1; DK2773821T3

Abstract

The invention relates to a drywall frame comprising : at least one U-channel, said U-channel comprising two opposing longitudinal sidewalls interconnected by a planar web, where said planar web comprises openings; and a plurality of acoustic studs. The invention also relates to the use of the U-channel of the invention for improving the acoustic properties of drywalls.

Description

DRYWALL WITH IMPROVED ACOUSTIC PROPERTIES

AND CHANNEL THEREFOR

FIELD OF THE INVENTION

The invention relates to a drywall having improved acoustic properties and to the use of a U-channel (or runner or track) for improving the acoustic properties of a drywall.

TECHNICAL BACKGROUND

A common building technique for the fabrication of building walls, and in particular internal walls, is to fasten sheets or boards of walling material, such as plasterboard, to vertical studs. Typically, each stud is secured to a horizontal beam or channel or runner secured to either the floor or ceiling of the room or both in which the interior drywall is being constructed.

This wall construction technique is both relatively simple and inexpensive and further allows existing room spaces to be subdivided if required, for example when altering the use of an existing building. This wall construction technique also allows separation walls (typically with twin frame/double frame dwelling partition) and distribution walls (typically single frame) to be erected. Staggered structures are also commonplace, with single runner (or U-channel) or with twin angles.

Sound insulating has always been an issue with any interior wall.

Twin frame walls have rather good insulating properties, but require space and are costly to build.

Rather than fasten a sheet of plasterboard to either side of the same wall stud, it is common practice to use two rows of parallel wall studs and fasten a single sheet of plasterboard to the outside faces of each of the paired studs. This is done to create a relatively large air gap within the resulting wall that provides low frequency sound insulation. To further improve such a double wall, twin angles should be preferred over large single channels or runners.

However, this kind of "double stud" construction usually requires some form of brace to be fastened between parallel studs spanning the air gap to give the structure adequate strength. Furthermore, by using a double row of studs for a single wall, the cost of materials used, and time required to install two rows of tracks, is significantly increased over the costs that would be incurred if a single stud construction could be used.

Single frame walls, with improved acoustic properties, would thus be of high interest.

Single frame drywalls hence require adaptation to have improved acoustic properties. Insulating material, such as rock wool or glass wool is inserted in the air gap between the boards. The studs have also been modified to improve the acoustic properties.

For example, WO-A-03/102322 provides a wall stud comprising two opposing sidewalls interconnected by a spanning web, the spanning web comprising first and second substantially planar members connected to the respective sidewalls and a member interconnecting the first and second planar members, the latter member having at least one row of elongate slots formed therein along a longitudinal axis thereof, said member interconnecting the first and second planar members being preferably substantially semicircular.

US-A-6381916 (or EP-A-1074671 ) provides asection for building walls comprising

- two parallel section legs having two longitudinal edges and extending spaced apart from each other, each section leg having a longitudinal inwardly pointing edge flange extending along one of said longitudinal edges;

- a common section bridge connecting said section legs along said longitudinal edges, opposite from said edge flanges, said bridge having at least one elastic segment having low transverse spring temper extending in a longitudinal direction of the section;

- wherein said at least one elastic segment is shaped from a plane formed by said section bridge and provides a flexible connection between said section legs;

- wherein said recesses are slots extending in the longitudinal direction of the section.

The above solutions, like all acoustic solutions, are based on the use of a resilient section between the two lateral sidewalls of the stud. It follows that sound insulation in drywalls is based on resilience.

The elements of the metallic structure have received modifications at the stud only so far. Channels are known since decades. Very few modifications have been brought to them, apart modifications towards "low-cost" channels. Such "low- cost" channels comprise, like the studs, two opposing longitudinal sidewalls interconnected by a planar section bridge or web, where said planar section bridge or web is formed, at least in part, with expanded metal (or deployed metal). The amount of metal used is thus less than with standard channels, allowing cost reduction.

Yet, there is still a need for a metallic structure or frame for use in interior walls that would improve the acoustic properties of the final drywall, and an improved drywall.

SUMMARY OF THE INVENTION

The invention provides a drywall frame comprising :

- at least one U-channel, said U-channel comprising two opposing longitudinal sidewalls (2, 3) interconnected by a planar web (4), where said planar web comprises openings

(5a, 5b, 5c, 5d, 5e, 5f) ; and

- a plurality of acoustic studs (7).

According to one embodiment, the openings are placed in the central part of said planar web, or in which the openings are placed at distal parts of said planar web, or in which the openings are placed at the edges formed by the planar web and the sidewalls.

According to one embodiment, the openings are slots. The slots can be arranged in rows. The slots can be arranged in one row located in the median part of the web. The slots can be arranged in two or more rows located in the median part of the web, at distal parts of said planar web or at the edges formed by the planar web and the sidewalls. The slots can have the following dimensions: length from 80mm to 500mm, preferably from 200mm to 480mm; separation between the slots from 20mm to 150mm, preferably from 20mm to 50mm; width from 5mm to 100mm, preferably from 5mm to 80mm.

According to one embodiment, the openings are in the form of a grid. The grid can extend from 10 to 80%, preferably from 30 to 60%, of the width of the planar web.

According to one embodiment, the openings are C, U or V shaped or generally chevron-like shapes and are intertwined in each other. The openings can have the following dimensions: length of the chevron-like form from 10mm to 400mm, preferably from 50mm to 300mm; width of the chevron-like form from 5mm to 40mm, preferably from 5 mm to 30mm; width of the see-through part of the openings from 0.5mm to 30mm, preferably from 1 mm to 20mm.

According to one embodiment, the openings have all the same shape.

According to one embodiment, the openings are obtained by laser techniques, mechanical techniques with or without metal removal including punching, piercing, stamping, expanding and deploying.

The drywall frame can be a single frame.

The invention also provides a drywall comprising the drywall frame of the invention together with a plurality of boards, preferably plasterboards, affixed onto said studs on each side thereof and preferably onto said U- channels.

According to one embodiment, the drywall further comprises a filler material placed between the boards.

The invention also provides the use of the U-channel of the invention for improving the acoustic properties of drywalls.

According to one embodiment, the drywall is a single frame, a staggered frame or a double frame.

The present invention allows improving the sound absorbing properties of a drywall.

Since the channels are affixed in the floor or ceiling of the room, it was believed, until the invention, that they will not serve in the sound transmission through the drywall. In an unexpected manner, the inventors have found that the U-channel does participate to the acoustic properties, and in an even more surprising manner that the technical solutions known for studs cannot be applied to the U-channels. Indeed, studs with merely openings or slots in the central planar web do not exhibit any improvement in the acoustic properties while the very same type of openings or slots does provide an improvement when applied to U-channels. The invention is based, at least partly, on this surprising finding.

BRIEF DESCRIPTION OF THE DRAWINGS

Figure 1 represents a perspective view of a first embodiment of the invention.

Figure 2 represents a perspective view of a second embodiment of the invention.

Figure 3 represents a top view from different embodiments of the invention.

Figure 4 represents a top view from different embodiments of the invention. Figure 5 represents a single frame of the invention with plasterboards being mounted on it.

DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION

The invention is now disclosed in more details in the following description.

The metallic frame of the invention comprises at least one U-channel, and a plurality of studs, said studs being introduced into said channels, where the channels longitudinal sidewalls will maintain said studs in place. This is conventional in the art and the methods for erecting drywalls are not changed with the invention.

The invention is based on the use of a specific U-channel (or runner or track), used in combination with acoustic studs, so as to provide a metallic structure where all elements are designed to improve the acoustic properties of the final drywall.

As is depicted in figure 1 , the U-channel (1 ) of the invention comprises two opposing longitudinal sidewalls (2, 3) interconnected by a planar web (4), where said planar web comprises openings (5a, 5b, etc). The sidewalls (2, 3) are substantially parallel to one another and/or substantially equal in width. In use the studs are forced into the U-channels, and can then be screwed if necessary. Preferred dimensions for the U-channel are the following: 48, 50, 62, 70, 75, 90, 100, 146, 150 and 200. The planar web 4 may be from 36mm to 200mm, preferably from 48mm to 150mm, in width. The width of the sidewalls (2, 3) may be from 25mm to 50mm, preferably from 25mm to 35mm. The thickness of the metal foil used to manufacture the U-channel is adapted, and is generally 0.5 or 0.6mm, but other thicknesses can be used if needed. The metal is standard and does not need any adaptation.

The openings can be placed in the central portion of the planar web, as is represented in figure 1 .

They may also be placed at a location of the web close to the lateral sidewalls, or even at the angles formed by the web and the sidewalls. This latter embodiment is depicted in figure 2.

The openings may be located at more than one location in the web. The openings can have various shapes. One preferred shape is a slot, with an elongated shape. The openings generally comprise a plurality of slots, arranged in a row or a plurality of rows, typically 2 or 3 adjacent rows. In the event more than one row of slots is present, the slots can be placed in correspondence, or be offset one with respect to the other. The offset may be symmetrical or not. Figure 3a represents the embodiment shown in figure 1 , viewed from the above, for the web part 4 only. Figure 3b is a variant, with slots of substantially greater surface. Figure 3c represents an embodiment where the slots (5a, 5b, 5c, 5d, 5e) are arranged in two adjacent rows (6a, 6b), the slots being offset. In the embodiment shown in Figure 3c first and second rows of slots are provided, with the second row of slots being displaced along the length of the planar web 4 by approximately half the length of a slot with respect to the first row of slots. The two rows of slots are equally spaced apart the median line of the planar web 4. Figure 3d represents an embodiment where the slots (5a, 5b, 5c, 5d, 5e, 5f) are arranged in two adjacent rows (6a, 6b), the slots being aligned from one row to another.

The length of the slots may be from 80mm to 500mm, preferably from 200mm to 480mm. The separation between the slots along the direction of one given row may be from 20mm to 150mm, preferably from 20mm to 50mm. (The length to separation ratio of the slots can be approximately 4:1 to 25:1 , preferably 5:1 to 15:1 ). The width of the slots may be from 5mm to 100mm, preferably from 5mm to 80mm. When two or more rows are contemplated, the distance between their respective adjacent axis is calculated so as to have enough material to maintain mechanical strength. Typically this distance between adjacent axis is such that the distance between two slots from two different parallel adjacent rows may be from 10mm to 150mm, preferably from 10mm to 80mm.

A row of diagonal slots can also be used, preferably in the median part of the planar web. The slots then would extend across part or whole of the width of the planar web.

As represented in figure 4a, 4b, 4c and 4e, the openings may also have other designs such as C or U or V shapes, generally speaking chevronlike shapes, where the C or U or V openings or chevrons-like are intertwined in each other, the respective apex are opposite one to the other. More than one of such chevron-like openings may be present in a row, as is represented in figure 4d. Alternatively the rows can be repeated at different locations on the web of the U-channel. With this geometry, the sound track is longer than for a direct connection. Sound attenuation is thus improved with this geometry.

The length of the C/U/V (chevron-like) openings may be from 10mm to

400mm, preferably from 50mm to 300mm. The width of the C/U/V (chevronlike) form may be from 5mm to 40mm, preferably from 5 mm to 30mm. The width of the openings (i.e. the part that is see-through) may be from 0.5mm to 30mm, preferably from 1 mm to 20mm. Two or more chevron-like openings may be used for the repetition of the pattern. Otherwise the dimensions provided above would equally apply. For example, the distance between adjacent axis of rows of intertwined chevron-like openings is such that the distance between two slots from two different parallel adjacent rows may be from 10mm to 150mm, preferably from 10mm to 80mm.

The openings can also be in the form of a grid, notably obtained by metal expansion or deployment. The grid may extend over a part of the planar web, or over substantially the entire width of the web. The grid may thus extend from 10 to 80%, preferably from 30 to 60% of the width of the planar web.

Holes, e.g. formed by mechanical processes, are also possible. The metal that may remain after formation of the openings will preferably remain in the inner volume of the U-channel; a flat and smooth surface may thus remain available on the outer of the U-channel.

Openings are preferably all of the same shape, with the same length and width.

Different techniques can be used to form the openings. Laser cutting is one technique, which can be used on-line. Other techniques using mechanical tools can be used, as is known in the art. Punching, piercing, stamping and any other known methods can be used. Metal expansion or deployment is also a possible method. Existing U-channels or tracks formed using the latter technique are already known.

Openings can be formed with or without metal removal. In the event of a mechanical technique without metal removal, the metal that is taken out of the piece to form the openings remain preferably on one side of the metal sheet. Openings, e.g. slots can be stamped through and have slot edges set upright toward one side. Said upright slot edges preferably protrude into an interior portion of said upright section.

Possible U-channels that can be used in the invention are the maxi-tec products or those manufactured by Dalian (expanded metal, optionally folded).

The web of the U-channel could be totally flat or with large groove. Both embodiments are known in the field of channels. When simply placed on the wall, the planar web will show a gap, with the substrate, of about 0.5 to 2mm, for example. This may be useful during manufacture of the channel. The embodiment with large groove can also be useful during use, since the sidewalls will, as a consequence of the planar web being forced towards the floor or ceiling, bend towards the interior of the channel and provide improved grasping of the studs.

The acoustic studs used in the invention for manufacture of the frame are those studs which are known to improve the acoustic properties of a drywall. A stud will be defined as acoustic if, when used in a standard drywall instead of a standard stud with the same metal thickness, provides a gain of at least 2dB for the sound transmission across the wall. Examples of acoustic studs are those subject of WO-A-03/102322 and EP-A-1074671 . Sound performances are measured using the standards defined in the examples section.

Acoustic studs typically comprise two opposing longitudinal sidewalls interconnected by a section bridge, said bridge having elastic properties. Typically, the section bridge comprises first and second substantially planar members connected to the respective sidewalls and a member interconnecting the first and second planar members, the latter member providing the resilience. Resilience is improved in studs by the use of perforations, typically slots arranged along the longitudinal direction of the stud.

The invention can be practiced with any kind of acoustic stud.

While the invention can be used for double-frame walls or staggered walls, it is preferably to use the invention for single-frame walls.

The metallic frame is used with standard wallboards such as plasterboards. The walls are erected according to the known standards.

Figure 4 represents a single frame erected, with plasterboards being mounted on it. The U-channels (also known as runners or tracks or beams ) are secured (typically with screws or glue) to the floor and ceiling of the room. Acoustical studs 7 are inserted into the U-channels. Plasterboards 8 are then fixed onto the studs in a standard manner (e.g. with screws). Plasterboards are also preferably fixed onto the U-channels in a standard manner (e.g. with screws).

An insulating material, such as mineral woo, rock wool, glass wool, spun bonded polyester wool foamed plastics, foamed polymers, or any filler material known to improve acoustic properties, can be used to fill in the gap inside the drywall. This is conventional in the art.

The invention further relates to the use of the U-channel for improving the acoustic properties of the drywalls. This improvement is reached in single-frame drywalls, but also in staggered frame or even in double-frame drywalls. The present invention allows replacing the corners/angles typically used and yet obtain improved acoustic properties.

The U-channels of the invention also provide ease of handling, notably compared to corners/angles, especially on the site of use. They are also easier to align, compared again to angles/corners. U-channels of the invention are otherwise handled in a way similar to standard U-channels.

Acoustic improvements are not obtained to the detriment of the handling or the mechanical strength (once installed).

The following examples illustrate the invention without limiting it.

The sound performances are measured according to standards, BS

En ISO 140-3 Acoustic -Measurement of sound insulation in buildings and of building elements- Part 3 Laboratory measurement of airborne sound insulation of building elements and BS EN ISO 717_1 Rating of sound insulation in buildings and of building elements- Part 1 Airborne sound insulation.

EXAMPLES

The acoustic performances Rw+C are measured for a double-frame drywall with standard 62 studs. Width of the channel and the studs are 62 mm. Are tested angles/corners, standard U-channels ("std channel"), a U- channel according to the embodiment of figure 3b ("U-channel 1 ") and a U- channel according to the embodiment of figure 4e and ("U-channel 2"). U- channel 1 comprises slots of a length of 230mm, a width of 45mm and separations between two slots of 50mm. U-channels 2 comprises chevronlike openings, with a length for the central part of 200mm, flanked with inclined parts, these parts forming an angle of 45° with the axis of the slot and being 20mm long each (thus forming a width of about 14.14mm). Two parallel chevron-like openings are offset one with respect to the other by 20mm. The see-through is about 1 mm.

The results are given in the table below.

Type Angles Std Channel U-channel 1 U-channel 2

Rw+C (dB) 53 49 52 52

Claims

Drywall frame comprising :

- at least one U-channel (1 ), said U-channel comprising two opposing longitudinal sidewalls (2, 3) interconnected by a planar web (4), where said planar web comprises openings (5a, 5b, 5c, 5d, 5e, 5f) ; and

- a plurality of acoustic studs (7).

Drywall frame of claim 1 , in which the openings (5a, 5b, 5c, 5d, 5e, 5f) are placed in the central part of said planar web (4), or in which the openings are placed at distal parts of said planar web (4), or in which the openings are placed at the edges formed by the planar web (4) and the sidewalls (2, 3).

Drywall frame of claim 1 or 2, in which the openings (5a, 5b, 5c, 5d, 5e, 5f) are slots.

Drywall frame of claim 3, in which the slots are arranged in rows.

Drywall frame of claim 4, in which the slots are arranged in one row located in the median part of the web.

Drywall frame of claim 4, in which the slots are arranged in two or more rows located in the median part of the web, at distal parts of said planar web or at the edges formed by the planar web and the sidewalls.

Drywall frame of any one of claims 3 to 6, in which the slots have the following dimensions: length from 80mm to 500mm, preferably from 200mm to 480mm; separation between the slots from 20mm to 150mm, preferably from 20mm to 50mm; width from 5mm to 100mm, preferably from 5mm to 80mm.

8. Drywall frame of claim 1 or 2, in which the openings are in the form of a grid.

9. Drywall frame of claim 8, in which the grid extends from 10 to 80%, preferably from 30 to 60%, of the width of the planar web.

10. Drywall frame of claim 1 or 2, in which the openings are C, U or V shaped or generally chevron-like shapes and are intertwined in each other.

11. Drywall frame of claim 10, in which the openings have the following dimensions: length of the chevron-like form from 10mm to 400mm, preferably from 50mm to 300mm; width of the chevron-like form from 5mm to 40mm, preferably from 5 mm to 30mm; width of the see-through part of the openings from 0.5mm to 30mm, preferably from 1 mm to 20mm.

12. Drywall frame of any one of claims 1 to 1 1 , in which the openings have all the same shape.

13. Drywall frame of any one of claims 1 to 12, in which the openings are obtained by laser techniques, mechanical techniques with or without metal removal including punching, piercing, stamping, expanding and deploying.

14. Drywall frame of any one of claims 1 to 13, which is a single frame.

15. Drywall comprising the drywall frame of anyone of claims 1 to 14 together with a plurality of boards (8), preferably plasterboards, affixed onto said studs (7) on each side thereof and preferably onto said U-channels.

16. Drywall of claim 15, further comprising a filler material placed between the boards.

17. Use of the U-channel disclosed in any one of claims 1 to 13 for improving the acoustic properties of drywalls.

18. Use of claim 17, wherein the drywall is a single frame, a staggered frame or a double frame.