U.S. patent application number 12/316657 was filed with the patent office on 2010-06-17 for non load-bearing interior demising wall or partition.
Invention is credited to Robert William Brown.
Application Number | 20100146874 12/316657 |
Document ID | / |
Family ID | 42238910 |
Filed Date | 2010-06-17 |
United States Patent
Application |
20100146874 |
Kind Code |
A1 |
Brown; Robert William |
June 17, 2010 |
Non load-bearing interior demising wall or partition
Abstract
A non load-bearing interior demising wall construction
comprising a plurality of CAF panels each sized to span the full
wall height and placed in aligned edge to edge abutted position and
a plurality of stiffening means also sized to span the full wall
height. CAF panels and stiffening means slidably disposed within a
top and bottom track and sized to provide a friction fit therein. A
plurality of wall facing sheets sized to span the full wall height
placed in edge to edge abutted position to as to provide a seamless
wall face with said wall facing sheets residing outside said top
and bottom tracks and attached to said stiffening means.
Preferably, top and bottom track and stiffening means are comprised
of readily available standard drywall materials.
Inventors: |
Brown; Robert William;
(Bedford, TX) |
Correspondence
Address: |
Robert W. Brown
820 Mayfair Hill Ct.
Bedford
TX
76021
US
|
Family ID: |
42238910 |
Appl. No.: |
12/316657 |
Filed: |
December 16, 2008 |
Current U.S.
Class: |
52/145 |
Current CPC
Class: |
E04B 2/7453 20130101;
E04B 2/7409 20130101 |
Class at
Publication: |
52/145 |
International
Class: |
E04B 1/84 20060101
E04B001/84 |
Claims
1. An improved wall or partition construction, comprising: a bottom
track member having a U-shaped cross section with front and back
legs defining an interior channel area, said bottom track member
centered along the bottom of a wall line with said interior channel
area opening upward; a top track member having a U-shaped cross
section with front and back legs defining an interior channel, said
top track member centered along the top of a wall line with said
interior channel area opening downward, said top track member
positioned in generally aligned and opposed proximity to said
bottom track member and defining a vertical distance therebetween;
a plurality of CAF panels, each having a generally rectangular
shape with a front and rear face and a top, bottom, left and right
edge, said panels positioned between said top and bottom track
members such that each top and bottom edge are slidably disposed
within respective channel area, said panels positioned in relative
edge to edge abutted relation; stiffening means spanning vertical
distance between said top and bottom tracks and slidably disposed
within said interior channel areas; a plurality of front wall
facing sheets, each facing sheet having a generally rectangular
shape with a top, bottom, left and right edge, said facing sheets
positioned in relative edge to edge abutted relation, sized to span
said vertical distance between said top and bottom track members
and positioned such that said top and bottom edge of each facing
sheet resides outside respective channel areas; and penetrating
connector means, said penetrating connector means positioned
through each said front wall facing sheet and further penetrating
into said stiffening means so as to make a rigid attachment
therebetween.
2. The construction of claim 1 wherein said stiffening means
comprises a plurality of elongated rail members, each having a
length substantially equal to the distance between said top and
bottom track members and sized to provide a friction fit when
slidably disposed within said channel area of said top or bottom
channel along with said CAF panel.
3. The construction of claim 2 wherein said elongated rail members
have a cross sectional shape selected from the following group;
square, rectangle, hat, circle, ellipse, U, C, I, and H.
4. The construction of claim 2 wherein said elongated rail members
are comprised of standard SSMA 21/2''.times.11/2'' furring
channels.
5. The construction of claim 1 wherein said top and bottom track
members are comprised of standard SSMA 31/2'' drywall track.
6. The construction of claim 1 wherein said front wall facing
sheets are comprised of gypsum wall board.
7. The construction of claim 1 wherein said front wall facing
sheets are comprised of plywood, oriented strand board, or other
wood-based paneling.
8. The construction of claim 1 wherein said front wall facing
sheets include a compressed non-wood fiber core.
9. The construction of claim 8 wherein said front wall facing
sheets further comprise a CAF panel.
10. The construction of claim 1 wherein said penetrating connector
means comprises a conventional penetrating connector selected from
the group; drywall screw, deck screw, screw, nail, brad, tack and
rivet.
11. The construction of claim 1 further comprising: a plurality of
rear cladding sheets, each cladding sheet having a generally
rectangular shape with a top, bottom, left and right edge, said
cladding sheets positioned in relative edge to edge abutted
relation and positioned to span said vertical distance between said
top and bottom track members and positioned such that said top and
bottom edge of each facing sheet resides outside respective channel
areas; and penetrating connector means, said penetrating connector
means positioned through each said rear cladding sheet and further
penetrating into a said CAF panel so as to make a rigid attachment
therebetween.
12. The construction of claim 11 wherein said rear cladding sheets
are comprised of gypsum wall board.
13. The construction of claim 11 wherein said rear cladding sheets
are comprised of plywood, oriented strand board, or other
wood-based paneling.
14. The construction of claim 11 wherein said rear cladding sheets
include a compressed non-wood fiber core.
15. The construction of claim 11 wherein said penetrating connector
means comprises a conventional penetrating connector selected from
the group; drywall screw, deck screw, screw, nail, brad, tack and
rivet.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] Not Applicable
FEDERALLY SPONSORED RESEARCH AND DEVELOPMENT STATEMENT
[0002] This invention was not developed in conjunction with any
federally sponsored contract.
MICROFICHE APPENDIX
[0003] Not applicable.
INCORPORATION BY REFERENCE
[0004] Not applicable
BACKGROUND OF THE INVENTION
[0005] The primary function of interior walls and partitions is to
divide building space into separate, private spaces. Many other
factors, however, must be considered by designers and builders, one
of which is sound control. In hotels, for example, the prevention
of sounds originating in one room from passing through walls and
into adjacent rooms is of major concern. Home media rooms have
introduced a greater need for sound control into many home
construction projects, and the need for sound isolation between
adjacent office spaces in commercial office buildings is
significant and growing.
[0006] Sound transmission through walls is typically expressed
according to one of two single-number rating systems--Sound
Transmission Class (STC) and Weighted Sound Reduction Index
(R.sub.w). Both are single-figure ratings schemes intended to rate
the acoustical performance of a partition element under typical
conditions involving office or dwelling separation; the higher the
value of either rating, the better the sound attenuation. The
rating is intended to correlate with subjective impressions of the
sound insulation provided against the sound of speech, radio,
television, music, office machines and similar sources of sound
characteristic of offices and home dwellings.
[0007] The first rating system is called Sound Transmission Class
(STC). STC is defined by the American Society for Testing Materials
(ASTM) standard E 413. To assign an STC rating to a barrier
separating two rooms, a sound is generated in one of the rooms, the
sound power is measured on both sides of the barrier, and the ratio
between the two measurements (the transmission loss) is stated in
decibels. Sixteen measurements are made in each room, at 1/3 octave
intervals from 125 Hz to 4000 Hz. A higher STC rating indicates a
greater sound transmission loss through a structure. The E413
standard specifies a transmission loss curve having 16 points on
the same 1/3 octave intervals. From 125 to 400 Hz, the curve slopes
upward 9 dB per octave; from 400 Hz to 1250 Hz, 3 dB per octave,
and it is flat from 1250 Hz to 4000 Hz. The curve is moved up and
down until the sum of all 16 differences between the curve's value
and the measured values for the barrier is less than 32 dB
(providing no single difference is more than 8 dB). The rating is
then expressed as the curve's loss in decibels at 500 Hz.
[0008] The second rating system is called Weighted Sound Reduction
Index (R.sub.w) and is defined by International Standards
Organization standard ISO 717. Test procedure for R.sub.w are
similar to STC except the frequency range for R.sub.w spans
100-3150 Hz whereas, as indicated supra, STC covers a frequency
range of 125-4000 Hz. STC and R.sub.w correlate very well. For
architectural elements such as doors, windows and walls,
differences in STC and R.sub.w are typically less than 1%.
[0009] When sound waves strike a surface, some of the energy is
usually reflected while some is transmitted through the surface. A
typical objective in reducing sound transmission through a
structure is to isolate the source from the structure before the
energy can be transmitted to the structure, causing the structure
to vibrate. The primary ways to reduce sound transmission through
multi-component structures is to add mass and to decouple or
isolate individual components so that vibrations cannot be passed
from one component to the next.
[0010] Conventional wall construction techniques tend to rely on a
stud frame interior with wall covering panels comprised of gypsum
board, plywood or other largely modular panels. Interior walls in
offices, hotels and the like are typically made by erecting a frame
that includes vertical studs, either wood or steel, on a 12'', 16''
or sometimes 24'' spacing, lining each side with gypsum board
(sheet rock) panels, then finishing the wall surfaces with a
variety of textures and paint. When additional thermal and/or
acoustic insulation is needed, insulation medium such as
fiberglass, rock wool or mineral wool will commonly be placed to
fill the interior space between vertical studs and gypsum board
panels. Sound transmission through walls is commonly reduced by
adding a second layer of gypsum board to one or both sides. Sound
transmission can be further reduced by widening the wall and
staggering the studs such that no stud spans the full width of the
wall. Sound transmission through a wall can be slightly reduced by
surface or exterior treatments such as the application of light,
resilient materials like carpeting, folded or layered upholstery,
or the like, but these measures are usually done to affect
reverberation within a room not attenuation through a wall.
[0011] Decoupling can be done in many ways and is the subject of
much development. Typically, decoupling is done by means of soft,
resilient and/or generally bulky materials. Isolated or still air
is an effective decoupler and there are many applications wherein
the insulation of sound and heat are accomplished analogously.
Decoupling can be enhanced by the use of viscoelastic materials,
typically high molecular weight polymers, to isolate components and
reduce contact between larger or more rigid components. The
viscoelastic materials, in effect, allow the larger and/or more
rigid components to vibrate independently and, more importantly,
act to dampen the vibration of the components.
[0012] Viscoelastic materials, as the name implies, exhibit both
elastic and viscous properties and are generally modeled using a
combination of springs and dashpots. Springs simulate elastic
behavior while dashpots simulate viscous behavior. When a
viscoelastic material is made to vibrate, a complex strain is
generated on the material thereby generating a complex stress. The
elastic modulus (E) is known to be the ratio of stress (.sigma.)
and strain (.epsilon.) in a material and can be described as the
amount of strain resulting from an applied stress
(E=.sigma./.epsilon.). In a viscoelastic material, the elastic
modulus is comprised of two components, a storage elastic modulus
(E.sub.S) which results from the elastic properties of the
material, and a loss elastic modulus (E.sub.L) resulting from the
viscous properties of the material. The ratio of loss modulus to
storage modulus is called loss tangent (tan .delta.) and is the
mathematic ratio between the two (tan .delta.=E.sub.L/E.sub.S). The
loss modulus component corresponds to a materials ability to
convert dynamic energy to electric or thermal energy, thus an
ability to dampen vibrations. It follows that as a materials tan
.delta. increases, so does that materials ability to dampen
vibrations.
[0013] Decoupling can also be achieved by means of resilient
channel members used as part of a wall construction. Resilient
channels, typically transversely mounted, act to absorb vibrational
energy instead of transmitting the energy from one wall component
to the next. Historically, however, less than optimum construction
and installation practices often lead to acoustic short circuits
around or across resilient channels essentially negating their full
effect.
[0014] Another technology often employed is the use of panels
comprised of a honeycomb core. In some cases, the cells of the
honeycomb core effectively trap dead air which is a relatively poor
acoustic conductor. In more sophisticated applications, the
individual honeycomb cells may be designed as interconnected
Helmholtz resonators which dissipate acoustic energy by allowing
the viscous laminar flow of air between resonators.
[0015] It is known that sound insulation is best obtained from
multi-shell components wherein both the mass and the resiliency of
the components are factors, thus a best combination of weight and
bulk is typically sought. New materials, namely novel viscoelastic
polymers included as part of layered panels are finding use in high
STC wall construction, but these constructions tend to be expensive
and remain largely unproven.
[0016] All of the knowledge of the benefits of decoupling whether
by means of viscoelastic materials, resilient channel members,
honeycomb core materials, or other novel approaches not
withstanding, most interior demising walls remain the simple wall
structures described above; spaced studs (wood or steel) with one
or more layers of drywall on each face, and maybe an insulation
material filling the walls interior cavities. The reasons for this
are both functional and economic; viscoelastic materials, resilient
channels, and other technologies are expensive, hard to effectively
construct and install in the field, or both. For example, resilient
channels can be and are commonly rendered ineffective by simple
means of misplaced screws that create bridging across the channel
and eliminate the decoupling effect that the resilient channel
would otherwise provide.
[0017] Compressed agricultural fiber (CAF) panels were invented and
developed in Sweden in 1933 and first commercialized by the Stramit
Company shortly thereafter. CAF panels produced today are similar
to those first developed by Stramit and are basically comprised of
two components; a highly compressed straw core, and a paper or
paperboard exterior liner. The panels are produced by means of a
dry extrusion process wherein dry straw is forced through a heated
dye by a heavy reciprocating ram. The dye is essentially a series
of two pair of top and bottom platens which are spaced at a
distance that defines the panel thickness. The elongated platens
are heated to approximately 400.degree. F. A top and bottom
paperboard liner is coated on one side with adhesive, and then fed
through the second pair of platens such that paper board covers the
entire outer surface of the straw core as the board exits the
second pair of platens.
[0018] CAF panels differ from other cellulose fiber-based panels
(particle board, OSB, etc.) in that CAF panels contain no glues or
resins to bond the internal fibers together. CAF panels only
contain enough glue to bond an exterior paper liner to the
compressed straw core, and that glue is typically a non-toxic,
water-based polyvinyl acetate glue that generates virtually no
VOC's, thus the formaldehyde issues and off gassing associated with
so many wood or other cellulose-based panels and/or building
products simply do not exist with CAF panels.
[0019] CAF panels can currently be manufactured to any thickness
between 11/2'' and 31/2'', and are most commonly made in a 2'' or
21/4'' thickness. Thinner CAF are currently under development.
Densities vary slightly among manufacturers, but will commonly fall
within the range of 1.6-2.1 pounds/square foot/inch of thickness. R
values and sound attenuation (STC) properties vary with density. R
values commonly within the range of 1.8-2.0/inch of thickness,
whereas STC for a common 2'' thick panel will fall within the range
of 30-34. CAF panels are very effective at sound attenuation, i.e.,
preventing acoustic energy from passing through the material.
Though yet unproven, there is considerable belief that the
exceptional sound attenuation properties of CAF panels is due to
some degree of viscoelastic behavior as CAF panels tend to
attenuate acoustic energy at a higher level than their mass would
inherently allow.
[0020] Though having existed since the 1930's, CAF panels are just
beginning to find sustainable markets in the U.S. The rapidly
growing interest now seen within the U.S. and new markets that are
developing as a result of this interest is due in large part to the
environmental-related properties of CAF panels. More specifically,
CAF panels are made primarily from rapidly renewable sources (wheat
straw, rice straw, and the like), require relatively little energy
to manufacture, are readily recycled or easily disposed of, and
contain only environmentally benign components. As mentioned supra,
CAF panels contain virtually no VOC's and generate virtually no
off-gassing. Conservative calculations indicate that on a per unit
weight basis, the amount of energy required to manufacture gypsum
board is over 24 times higher than that required to manufacture CAF
panels. Consequently, CAF panels garner generous points for
projects seeking US Green Building Council LEED certification. The
growing interest in LEED is primary to the growing domestic markets
for CAF panels.
[0021] In modern office buildings, business and conference centers,
hotels, classrooms, medical facilities, and the like, the
fitting-out of occupiable space is continuously becoming more
important and ever more challenging. In the competitive business
environment, cost concerns alone dictate the efficient use of
interior space. Thus, the finishing or fitting-out of building
spaces for offices and other areas where work is conducted has
become a very important aspect of effective space planning and
layout.
[0022] Business organizations are constantly changing as are their
work patterns and the technology utilized therein. Building space
users require products that provide for change at minimal cost. At
the same time, their need for functional interior accommodations
remains steadfast. Issues of privacy, functionality, aesthetics,
acoustics, etc., are unwavering. For architects and designers,
space planning for both the short and long term is a dynamic and
increasingly challenging problem. Changing work processes and the
technology required demand that designs and installation be able to
support and anticipate change.
[0023] The cost efficient use of building floor space is also an
ever-growing concern, particularly as building costs continue to
escalate. Open office plans that reduce overall office costs are
commonplace, and generally incorporate large, open floor spaces.
These spaces are often equipped with modular furniture systems that
are readily reconfigurable to accommodate the ever changing needs
of specific users, as well as the divergent requirements of
different tenants. However, for privacy, productivity, or other
reasons, interior walls and/or partitions are still required
although the functionality requirement of interior walls is
changing.
[0024] As mentioned supra, office walls and/or partitions are
typically made by erecting a wood or steel stud frame comprising
vertical studs spaced on a regular interval, lining each side with
gypsum board (sheet rock) panels, then finishing the wall surfaces
with a variety of textures and paint. When additional thermal
and/or acoustic insulation is needed, insulation medium such as
fiberglass, rock wool, mineral wool or cellulose will commonly be
placed to fill the interior space between vertical studs and gypsum
board panels. These conventional walls have proven sturdy, provide
adequate superior privacy and sound proofing, and provide a surface
that easily accepts wall hangings such as pictures, paintings,
plaques and the like. Furthermore, as is commonly known,
conventional walls can easily be repainted, retextured, and,
readily patched and repaired when damaged. Conventional gypsum
board partitions are typically custom built floor-to-ceiling
installations that, due primarily to the fixed vertical studs, are
time-consuming to erect and build.
[0025] As previously stated, interior walls in offices, hotels and
the like are typically made by erecting a frame that includes
vertical studs, either wood or steel, on a 12'', 16'' or 24''
spacing, lining each side with gypsum board (sheet rock) panels,
then finishing the wall surfaces with a variety of textures and
paint. FIGS. 12a-12f illustrate a cross-sectional plan view of
conventional interior partition constructions.
[0026] FIG. 12a shows a nominal 31/2'' steel stud framed wall with
one layer of 1/2'' gypsum board on each face and 31/2'' of
fiberglass batt/fill in the interior. This wall provides an STC 39
as per NRC-CNRC Report IRC-IR-761, wall no. 25. Replacing the
31/2'' steel studs in this wall with nominal wood 2.times.4 studs
reduces the STC to 32.
[0027] FIG. 12b shows a nominal 31/2'' steel stud framed wall with
one layer of 5/8'' gypsum board on each face and 31/4'' of mineral
wool batt/fill in the interior. This wall provides an STC 39 as per
NRC-CNRC Report IRC-IR-761, wall no. 63. Replacing the 31/2'' steel
studs in this wall with nominal wood 2.times.4 studs reduces the
STC to 34.
[0028] FIG. 12c shows a nominal 31/2'' steel stud framed wall with
one layer of 1/2'' gypsum board on one face, two layers of 1/2''
gypsum board on the other face, and 31/2'' of fiberglass batt/fill
in the interior. This wall provides an STC 44 as per NRC-CNRC
Report IRC-IR-761; wall no. 84. Replacing the 31/2'' steel studs in
this wall with nominal wood 2.times.4 studs and replacing the
fiberglass with a comparable thickness of cellulose fill reduces
the STC to 37.
[0029] FIG. 12d shows a nominal 31/2'' steel stud framed wall with
one layer of 5/8'' gypsum board on one face, two layers of 5/8''
gypsum board on the other face, and 31/4'' of mineral wool
batt/fill in the interior. This wall provides an STC 46 as per
NRC-CNRC Report IRC-IR-761, wall no. 99.
[0030] FIG. 12e shows a nominal 31/2'' steel stud framed wall with
two layers of 1/2'' gypsum board on each face and 31/2'' of
fiberglass batt/fill in the interior. This wall provides an STC 52
as per NRC-CNRC Report IRC-IR-761, wall no. 111.
[0031] FIG. 12f shows a nominal 31/2'' steel stud framed wall with
two layers of 5/8'' gypsum board on each face and 3'' of mineral
wool batt/fill in the interior. This wall provides an STC 52 as per
NRC-CNRC Report IRC-IR-761, wall no. 129.
[0032] A large number of variations of the basic conventional
stud-frame wall constructions illustrated in FIGS. 12a-12f exist.
Most variations made in order to improve acoustic attenuation
involve stud configurations intended to decouple the two opposed
wall faces. Most variations involve either a staggered stud within
a common frame or two separate frames, closely spaced, but fully
decoupled. These common options are illustrated in FIGS. 13a and
13b.
[0033] In addition to variations of conventional wall constructions
illustrated in FIGS. 12a-12f, 13a, 13b and those discussed above,
there exist enhanced gypsum wallboard materials that include
viscoelastic materials and/or other sound attenuation enhancing
components. The enhanced gypsum wallboards are commonly used in a
conventional manner as a simple replacement for conventional gypsum
wallboard.
[0034] Still further, there exist countless demountable and/or
moveable interior partition systems of varying degrees of
complexity and costs. Two characteristics are consistent within the
art and within these various partition systems: they are more
expensive than the conventional wall constructions illustrated in
FIGS. 12 and 13 and/or they fail to meet the environmental
properties required to meet LEED certification standards.
[0035] Additionally, CAF panels can and have been used in several
wall configurations ranging from conventional stud walls wherein
commonly used gypsum wallboard (sheet rock) is essentially replaced
with CAF panels to simple studless walls comprised only of CAF
panels held in place at the top and bottom, typically by a simple
channel. Each of these constructions has substantial limitations
that have precluded any commercial success. Simply using CAF panels
in lieu of gypsum wallboard is costly and time consuming; one must
build a conventional wood or steel stud frame, mount to CAF panels
to the stud frame, and then cut openings for utilities and the
like. Further, this method results in a wall that is much thicker
than conventional drywall walls, thus incompatible with standard
doors, windows, etc., without substantial modifications. On the
other hand, simple interior partitions comprised of only a single
plane of CAF panels lack the needed stiffness, are generally
incompatible with conventional doors, windows and other hardware,
and do not meet most codes without running utilities (wiring,
plumbing, etc.) exposed on the surface; clearly an unacceptable
practice. Even the simplest of configurations--using a single plane
of CAF panels wherein no utilities are required--results in a wall
that lacks stiffness, regardless of panel thickness. Among other
problems, any texturing and/or paint on the wall surfaces tends to
crack when the relatively flimsy walls are displaced by human
contact, or more likely, by internal changes in static
pressure.
[0036] Needed in the art is an interior wall and/or partition
construction that effectively exploits the unique and favorable
physical and acoustic properties of CAF panels yet overcomes the
particular physical limitations normally encountered. Further, what
is needed in the art is an interior wall and/or partition
construction that is quicker and more cost effective to initially
install than conventional wall constructions, and quicker and more
cost effective to move and/or relocate; essentially being
demountable. Still further, what is needed in the art is an
interior wall construction method that provides the sturdiness,
look and feel, and general dimensions of conventional walls and/or
partitions while providing quicker and easier reconfigurability and
improved acoustic attenuation for growing privacy needs. Finally,
what is increasingly needed in the art is an interior wall and/or
partition system with the requisite environmental properties to
meet the requirements of the U.S. Green Building Council's LEED
criteria. The invention disclosed herein meets these needs, and
represents a significant improvement over existing art.
SUMMARY OF THE INVENTION
[0037] The present invention relates to interior wall
constructions, more particularly to interior wall constructions
comprised of compressed agricultural fiber (CAF) panels. Further,
the present invention relates to interior wall constructions
comprising CAF panels and stiffener channels held in place by a top
and bottom track and further comprising front wall facing comprised
of sheets placed along the front wall face in edge to edge abutted
relative position and with each facing sheets attached to one or
more stiffener channels. CAF panels, stiffeners and wall facing
sheets all sized to span to full vertical height of the wall.
Preferably, the top and bottom track and stiffener channel elements
all comprise standard drywall materials. Optionally, rear wall
facing sheets, also placed in edge to edge abutted relation and
sized to span the full vertical wall height are placed along the
rear wall face and attached to the CAF panels.
BRIEF DESCRIPTION OF THE DRAWINGS
[0038] FIG. 1 includes a general perspective view of the preferred
embodiment of subject demising partition.
[0039] FIG. 2 shows a plan view of the preferred embodiment of
subject demising partition.
[0040] FIG. 3 shows a detailed plan view of the preferred
embodiment of FIG. 2 including specific dimensions.
[0041] FIG. 4 shows a perspective view of the preferred embodiment
of FIG. 1 including an illustration of utilities.
[0042] FIG. 5 shows plan views of three (5a-5c) alternative
embodiments of subject demising partition.
[0043] FIG. 6 shows a plan view of another alternative embodiment
of subject partition.
[0044] FIGS. 7 thru 9 illustrate the stepwise construction of the
subject demising partition.
[0045] FIG. 10 provides a perspective view of an alternative
embodiment of a key element.
[0046] FIG. 11 provides an elevation view of an alternative
embodiment of a key element.
[0047] FIG. 12 (12a-12f) as discussed above, provides plan view of
conventional demising wall constructions.
[0048] FIG. 13 (13a & 13b) provides a plan view of two
conventional demising walls for improved acoustic attenuation.
DETAILED DESCRIPTION OF THE INVENTION
[0049] FIG. 1 provides a general perspective view of the preferred
embodiment of subject partition. The basic elements are comprised
of a top and bottom track (3), placed along the top and bottom of a
wall line and anchored to the floor and roof deck or ceiling by
means of conventional drywall track anchoring methods. Bottom track
(3) is not shown in FIG. 1. The size and weight/gauge of said top
and bottom track can be varied, but importantly, can be standard
drywall track such as common 31/2'' or 35/8'' track in standard
22GA or 25GA weights. Standard drywall track is readily available
and generally inexpensive thus contributing to the cost
effectiveness of subject partition. Further comprising the basic
elements are a plurality of CAF panels (1) inserted between top and
bottom tracks (3) and sized such that the vertical height of each
panel (1) generally matches the distance between top and bottom
tracks (3). Each panel (1) can be cut to size in the field, but
factory pre-cutting/pre-sizing is preferred in order to reduce
installation time. Said panels (1) are arranged in close edge to
edge abutted relation such as to create a continuous planar
wall.
[0050] Still further comprising the basic elements are a plurality
of vertical stiffening channels (2) also inserted between top and
bottom tracks (3) in generally vertical alignment and evenly spaced
laterally. In the preferred embodiments, stiffening channels (2)
will be evenly spaced at 12'', 16'' or 24'' intervals. The width of
top and bottom track (3), thickness of panels (1) and dimensions of
stiffening channels (2) will each be sized to provide a snug
friction fit such that panel (1) and stiffening channel (2) are
held firmly within said track (3). In the preferred embodiment,
this snug, friction fit is accomplished using standard,
off-the-shelf, readily available drywall materials and CAF panels.
Also in the preferred embodiment, said stiffening channel is a
standard 21/2''.times.11/2'' drywall furring channel, either
20GA-25GA, depending upon wall stiffness needs. Stiffening channels
(2) are an essential element as CAF panels alone do not provide
adequate stiffness without supplementation.
[0051] Further comprising the basic elements are a plurality of
front wall facing sheets (4) each sized to span the entire distance
from floor to ceiling/roof deck thus generally matching the
vertical distance between tracks (3) and placed in general edge to
edge abutted relationship so as to form a continuous wall facing.
Said front facing sheets are connected by means of a plurality of
penetrating connectors (6) placed through the facing sheet and each
terminating within an underlying stiffening channel (2). In the
preferred embodiment, front facing sheets are 5/8'' type-X gypsum
wallboard, and penetrating connectors (6) are standard 11/2'' #7
drywall screws or equal.
[0052] Finally comprising the basic elements are a plurality of
back cladding sheets (5), generally sized and arranged in edge to
edge abutted relation, much like the front facing sheets but on the
opposite side and facing the opposite direction. Further, back
cladding sheets (5) are placed against said CAF panels (1) and
attached thereto using a plurality of penetrating connectors (7),
each penetrating through a back cladding sheet (5) and terminating
within a CAF panel (1). In the preferred embodiment, said back
cladding sheets are each 5/8'' type-X gypsum wallboard, and
penetrating connectors (7) are standard 2''#7 drywall screws or
core board screws.
[0053] Optional elements include stiffening channel penetrating
connector (11) use to secure each stiffening channel (2) to a CAF
panel (1) and front facing sheet edge connectors (10). Both
elements (10 and 11) are preferably standard 11/2'' #7 drywall
screws.
[0054] FIG. 2 shows a plan view of the preferred embodiment and a
better illustration of the aligned and abutted respective
relationship between like CAF panels (1), like front facing sheets
(4), and like rear cladding sheets (5) and clearly shows
penetrating connectors (6) each terminating within a stiffening
channel (2) and penetrating connectors (7) each penetrating through
a back cladding sheet (5) and terminating within a panel (1). FIG.
2 also shows the even lateral spacing between adjacent stiffening
channels (2). As mentioned supra, lateral spacing between
stiffening channels is variable and can be tailored by specific
application, but it should be apparent the necessary correlation
between the lateral spacing of stiffening channels (2) and the
width of front facing sheets (4) so that the vertical joint line
where two adjacent front facing sheets meet will always align with
a stiffening channel (2).
[0055] FIG. 3 provides a detailed illustration of the preferred
embodiment including dimensions. This detail is provided to
illustrate that in the preferred embodiment, the subject partition
utilizes standard, off-the-shelf, materials that are cost
effective, easily obtained and in good supply. As mentioned supra,
in the preferred embodiment, top and bottom track (3) are standard
31/2'' drywall channel, 20Ga-25Ga. CAF panel (1) is a standard 2''
thick strawboard panel normally available in 32'' or 48'' widths,
either of which is compatible with the preferred embodiment.
Stiffening channel (2) is a standard 21/2''.times.11/2'' drywall
furring channel, 20Ga-25Ga. Both front wall facing sheets and back
cladding sheets are standard 5/8'' type-X gypsum wallboard,
normally available in 48'' wide sheets. Both penetrating connectors
(6 and 7) are standard #7 drywall screws, 11/2'' and 2''
respectively. Screw length and size can be varied.
[0056] In the preferred or alternative embodiments, front wall
facing and rear cladding sheets can be finished any number of ways,
both conventional and non-conventional. Wall treatments such as
painting, texturing, wall papering, etc., generally do not
significantly effect acoustic attenuation or other physical
properties, thus wall treatments are beyond the scope of this
invention.
[0057] The steps required to construct subject partition are
illustrated in FIGS. 8 and 9. FIG. 8 includes the first two steps:
first, a top and bottom track (3) are laid out along the wall
centerline, the bottom track attached to the floor and top track
attached to the roof deck or ceiling, depending upon the structure;
second, CAF panels (1) are inserted between the top and bottom
tracks (3) and then slid into proper adjacent position. Preferably,
CAF panels (1) are factory pre-cut to match the vertical distance
between tracks (3) such that a snug fit exists between each panel
(1) and track (3) while still allowing for each panel to slide
laterally for proper positioning. As a series of top and bottom
tracks (3) are installed, one end must be left open in order to
introduce panels (2) therebetween.
[0058] Each panel (1) is positioned against to back lip of top and
bottom tracks (3) to provide room within the spaced tracks to
accept a plurality of stiffening channels (2). Stiffening channels
(2) can be sized to match the vertical distance between channels
(3) wherein each channel (2) must be inserted at the end of the
tracks, then laterally slid into position.
[0059] FIG. 10 shows and alternative embodiment wherein consecutive
pieces of top and bottom track (3) are installed such that a gap
(16) exists between pieces. Said gap (16) should be slightly wider
that the over width of stiffening channel (2) such that individual
stiffening channels (2) may be inserted through gap (16) pushed
flush against panel (1) then moved laterally into proper position.
In the preferred embodiment, stiffening channels (2) are comprised
of standard 21/2''.times.11/2'' drywall furring channels, thus if
these are used, said gap (16) should preferably be approximately
23/4'' to 3'' wide.
[0060] A second alternative is illustrated in FIG. 11 which shows
stiffening channels (2) sized slightly shorter than the panels (3)
and clipped or tapered along one corner of each end (12), allowing
for each channel to be turned slightly off vertical, inserted
between top and bottom channels (3), then returned to vertical.
Stiffening channels are generally evenly spaced, normally at 12'',
16'' or 24'' on centers, but actual spacing is easily adjusted to
accommodate specific needs and/or requirements.
[0061] In all cases, top and bottom tracks (3), panels (1) and
stiffening channels (2) are sized so that the internal width of
each track (3) will accept the thickness of one panel (1) and one
stiffening channel (2) such that a snug friction fit (15) exists
between each element thereby allowing stiffening channels to be
laterally moved by means of a firm hand, tapping with a rubber
mallet, or comparable non-destructive application of force. Snug
friction fit is illustrated and noted on FIG. 8.
[0062] FIG. 9 illustrates the final basic steps required to erect
and/or assemble subject partition wherein front wall facing sheets
(4) are positioned against stiffening channels (2) and top and
bottom tracks (3) to create a front wall face. Said wall facing
sheets (4) are positioned such that the left and right vertical
edge of each sheet approximately aligns with the vertical
centerline of a stiffening channel so that the edge of two adjacent
wall facing sheets (4) can be attached to a common stiffening
channel (2) by means of a plurality of penetrating connectors or
the like. As illustrated, a plurality of penetrating connectors
(6), such as standard drywall screws, core board screws or the
like, should be placed through each sheet and anchored into each
stiffening channel, in generally vertical alignment with each
underlying stiffening channel. In the preferred embodiment,
penetrating connectors (6) will be placed along a generally
vertical line, attached to each underlying stiffening channel and
spaced no more than 18'' apart.
[0063] Off the shelf, readily available drywall track is typically
available in 10 ft. lengths, so a recommended installation process
is to install one each 10' piece of top and bottom track (3),
insert 2 to 3 panels (1), depending upon panel width, insert the
appropriate number of stiffening channels (2) then install another
top and bottom pair of track (3), etc., until the required wall
length is completed. As shown in FIG. 9, front facing sheets (4)
and rear cladding sheets (5) may then be easily installed along the
entire wall length.
[0064] Three alternative embodiments are shown in FIGS. 5a-5c. The
top illustration, FIG. 5a, shows a partition construction identical
to the preferred embodiment discussed supra, with the exception of
the absence of back cladding sheets (5). Most CAF panels can be
textured, painted and/or generally finished comparably to gypsum
wallboard, thus excluding cladding sheets (5) and finishing the
surface of CAF panel (1) becomes a natural variation wherein the
additional wall thickness and/or fire resistance provided by the
gypsum wallboard is not needed. In the middle illustration, FIG.
5b, a symmetric variant is shown wherein a wider top and bottom
track (3) is used to accommodate stiffening channels (2) placed on
both sides of panels (1), and front facing sheets (4) are used on
both wall faces. Finally, a third alternative embodiment is shown
in FIG. 5c wherein the preferred embodiment is constructed, then a
second layer of front facing sheets (4,8) and rear cladding sheets
(5,9) are added and secured using a plurality of penetrating
connectors (7).
[0065] In all variations and embodiments, the 5/8'' gypsum
wallboard used for front facing sheets (4) and rear cladding sheets
(5) can be replaced by thinner or thicker gypsum wallboard, various
wood-based panels such as plywood, OSB, MDF and the like, or CAF
panels of various thicknesses. Preferably, CAF panels in the
1/2''-5/8'' range will be used. Overall wall thickness, and the
material selected for use as the front and rear facing sheets may
largely be determined by specific physical requirements for the
finished partition such as fire ratings and/or acoustic attenuation
needs.
[0066] As shown in FIG. 4, comparable to conventional drywall, the
space between front facing sheet (4) and CAF panel (1) can easily
accommodate utilities. For the purposes of illustrating this, FIG.
4 shows a utility/electric service detail in which a junction box
(14) containing a duplex receptacle is positioned and attached to
panel (1). It is recommended that junction boxes, gang boxes and/or
other utility accommodating structures be positioned and attached
the panel (1) before first facing sheet (4) is installed. Just as
would be done when constructing a conventional drywall, a properly
sized opening that corresponds to the location and size of the
internal junction box, is cut in the front facing sheet (4) prior
to positioning and attaching the front facing sheet (4) in place.
As is also the case with conventional drywall, loose wiring, EMT,
conduit, and the like can be run inside the subject partition as
required and/or allowed by local building codes. Likewise, plumbing
and other utility wiring such as communications cables can be
accommodated in conventional fashion.
[0067] To properly utilize the partition disclosed herein and
preserve optimum physical properties, utilities (electric,
plumbing, etc.) run therein should only be provided to one side on
the wall so as to not require openings to be cut through CAF panel
(1). One of the primary attributes of subject partition is
substantially improved acoustic attenuation. Preserving said
acoustic attenuation properties requires that all panels (1) remain
intact and uncompromised. Thus, no openings, regardless of size
should be cut through CAF panel (1). This stipulation provides
substantial benefit over current/conventional practices as the
subject partition will always provides and in-tact, solid sound
barrier and the acoustic attenuation properties will be consistent
and predictable from application to application. In conventional
drywall constructions, the acoustic attenuation property of the
wall is often an inverse function of the number of utility openings
cut therein; more openings beget less attenuation. Notably, in all
embodiments, additional acoustic attenuation, and in particular,
improved attenuation in certain frequency ranges may be gained by
filling the interior wall space between CAF panels (1) and front
facing sheets (4) will thermal or acoustic battings such as
fiberglass, cellulose, mineral wool or the like.
[0068] The various embodiments disclosed herein are all explicitly
non-load bearing and generally intended for partitioning interior
space wherein acoustic attenuation is important, yet a low cost,
quick and easily built wall is needed. Partitioning of interior
commercial office space, school rooms, retail space and the like
are typical examples of where this wall construction will find
application.
[0069] Though providing the look, feel and function of a permanent
partition, the wall/partition disclosed herein is much easier to
disassemble and relocate than conventional drywall. Referring again
to FIG. 1, relocation requires the removal of rear penetrating
connectors (7), followed by the removal of rear cladding sheets
(5). If handled correctly, rear cladding sheets (5) may be reused.
Front penetrating connectors (6) and optional facing sheet edge
connectors (10) should then be removed, followed by the removal of
front facing sheets (4). As with the rear cladding sheets (5),
front facing sheets (4) may be reused if properly handled and/or
preserved.
[0070] Next, stiffening channels (2) can be removed by sliding each
to the end of a track or by tilting until clear of top channel (3).
Optional stiffening channel connectors (11) should be removed to
facilitate removal of stiffening channels (2) if present. CAF
panels (1) may then be removed in the same manner as installed.
This leaves only the top and bottom channels (3) which are removed
just by standard drywall track removal techniques. Top and bottom
track (3) will likely be damaged during removal and should not be
reused. Otherwise, every component, including penetrating
connectors, may be reused if desired. In some cases, the additional
handling required to reuse rear cladding (5) and front facing
sheets (4) may preclude their use and cause the use of
new/replacement panels to be more economical.
[0071] While the subject invention has been set forth in this
disclosure with respect to the preferred embodiment, and in some
cases optional embodiments have been set forth, it will be
appreciated by those skilled in the art that there are many ways to
implement the invention without departing from the scope and spirit
of the invention as disclosed herein.
[0072] The embodiments described supra are exemplary. Many details
are found in the art; therefore, many such details are neither
shown nor described. Even though numerous characteristics and
advantages of the present invention have been described in the
accompanying text, the description is illustrative only, and
changes may be made in the detail, especially in matters of size
and/or order within the principles of the invention to the full
extent indicated by the broadest possible meaning of the terms of
the following claims. The limits of the invention and bounds of the
patent protection are measured by and defined in the following
claims.
* * * * *