U.S. patent application number 17/604662 was filed with the patent office on 2022-08-11 for stiffener for construction elements.
The applicant listed for this patent is Saint-Gobain Placo, Kanakavel Saminathan. Invention is credited to Rizwan Ahmed, Vikram S, Kanakavel Saminathan.
Application Number | 20220251838 17/604662 |
Document ID | / |
Family ID | |
Filed Date | 2022-08-11 |
United States Patent
Application |
20220251838 |
Kind Code |
A1 |
Saminathan; Kanakavel ; et
al. |
August 11, 2022 |
Stiffener for Construction Elements
Abstract
A stiffener 50 for construction elements for providing
resistance against deflection and cracking is disclosed comprising
a U-shaped cross-section with a web 10 and two flanges 20a, 20b
extending transversely from the web 10 and having ribs 30 rising
parallel, perpendicular or diagonal from the flanges 20a, 20b. The
stiffener 50 is configured to be fixed within the construction
element. A drywall stud and a ceiling section provided with a
plurality of stiffeners 50 of the present disclosure spaced at
desired locations along their length is also disclosed. Such
drywall studs and ceiling sections comprising stiffeners 50 of the
present disclosure reduce deflection of drywall partition and
suspended ceiling system, respectively by up to 50%.
Inventors: |
Saminathan; Kanakavel;
(Siruseri, Chennai, IN) ; S; Vikram; (Tamil Nadu,
Chennai, IN) ; Ahmed; Rizwan; (Maharashtra, Mumbai,
IN) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Saminathan; Kanakavel
Saint-Gobain Placo |
Siruseri, Chennai
Suresnes |
|
IN
FR |
|
|
Appl. No.: |
17/604662 |
Filed: |
April 20, 2020 |
PCT Filed: |
April 20, 2020 |
PCT NO: |
PCT/IN2020/050369 |
371 Date: |
October 18, 2021 |
International
Class: |
E04C 3/07 20060101
E04C003/07; E04B 2/58 20060101 E04B002/58; E04B 9/06 20060101
E04B009/06 |
Foreign Application Data
Date |
Code |
Application Number |
Apr 24, 2019 |
IN |
201941016268 |
Claims
1. A stiffener for a construction element for providing resistance
against deflection and cracking, said stiffener comprising a
U-shaped cross-section with a web and a first flange and a second
flange extending transversely from the web at an angle X more than
or equal to 90 degrees and one or more ribs rising from each of the
first and the second flanges and extending towards each other,
wherein the stiffener is configured to be fixed within the
construction element.
2. The stiffener as claimed in claim 1, wherein a height H of at
least one rib is equal to or less than a height H' of the first
flange or second flange.
3. The stiffener as claimed in claim 1, wherein a length L of at
least one rib is equal to or less than a length L' of the web.
4. The stiffener as claimed in claim 1, wherein a length L of at
least one rib is greater than a length L' of the web.
5. The stiffener as claimed in claim 4, wherein a length L of at
least one rib equals a distance D between the first and second
flanges.
6. The stiffener as claimed in claim 1, wherein the ribs on the
first flange correspond or alternative with the ribs on the second
flange.
7. The stiffener as claimed in claim 1, wherein the first and
second flanges protrude inward to form ribs.
8. The stiffener as claimed in claim 1 optionally comprises one or
more ribs rising from the web.
9. The stiffener as claimed in claim 1, wherein the one or more
ribs are arranged perpendicular or parallel or diagonal to the
first and second flanges or web, respectively.
10. The stiffener as claimed in claim 1, wherein the ribs 30, are
arranged in form of a cluster.
11. The stiffener as claimed in claim 1 is made of a material
selected from aluminum and mild steel coated with galvanized iron
(GI).
12. The stiffener as claimed in claim 1 has a thickness ranging
between 0.4 mm and 2 mm.
13. The stiffener as claimed in claim 1, wherein the construction
element is selected from a drywall stud and a ceiling section.
14. A drywall partition providing structural integrity to resist
destructive forces comprising: a plurality of vertical drywall
studs retained between a floor channel and a ceiling channel,
wherein each vertical drywall stud comprises a plurality of
stiffeners as claimed in claim 1 spaced at desired intervals,
wherein the web and the first and second flanges of the stiffener
abuts a web and flanges of the drywall studs, respectively.
15. The suspended drywall ceiling as claimed in claim 14, wherein
the drywall stud has a base metal thickness reduced between 10% and
40% compared to a conventional drywall stud.
16. A suspended drywall ceiling providing structural integrity to
resist destructive forces comprising: a grid suspended from a
structural ceiling having intermediate beams interlocked with
ceiling sections comprising a plurality of stiffeners as claimed in
claim 1 spaced at desired intervals, wherein the web and the first
and second flanges of the stiffener abuts a web and flanges of the
ceiling sections, respectively.
17. The suspended drywall ceiling as claimed in claim 16, wherein
the ceiling section has a base metal thickness reduced between 10%
and 40% compared to a conventional ceiling section.
18. The suspended drywall ceiling as claimed in claim 16,
exhibiting up to 50% less deflection compared to a conventional
ceiling system.
Description
TECHNICAL FIELD
[0001] The present disclosure relates, in general to construction
elements for use in partitions and ceiling structures of buildings,
and more specifically to construction elements provided with
stiffeners for improving stiffness, partition height and crack
resistance of partitions and ceiling systems; and a drywall stud
and ceiling section provided therewith.
BACKGROUND
[0002] Wall constructions, for example, drywall partitions are
typically constructed from a series of spaced apart studs arranged
between floor and ceiling channels and drywall surface material
such as gypsum boards secured to the surfaces of the studs.
Generally, these studs are non-load bearing and allow for rapid
construction. Conventional metal studs used in non-load bearing
applications, however, are not as structurally stable to carry
horizontal loads due to wind and other forces along the stud
length. Therefore, it is known to arrange reinforcement structures
at the points where building components such as boards or frames
are joined with the studs. Such reinforcement structures are
generally U-shaped and are mounted within the stud or as bridging
members that extend between the series of stud members.
[0003] Referring to U.S. Pat. No. 3,624,694 discloses a reinforced
stud construction used in partitions of buildings. Referring to
European publication number 0,096,675 discloses an arrangement in a
wall stud that provides for a reinforcing insertion structure. Yet
another U.S. Pat. No. 3,425,159 describes a snap-fit reinforcement
member for use with a door closing or other operating devices.
Similarly, referring to U.S. Pat. Nos. 7,836,657; 7,559,519 and
6,164,028 all describe reinforcement members that are arranged as
bridging members between corresponding studs.
[0004] The constructions described above in the referenced patent
documents have certain disadvantages even in the presence of the
reinforcement members. The reinforcement members are generally
U-shaped profiles attached to web of the studs. This involves
additional cost for material as well as work in order to join the
studs with the reinforcement member. Secondly placing these
reinforcement members is tedious and time consuming, especially if
the reinforcing members are adequately fixed to the studs. Thirdly
these reinforcement members are not designed to be installed in a
practical and economical way. Lastly none of the cited prior art
provide a solution that could be adapted for constructing both an
interior partition as well as a ceiling system.
[0005] Therefore, notwithstanding all the past improvements made in
order to improve the structural stability and durability of studs
used in drywall constructions, there is still scope for improved
designs for obtaining stiffer partitions and ceiling systems;
provide backings for flanges of channels to allow for screwing or
nailing without bending the flanges; provide simple and inexpensive
stiffeners that prevent individual studs from twisting and/or
buckling under load and reduce cracks in the ceiling systems
(provided, the cracks are a result of irregular installation
procedures). Further, achieving all the above parameters without
increasing complexity of stiffener manufacture, installation and
transport are integral.
[0006] The present disclosure achieves all the above technicalities
by providing a stiffener that has an optimized design structure
that increases the stiffness of the partition and ceiling system by
exhibiting 50% less deflection levels compared to conventional
drywall constructions. Further the stiffeners of the present
disclosure do not increase material cost by having a thickness
equivalent to the reduced thickness of the partition stud and the
ceiling sections arranged therewith. Furthermore, the stiffener
design carry flexibility to be made by the various methods outlined
in the disclosure and allows for easy and effective transportation
of the studs and ceiling sections fixed with these stiffeners.
Alternatively, the simple design of the stiffeners is compatible
for on-site fixing of the stiffener with the studs and ceiling
sections.
SUMMARY OF THE DISCLOSURE
[0007] In one aspect of the present disclosure, a stiffener for a
construction element for providing resistance against deflection
and cracking is disclosed. The stiffener comprises of a U-shaped
cross-section with a web and two flanges extending transversely
from the web at an angle X more than or equal to 90 degrees and one
or more ribs rising from each of the flanges and extending towards
each other. The stiffener is configured to be fixed within the
construction element.
[0008] In another aspect of the present disclosure, a drywall stud
fitted with one or more stiffener is disclosed. The web and flanges
of the stiffener abuts the web and flanges of the drywall stud.
[0009] In one another aspect of the present disclosure, a ceiling
section fitted with one or more stiffener is disclosed. The web and
flanges of the stiffener abuts the web and flanges of the ceiling
section.
[0010] In yet another aspect of the present disclosure, a drywall
partition system which provides structural integrity to resist
destructive forces is disclosed comprising a plurality of vertical
drywall studs fitted with a plurality of stiffeners at desired
intervals and retained between a floor channel and a ceiling
channel.
[0011] In still another aspect of the present disclosure, a
suspended ceiling system which provides structural integrity to
resist destructive forces is disclosed comprising a grid suspended
from a structural ceiling having intermediate beams interlocked
with ceiling sections fitted with a plurality of stiffeners at
desired intervals.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] Embodiments are illustrated by way of example and are not
limited in the accompanying figures.
[0013] FIG. 1A illustrates a three dimensional view of an exemplary
stiffener for drywall studs, in accordance with an embodiment of
the present disclosure;
[0014] FIG. 1B illustrates a three dimensional view of an exemplary
stiffener for drywall studs, in accordance with another embodiment
of the present disclosure;
[0015] FIG. 2 illustrates a three dimensional view of an exemplary
stiffener for ceiling sections, in accordance with an embodiment of
the present disclosure;
[0016] FIG. 3 illustrates a drywall stud comprising an exemplary
stiffener, according to an embodiment of the present
disclosure;
[0017] FIG. 4 illustrates a ceiling section comprising an exemplary
stiffener, according to an embodiment of the present
disclosure;
[0018] FIG. 5A to 5G illustrate exemplary stiffener for drywall
studs, in accordance with multiple alternate embodiments of the
present disclosure;
[0019] FIG. 6 illustrates a drywall partition system, according to
one exemplary embodiment of the present disclosure;
[0020] FIG. 7 illustrates a suspended ceiling system, according to
one exemplary embodiment of the present disclosure; and
[0021] FIG. 8 illustrates arrangement of two drywall studs provided
with stiffeners during transportation.
[0022] Skilled artisans appreciate that elements in the figures are
illustrated for simplicity and clarity and have not necessarily
been drawn to scale. For example, the dimensions of some of the
elements in the figures may be exaggerated relative to other
elements to help to improve understanding of embodiments of the
disclosure.
DETAILED DESCRIPTION
[0023] Wherever possible, the same reference numbers will be used
throughout the drawings to refer to the same or the like parts.
Embodiments disclosed herein are related to a stiffener for drywall
studs and ceiling sections that improves deflection, partition
height and crack resistance of the partition and ceiling system
accordingly.
[0024] FIG. 1A illustrates an exemplary stiffener 50 for a drywall
stud, in accordance with an embodiment of the present disclosure.
As shown, the stiffener 50 is U-shaped in cross section and
includes a web 10; a pair of side flanges 20a, 20b arising
perpendicularly (angle X equals 90-degrees) to the web 10; and ribs
30 rising from each of the flanges 20a, 20b. The ribs 30 shown in
FIG. 1A are perpendicular to the flanges 20a, 20b. There are three
ribs 30 on the flange 20a that correspond to the three ribs 30 on
the flange 20b. In this embodiment of the present disclosure, the
ribs 30 on the flanges are provided to correspond with each other.
Alternatively, the ribs 30 on flanges 20a, 20b can also be provided
to alternate with each other. Further the stiffener 50 is provided
with one or more rivet holes 40 for riveting the stiffener 50 to
the drywall stud. These rivet holes 40 in multiple embodiments of
the present disclosure can be provided on the web 10 or flanges
20a, 20b or both.
[0025] The stiffener 50 is configured to be fixed within the
drywall stud, spaced along the length of the drywall stud as
desired to provide stiffening for the flanges 20a, 20b. The
stiffener 50 backs the flanges 131a, 131b of a drywall stud 100 to
hold them in place when screws are driven into the flanges 20a, 20b
for fastening drywall panels to the flanges 131a, 131b in order to
form a wall structure as will be described later. If not for these
stiffeners, the flanges of the drywall stud may bend inwardly
during screwing and may not provide for the penetration of the
screws through the flanges thereby impairing the fastening
procedure. Such bending of the flanges is prevented by providing
stiffeners along the length of the drywall stud to hold the flanges
in place for screwing.
[0026] Therefore, additional strength and stiffness are imparted to
the drywall studs by providing stiffener 50 of the present
disclosure which in turn result in structural stability to the
drywall structures constructed therefrom. Although stiffeners
similar to the U-shaped structure shown in FIG. 1A are known in the
prior art, such stiffeners never disclosed inwardly protruding ribs
30 from the flanges 20a, 20b. Such kind of protrusions were never
considered because of the complexity associated with their
manufacture, inconvenience caused during transport of drywall studs
fixed with these stiffeners, additional material cost &
manpower requirement for their production and fabrication. However,
the inventors of the present disclosure have designed the stiffener
50 described herein to have one or more ribs 30 in order to provide
uniform load distribution to the stiffener and as well added
resistance to the longitudinal wind forces that could impact the
stability of a drywall system. The stiffener 50 of the present
disclosure further carries a simple design which is easy to
manufacture, demands no changes to the transport mechanism
currently in practice, optimizes material cost for its production
and allows flexibility in assembling the stiffener 50 in production
site and on-site during installation.
[0027] The ribs 30 of the stiffener 50 can be designed to be at
various angles from the flanges 20a, 20b. In the embodiment shown
in FIG. 1A the ribs 30 are at 90-degree angle from the flanges 20a,
20b. In alternate embodiment, the ribs 30 could be designed to be
at acute or obtuse angles from the flanges 20a, 20b. In still
alternate embodiments, each of the ribs 30 in the stiffener 50
could be designed to have a different angle from the flanges 20a,
20b. In one embodiment of the present disclosure, the ribs 30 have
a height H which is equal to or less than the height H' of the
flanges 20a, 20b. In the embodiment shown in FIG. 1A all ribs 30 of
the stiffener 50 have a height H equal to the height H' of the
flanges 20a, 20b. However, stiffeners could also be designed to
have a plurality of ribs 30, wherein the height H of a few of the
ribs 30 is less than H' and that of a few others are equal to H'.
In still another embodiment, the ribs 30 could be designed to be
provided intermittently on the flanges 20a, 20b. However, the
embodiment shown in FIG. 1A illustrates ribs 30 that are continuous
in design running from the bottom edge of the flanges 20a, 20b to
the top edge of the flanges 20a, 20b.
[0028] In one embodiment of the present disclosure, the ribs 30
have a length L less than the length L' of the web 10. In an
example embodiment, the length of the ribs 30 is 2 mm. This is of
particular relevance because the drywall studs fitted with the
stiffeners 50 of the present disclosure could still be transported
by arranging one drywall stud atop another as illustrated in FIG.
8. FIG. 8 illustrates cross-sectional view of two drywall stud 100
provided with stiffener 50 of the present disclosure arranged for
transportation. The gap provided between the ribs 30 rising from
the flange 20a and the ribs 30 rising from the flange 20b allows
for accommodating another drywall stud atop the bottom drywall stud
thereby enabling effective space utilization. Therefore, the
conventional arrangement for transporting drywall studs remains
unaffected by the introduction of the stiffeners 50 of the present
disclosure.
[0029] The stiffener 50 is made of a material selected from
aluminum or mild steel coated with galvanized iron (GI). The
thickness of the stiffener 50 ranges between 0.4 mm and 2 mm. In a
particular embodiment, the thickness of the stiffener 50 is 1 mm.
The base metal thickness of a drywall stud desired to be fixed with
the stiffener 50 of the present disclosure could have a reduced
base metal thickness compared to conventional drywall studs. This
drywall stud even with reduced base metal thickness when fitted
with the stiffeners 50 of the present disclosure imparts improved
stiffness and performance to the wall system construction
therefrom. By means of this the additional material cost incurred
for the stiffener making is controlled because the reduced
thickness of the base metal compensates for the material cost
incurred for the stiffeners.
[0030] In an optional embodiment of the present disclosure, ribs
30' could be provided on the web 10 of the stiffener 50 as
illustrated in FIG. 1B. Here the ribs 30' are provided on the web
10 in the space between the ribs 30 rising from the flange 20a and
flange 20b. Again the number, design and angle of the ribs 30'
rising from the web 10 could be varied and all such modifications
fall within the scope of this disclosure. The U-shaped
cross-section of the stiffener 50 has a dimension that is slightly
smaller than the conventional U-shaped drywall studs such that the
stiffener 50 fits inside the drywall studs. Although in the
embodiments described in FIG. 1A and FIG. 1B, the stiffener 50 are
provided with rivet holes 40 for riveting them to the drywall
studs, other means of fixing the stiffeners within the drywall stud
are also encompassed by the teachings of the present disclosure.
For example, stiffeners 50 could be adhesively bonded to the
drywall studs by providing a foam backing on the drywall web and
flanges at positions where the stiffeners 50 are desired to be
attached.
[0031] FIG. 2 illustrates a stiffener 50' for ceiling sections,
according to another embodiment of the present disclosure. The
primary difference between the stiffener 50 illustrated in FIG. 1A
and FIG. 1B used for drywall studs and the stiffener 50'
illustrated in FIG. 2 used for ceiling sections is that the flanges
20a', 20b' rising from the web 10' of the stiffener 50' have an
angle X greater than 90-degrees. This is of significance owing to
the shape of the ceiling sections used for construction of drywall
ceilings. Further the length L of the ribs 30' of the stiffener 50'
is greater than the length L' of the web 10'. In a particular
embodiment, the length L of the ribs 30' ranges between 2 mm to 35
mm. Furthermore, the length L of the ribs 30' of the stiffener 50'
is equal to the distance D between flanges 20a' and 20b'. Two rivet
holes 40' are provided on the flanges 20a', 20b' for riveting the
stiffener 50' to the ceiling section. Alternatively, rivet holes
40' could also be provided on the web 10' of the stiffener 50' for
riveting purposes.
[0032] FIG. 3 illustrates a drywall stud 100 fitted with a
stiffener 50 of the present disclosure, according to one embodiment
of the present disclosure. The drywall stud 100 comprises of a web
130 at the bottom having two flanges 131a, 131b at their outer ends
with edge portions 132a, 132b bent inwardly towards each other. The
stiffener 50 fits in the drywall stud 100 with its web 10 and
flanges 20a, 20b abutting against the web 130 and flanges 131a,
131b of the drywall stud 100, respectively. The dimension of the
stiffener 50 is adjusted such that it is snap fitted into the
drywall stud 100 and retained in position to absorb forces required
for driving screws in the flanges 131a, 131b of the drywall stud
100 during fastening of the drywall panels. Conventionally, gypsum
panels are used for this purpose. Two gypsum panels will be secured
to the flanges 131a, 131b of the drywall stud 100 by means of
screwing. The stiffener ribs 30 add strength to the flanges 20a,
20b of the stiffener 50 during compression and therefore provide
solid backing for the flanges 131a, 131b of the drywall stud 100
during screwing.
[0033] The stiffener 50 of the present disclosure can also be
fitted within a drywall stud 100 that do not have edge portions
132a, 132b. In the embodiment illustrated in FIG. 3, the stiffener
is riveted to the web 130 of the drywall stud 100 through rivet
holes 40 provided on the web 10 of the stiffener 50. In one
embodiment, the rivet holes 40 have a diameter ranging between 1 mm
to 3 mm and are provided at the edges of the web 10 of the
stiffener. Alternate means of fixing the stiffener 50 within the
drywall stud 100 may also be exercised. In alternate embodiments
the stiffener 50 may also be riveted to the flanges 131a, 131b of
the drywall stud 100 through rivet holes provided on the flanges
30a, 30b of the stiffener 50. Multiple stiffeners 50 can be fixed
within a drywall stud 100 depending on the positions of the drywall
stud where screwing would occur. In an example embodiment,
stiffeners 50 are fixed in a drywall stud at every 2 feet interval.
In another example embodiment, stiffeners 50 are fixed in the top
and bottom edges of the drywall stud.
[0034] FIG. 4 illustrates a ceiling section 200 fitted with a
stiffener 50' of the present disclosure, according to one
embodiment of the present disclosure. The ceiling section 200
comprises of a web 230 at the bottom having two flanges 231a, 231b
at their outer ends with edge portions 232a, 232b bent outwardly
away from each other. The flanges 231a, 231b extend at an angle
greater than 90-degrees from the web 230 of the ceiling section
200. It is to this angle that angle X formed between the flanges
20a', 20b' and web 10' of the stiffener 50' correspond to. The
stiffener 50' fits inside the ceiling section 200 with its web 10'
and flanges 20a', 20b' abutting against the web 230 and flanges
231a, 231b of the ceiling section 200, respectively.
[0035] The dimension of the stiffener 50' is adjusted such that it
is snap fitted into the ceiling section 200 and retained in
position to absorb forces required for driving screws in the web
230 of the ceiling section 200 during fastening of the drywall
panels. Conventionally, gypsum panels are used for this purpose.
Gypsum panels are usually secured to the web 230 of the ceiling
section 200 by means of screwing. The stiffener ribs 30' make the
flanges 20a', 20b' and web 10' of the stiffener 50' very stiff in
compression and therefore provide solid backing to the web 230 of
the ceiling section 200 during screwing. In addition to this, the
stiffener 50' also reduces crack formation in ceiling
constructions, particularly crack formations occurring due to
irregularity in the installations.
[0036] In one embodiment of the present disclosure, as illustrated
in FIG. 4 the stiffener 50' is fitted within the ceiling section
200 though a lancing 240 provided in the flanges 231a, 231b at
positions where the stiffener 50' are desired to be fixed. Lancing
240 is a rectangular cut-out provided on the flanges 231a, 231b of
the ceiling section 200 which is slightly bent inward to allow for
the insertion of the flanges 20a', 20b' of the stiffener 50'.
Alternatively, rivet holes could be provided on the stiffener 50'
similar to that provided on the stiffener 50 used for drywall studs
100 for fixing the stiffener 50' within the ceiling section 200. It
should be understood that drywall stiffeners 50 and the ceiling
stiffeners 50' can be manufactured with either riveting holes or
lancing feature and the present application tends to describe the
drywall stiffener 50 with rivet holes 40 and the ceiling stiffener
50' that is fixed to the ceiling section by a lancing feature only
for teachings purposes. In still another embodiment, the ceiling
stiffener 50' could be fixed within the ceiling section 200 using
both the lancing present on the flanges 231a, 231b (showed in FIG.
4) and rivet holes 40' provided on the web 10' of the stiffener 50'
(showed in FIG. 1A, FIG. 1B and FIG. 2 among others).
[0037] Multiple stiffeners 50' can be fixed within a ceiling
section 200 depending on the positions of the ceiling section where
screwing would occur. In an example embodiment, stiffeners 50' are
fixed in a ceiling section at every 2 feet interval.
Conventionally, ceiling sections are transported by stacking
ceiling sections one over the other. Owing to which, in the most
preferred embodiment of the present disclosure, the stiffeners 50'
are fixed within the ceiling section 200 at the installation site.
Nevertheless, the stiffeners 50' could also be fixed within the
ceiling sections 200 at the manufacturing site before
transportation by riveting or lancing.
[0038] It is to be understood that the present disclosure is not
limited in its application to the details of the construction and
arrangement of the parts illustrated in the accompanying figures,
since the present disclosure is capable of being implemented in
varied number of embodiments and practiced in various ways. Further
the terminology employed herein is for the purposes of description
and teaching of the present disclosure and do not in any sense
limit the scope of the present disclosure.
[0039] FIG. 5A to FIG. 5G illustrate stiffeners 50 for drywall stud
according to multiple embodiments of the present disclosure. FIG.
5A illustrates a stiffener 50 for drywall studs that has ribs 30
arranged parallel to the flanges 20a, 20b as well provided on the
web 10 of the stiffener 50. The ribs 30 on flange 20a, correspond
in position to the ribs 30 on flange 20b and run for the entire
length of the flanges 20a, 20b. FIG. 5B illustrates a stiffener 50
for drywall studs that has ribs 30 arranged on the edges of the
flanges 20a, 20b.
[0040] FIG. 5C to FIG. 5F illustrate stiffeners 50 which are
slightly different from the stiffeners 50 described so far in the
disclosure. This is because the stiffeners 50 described so far were
designed to have ribs protruding from their flanges. Whereas the
stiffeners 50 described in FIG. 5C to FIG. 5F are designed such
that the flanges of the stiffeners protrude inward to form rib
structures which are perpendicular, parallel or diagonal to the
flanges. FIG. 5C illustrates a stiffener 50 whose flanges 20a, 20b
are bent to form ribs 30 which run parallel to the flanges. Further
the web 10 of the stiffener 50 are also bent to form rib like
structure at the bottom of the stiffener 50. FIG. 5D illustrates a
stiffener 50 whose flanges 20a, 20b are bent to form ribs 30 which
run in a perpendicular direction to the flanges. Further the web 10
of the stiffener 50 are also bent to form rib like structure at the
bottom of the stiffener 50. The stiffener 50 illustrated in FIG. 5E
are provided with two ribs 30 that run diagonal to the flanges 20a,
20b and meet at the center portion of the flanges 20a, 20b.
Similarly, the stiffener 50 illustrated in FIG. 5F comprise of ribs
30 that are a combination of ribs that run parallel and diagonal to
the flanges 20a, 20b to form a cluster-shape.
[0041] FIG. 5G again illustrates a stiffener 50 for a drywall stud
that has ribs 30 whose length L is equal to the length of the web
L' and the ribs 30 run perpendicular between the flanges 20a and
20b of the stiffener 50.
[0042] All variations illustrated for the drywall stiffener 50
should be understood to be applicable for ceiling stiffener 50' of
the present disclosure. While the drywall stiffener 50 illustrated
in FIG. 1A, FIG. 1B, FIG. 5A and FIG. 5B can be manufactured by dye
casting, the drywall stiffener 50 illustrated in FIG. 5C to FIG. 5F
can be manufactured by embossing. Further the depths of the ribs 30
in these stiffeners could be optimized for the stiffeners to be
manufactured by cold-working. Therefore, the drywall stiffeners 50
and ceiling stiffeners 50' provide flexibility in terms of
manufacturing.
[0043] FIG. 6 illustrates a drywall partition 300 constructed from
drywall studs 100 that extend between a floor channel 310 and a
ceiling channel 320. The drywall studs 100 are retained by the
floor channel 310 at their bottoms and are retained by a similar
ceiling channel 320 at their top. Gypsum panels 330a, 330b are
fastened to the opposite sides of the drywall studs 100 by nails or
screws 340. The drywall studs 100 may be fastened to the floor
channel 310 and also to the ceiling channel 320 with screws 340 or
by other methods.
[0044] The drywall studs 100 are fixed with a plurality of
stiffener 50 of the present disclosure at positions that
necessitate screwing on the drywall studs 100 in order for the
gypsum panels 330a, 330b to be fastened on either sides of the
drywall studs 100. The stiffeners 50 can be fixed within the
drywall stud 100 in a variety of ways such as but not limiting to
riveting or lancing. Thus, when the screws are driven into the
flanges 131a, 131b to fasten the gypsum panels 330a and 330b to the
flanges 131a, 131b the stiffener 50 prevents the flanges 131a, 131b
from bending and allows the screws to penetrate relatively easily
through the flanges 131a, 131b. Likewise, the stiffener 50 holds
the flanges 131a, 131b in place if nails are pounded into the
flanges 131a, 131b rather than screws being driven into the flanges
131a, 131b. The stiffeners 50 also give additional structural
strength to the drywall studs 100 for general structural
strength.
[0045] The additional structural strength provided by the
stiffeners 50 of the present disclosure support higher partition
heights which otherwise would not be possible. Conventionally the
drywall partitions made of 48 mm drywall studs are constructed to
standard height of 2.5 meters. With the stiffeners 50 of the
present disclosure in place, the height achieved by a drywall
partition made of 48 mm drywall studs can be increased to 3.3
meters. This is made possible by the stiffness and reinforcement
provided by the stiffeners 50 of the present disclosure.
[0046] FIG. 7 illustrates a suspended drywall ceiling 400
comprising a grid 410 formed of intermediate beams 420 interlocking
with perpendicular extending ceiling sections 200. The grid 410 is
suspended from a structural ceiling by hang wires or the like, in
the well-known manner of suspended ceilings. The intermediate beams
420 and ceiling sections 200 are joined together by conventional
clipping mechanism. The construction of a suspended drywall ceiling
is well known. First, the grid 410 is constructed of the
intermediate beams 420, and suspended by hang wires from a
structural ceiling. Large sheets of gypsum panels 430 are then
secured to grid 410 from below by self-tapping screws inserted by
an installer with a power screwdriver, through the gypsum panels
430 into the ceiling sections 200. The gypsum panels 430 may
correspond in size to the distance between the centerlines of
ceiling sections 200 in the grid 410. In FIG. 7, two gypsum panels
430a, 430b are joined together at point 450, which forms the
centerline of the ceiling section 200.
[0047] As illustrated, the ceiling sections 200 are provided with
multiple ceiling stiffeners 50 within them. In the embodiment shown
in FIG. 7, the stiffeners 50' are provided at both the edges of the
ceiling sections 200 and one stiffener 50' provided centrally.
However, in alternate embodiments, stiffeners 50' may be provided
only at the top and bottom edge of the ceiling sections. The
stiffeners 50', particularly those provided in the ceiling section
200 having the point 450 are critical. This is because these
stiffeners 50' provide backing to the web 230 of the ceiling
section 200 such that the screwing of the gypsum panels 430 is done
efficiently.
[0048] If no stiffeners 50' are provided inside the ceiling
sections 200, the point 450 may cause the ceiling section 200 at
that location to crumble leading to the sagging of the suspended
ceiling 400 eventually resulting in the ceiling cracking over a
period of time. Such crumbling issues are also true for other
ceiling sections 200 present adjacent to the point 450. The
development of cracks in the suspended ceiling 400 is reduced in
accordance with the present disclosure by providing stiffeners 50'
inside the ceiling sections 200 which backs the web 230 of the
ceiling sections 200 to hold them in place when the screws are
driven into them, thus assuring the screws penetrate the web 230
and further restrict the flanges 231a, 231b of the ceiling sections
200 from crumbling or buckling over a period of time.
EXAMPLES
Comparative Example 1
Deflection Testing of Drywall Partitions
[0049] A drywall partition was constructed by erecting 48 mm
drywall studs having a thickness of 0.4 mm provided with 3.8 mm
drywall stiffeners 50 of the present disclosure between a
conventional floor channel and a ceiling channel. The 48 mm drywall
studs were provided with two stiffeners 50 one attached to the top
end of the drywall stud and the other attached to the bottom end of
the drywall studs. Deflection of the drywall partition having
stiffeners were measured by simulation and compared with the
deflection exhibited by a drywall partition having no stiffeners
when applied with a load of 200 Pa.
[0050] While the conventional drywall partition (with no
stiffeners) recorded a maximum deflection of 7.74 mm at 200 Pa, the
drywall partition constructed from drywall studs provided with
stiffeners of the present disclosure recorded a maximum deflection
of 3.81 mm at 200 Pa. Thus the deflection of the drywall partition
comprising stiffeners was found to be improved by almost 50%. This
is because the ribs of the stiffeners resist the deflection of the
flanges through uniform distribution of load. Further the 50%
improvement in the stiffness, stability and structural strength of
the partition system with stiffeners enable higher partition
heights.
Comparative Example 2
Deflection Testing of Suspended Ceiling
[0051] A suspended ceiling was constructed by erecting ceiling
sections provided with 3.8 mm ceiling stiffeners 50' of the present
disclosure to perpendicularly placed intermediate channels hung
from a structural ceiling. The ceiling sections were provided with
two ceiling stiffeners 50' each, one at each edge of the ceiling
section. Deflection of the suspended ceiling system having
stiffeners were measure by simulation and compared with the
deflection exhibited by a conventional suspended ceiling system
when applied with a load ranging between 50-75 N.
[0052] While the conventional suspended ceiling (with no
stiffeners) recorded a maximum deflection of 0.65 mm at 75 N, the
suspended ceiling system constructed from ceiling sections provided
with ceiling stiffeners of the present disclosure recorded a
maximum deflection of 0.0046 mm Thus the stiffness of suspended
ceiling system was found to be largely improved by the ceiling
stiffeners of the present disclosure, which can be attributed to
the ribs present in the ceiling stiffeners that resist the bending
od the ceiling sections during flexural load.
Comparative Example 3
Deflection Testing of Suspended Ceiling System
[0053] A 1800 mm cross 1200 mm suspended ceiling complete with
gypsum panels of size 1800 mm.times.1200 mm was constructed by
erecting ceiling sections provided with 3.8 mm ceiling stiffeners
50' of the present disclosure to perpendicularly placed
intermediate channels hung from a structural ceiling spanning to
1700 mm. The ceiling sections were provided with three ceiling
stiffeners 50' each, one at each edge of the ceiling section and
another stiffener positioned centrally. 30 kg of total weight by
applying 10 kg across each of the ceiling section provided with
stiffener was applied on the system from the top and deflection
cause by the load was measured from the bottom using a dial
gauge.
[0054] An exactly similar suspended ceiling system was constructed
without the stiffeners of the present disclosure and was applied
with 30 kg of load from top and deflection measured from the
bottom. While the suspended ceiling system provided with the
stiffener was found to deflect 15.1 mm the ceiling system without
the stiffener was found to deflect 26.5 mm thus demonstrating a
reduced deflection of almost 43%.
INDUSTRIAL APPLICABILITY
[0055] With use and implementation of the stiffeners of the present
disclosure, channels such as drywall studs and ceiling sections
with improved stiffness can be obtained without complicating the
stud construction. The stiffness of the channels is improved by the
backing provided by the stiffeners to the flanges of the drywall
studs and ceiling sections that allow screws or nails to be driven
into the flanges without bending the flanges. The present
disclosure provides a stiffener that can be easily inserted into
the channels by simple means and one that holds itself in place.
The present disclosure provides reinforced stud constructions
utilizing stiffeners that can be fabricated easily and economically
from sheet stock. The stiffeners resist crumbling/buckling of the
suspended ceiling systems thereby delaying and reducing development
of cracks.
[0056] The present disclosure also pays attention to the transport
of the channels fabricated with stiffeners by designing stiffeners
that make no change to the conventional means of transporting
channels. Further the stiffener designs provide flexibility of them
being produced by multiple methods such as dye casting, embossing
and cold-working. Furthermore, the stiffener design compensates the
additional cost of material involved in producing them by enabling
the use of channels having reduced thickness. Moreover, the
stiffener pieces are made from simple construction that fits
complementarily within the channels along with which they
co-act.
[0057] Note that not all of the activities described above in the
general description or the examples are required, that a portion of
a specific activity may not be required, and that one or more
further activities may be performed in addition to those described.
Still further, the order in which activities are listed is not
necessarily the order in which they are performed.
[0058] Benefits, other advantages, and solutions to problems have
been described above with regard to specific embodiments. However,
the benefits, advantages, solutions to problems, and any feature(s)
that may cause any benefit, advantage, or solution to occur or
become more pronounced are not to be construed as a critical,
required, or essential feature of any or all the claims.
[0059] The specification and illustrations of the embodiments
described herein are intended to provide a general understanding of
the structure of the various embodiments. The specification and
illustrations are not intended to serve as an exhaustive and
comprehensive description of all of the elements and features of
apparatus and systems that use the structures or methods described
herein. Certain features, that are for clarity, described herein in
the context of separate embodiments, may also be provided in
combination in a single embodiment. Conversely, various features
that are, for brevity, described in the context of a single
embodiment, may also be provided separately or in a sub
combination. Further, reference to values stated in ranges includes
each and every value within that range. Many other embodiments may
be apparent to skilled artisans only after reading this
specification. Other embodiments may be used and derived from the
disclosure, such that a structural substitution, logical
substitution, or another change may be made without departing from
the scope of the disclosure. Accordingly, the disclosure is to be
regarded as illustrative rather than restrictive.
[0060] The description in combination with the figures is provided
to assist in understanding the teachings disclosed herein, is
provided to assist in describing the teachings, and should not be
interpreted as a limitation on the scope or applicability of the
teachings. However, other teachings can certainly be used in this
application.
[0061] As used herein, the terms "comprises," "comprising,"
"includes," "including," "has," "having" or any other variation
thereof, are intended to cover a non-exclusive inclusion. For
example, a method, article, or apparatus that comprises a list of
features is not necessarily limited only to those features but may
include other features not expressly listed or inherent to such
method, article, or apparatus. Further, unless expressly stated to
the contrary, "or" refers to an inclusive-or and not to an
exclusive-or. For example, a condition A or B is satisfied by any
one of the following: A is true (or present) and B is false (or not
present), A is false (or not present) and B is true (or present),
and both A and B are true (or present).
[0062] Also, the use of "a" or "an" is employed to describe
elements and components described herein. This is done merely for
convenience and to give a general sense of the scope of the
disclosure. This description should be read to include one or at
least one and the singular also includes the plural, or vice versa,
unless it is clear that it is meant otherwise. For example, when a
single item is described herein, more than one item may be used in
place of a single item. Similarly, where more than one item is
described herein, a single item may be substituted for that more
than one item.
[0063] Unless otherwise defined, all technical and scientific terms
used herein have the same meaning as commonly understood by one of
ordinary skill in the art to which this disclosure belongs. The
materials, methods, and examples are illustrative only and not
intended to be limiting. To the extent that certain details
regarding specific materials and processing acts are not described,
such details may include conventional approaches, which may be
found in reference books and other sources within the manufacturing
arts.
[0064] While aspects of the present disclosure have been
particularly shown and described with reference to the embodiments
above, it will be understood by those skilled in the art that
various additional embodiments may be contemplated by the
modification of the disclosed machines, systems and methods without
departing from the spirit and scope of what is disclosed. Such
embodiments should be understood to fall within the scope of the
present disclosure as determined based upon the claims and any
equivalents thereof.
LIST OF ELEMENTS
[0065] 50 Stiffener for Drywall Stud [0066] 10 Web [0067] 20a, 20b
Flange [0068] 30 Rib [0069] 30' Rib [0070] 40 Rivet Holes [0071]
50' Stiffener for Ceiling Section [0072] 10' Web [0073] 20a', 20b'
Flange [0074] 40' Rivet Holes [0075] 100 Drywall Stud [0076] 130
Web [0077] 131a, 131b Flange [0078] 132a, 132b Edge Portion [0079]
200 Ceiling Section [0080] 230 Web [0081] 231a, 231b Flange [0082]
232a, 232b Edge Portion [0083] 240 Lancing [0084] 300 Drywall
Partition [0085] 310 Floor Channel [0086] 320 Ceiling Channel
[0087] 330a, 330b Gypsum Panels [0088] 400 Suspended Ceiling System
[0089] 410 Grid [0090] 420 Intermediate Channel [0091] 430a, 430b
Gypsum Panels [0092] 450 Joint Point [0093] X Angle between Web and
Flange of the Stiffener [0094] L Length of the Rib of the Stiffener
[0095] L' Length of the web of the Stiffener [0096] H Height of the
Rib of the Stiffener [0097] H' Height of the Flanges of the
Stiffener [0098] D Distance between the Flanges of the
Stiffener
* * * * *