Drywall construction system with spring rail

Abstract

The invention relates to a drywall construction system comprising a plurality of metal profiles which at least on one side are panelled using dry construction boards. At least on this one side spring rails are arranged between the metal profiles and the dry construction boards. The invention is suitable, in particular, for improving sound insulation in lightweight steel constructions.

Claims

1. A double sided drywall construction system comprising: a plurality of vertically oriented C-shaped metal profiles having first and second spaced flanges directly extending from and interconnected by a web portion with a metal sheet thickness of between 1 mm and 3 mm; a first plurality of top-hat shaped spring rails attached at a perpendicular orientation to at least some of the first flanges of the plurality of metal profiles, the first plurality of top-hat shaped spring rails including one or more recesses; a first plurality of plasterboards having a raw density greater than 1000 kg/m.sup.3 directly attached to the first plurality of top-hat shaped spring rails, wherein the first plurality of plasterboards are spaced from and not directly attached to the plurality of metal profiles and the first plurality of top-hat shaped spring rails are arranged between the metal profiles and the first plurality of plasterboards; a second plurality of plasterboards having a raw density greater than 1000 kg/m.sup.3 directly attached to at least some of the second flanges of the plurality of C-shaped profiles, wherein at least one of the first and second plurality of plasterboards comprise a first layer of plasterboard connected to a second layer of plasterboard; and insulation positioned in the cavity defined between the first and second plurality of plasterboards.

2. The double-sided drywall construction system according to claim 1, wherein the metal profiles have a sheet thickness between 1.5 mm and 3 mm.

3. The double-sided drywall construction system according to claim 1, wherein the top-hat shaped spring rails comprise a base having first and second parallel side edges, a first shank extending from the first edge and a second shank extending from the second edge and a plurality of recesses positioned in at least the first and second shanks, a first flange extending from the first shank and a second flange extending from the second shank, wherein the first and second flanges are co-planer, and at least one recess having a curved perimeter edge disposed on the first shank and at least one recess having a curved perimeter edge disposed on the second shank.

4. The double-sided drywall construction system according to claim 1, wherein at least one of the first plurality of spring rails is fastened to each of the plurality of metal profiles.

5. The double-sided drywall construction system according to claim 1, wherein up to 80% by volume of the cavity between the first plurality of plasterboards and the second plurality of plasterboards is filled with an insulation material.

6. The double-sided drywall construction system according to claim 1, wherein the sheet thickness is 1.5 mm.

7. The double-sided drywall construction system of claim 1, wherein the plurality of metal profiles, the first and second plurality of plasterboards and the first plurality of spring rails comprise a load bearing partition wall.

8. The double-sided drywall construction system according to claim 1, wherein the first plurality of top-hat shaped spring rails are oriented horizontally.

9. The double-sided drywall construction system according to claim 1, wherein a sound reduction index of greater than 73 dB for frequencies greater than 1000 Hz and less than 2000 Hz is provided.

10. The double-sided drywall construction system according to claim 1, wherein a sound reduction index of greater than 70 dB for frequencies greater than 4000 Hz is provided.

11. A drywall system, comprising: a load bearing partition wall having a plurality of metal profiles vertically oriented in a spaced relationship, each metal profile having at least a first outwardly facing side flange and a second outwardly facing side flange extending from and interconnected by a web portion, wherein the first and second side flanges face different directions, and each metal profile having a sheet metal thickness of 1.5 mm; a first plurality of sound decoupling top-hat shaped spring rails directly attached at a perpendicular orientation to each of the first side flanges of the plurality of metal profiles; a first plurality of plasterboards having a raw density greater than 1000 kg/m.sup.3 directly attached to the plurality of sound decoupling spring rails and spaced from and not directly attached to a metal profile, wherein the first plurality of sound decoupling spring rails are arranged between the first side of the metal profiles and the first plurality of plasterboards; and a second plurality of plasterboards having a raw density greater than 1000 kg/m.sup.3 directly attached to at least some of the second side flanges of the plurality of metal profiles; a cavity defined between the first and second plurality of plasterboards, wherein an insulation material is positioned in the cavity; and wherein, the drywall system provides a sound reduction index of greater than 73 dB for frequencies greater than 1000 Hz and less than 2000 Hz.

12. The drywall system of claim 11, wherein the first and second side flanges face in opposite directions.

13. The drywall system of claim 11, wherein, a sound reduction index of greater than 70 dB of sound reduction for frequencies greater than 4000 Hz is provided.

14. The drywall system of claim 11, wherein at least one of the first and second plurality of plasterboards comprise a first layer of plasterboard connected to a second layer of plasterboard.

15. The drywall system of claim 11, wherein the plurality of metal profiles are C-shaped.

16. The drywall construction system of claim 11, wherein the plurality of sound decoupling top-hat shaped spring rails each comprise a base having first and second parallel side edges, a first shank extending from the first edge and a second shank extending from the second edge and a plurality of recesses having a perimeter edge that is curved along at least a portion of the edge and positioned in at least the first and second shanks, a first flange extending from the first shank and a second flange extending from the second shank.

17. A drywall construction system, comprising: a plurality of vertically oriented metal profiles having first and second spaced flanges directly extending from and interconnected by a web portion and having a sheet thickness between 1 mm and 3 mm; a plurality of top-hat shaped metal spring rails each having a base having a first edge and a second edge spaced from the first edge, a first shank extending from the first edge of the base at an angle relative to the base, a second shank extending from the second edge of the base at an angle relative to the base, a first flange extending from the first shank at an angle relative to the first shank, and a second flange extending from the second shank at an angle relative to the second shank, at least one recess formed in each shank, the plurality of spring rails having a first open end and a spaced second open end spaced from the first open end, wherein the first and second shanks and base of each metal spring rail define a cavity and wherein the length between the first and second open end of the spring rails defines a longitudinal dimension of the spring rails, the plurality of spring rails fastened to the plurality of metal profiles and oriented wherein the longitudinal dimension of the spring rails is perpendicular to the longitudinal dimension of the metal profiles, and wherein the spring rails are fastened to at least one of the first and second flanges of the metal profiles; a first plurality of dry construction boards mounted to the first side of the plurality of metal profiles, a second plurality of dry construction boards mounted to a plurality of spring rails fastened to the second side of the plurality of metal profiles, the first and second plurality of dry construction boards having a raw density of greater than 1000 kg/m.sup.3; insulation disposed within each cavity of the plurality of spring rails.

18. The drywall construction system of claim 17, wherein a space is formed between the first and second plurality of dry construction boards, and the space is filled at least eighty percent by volume with insulation.

19. The drywall construction system of claim 17, wherein at least one of the first and second plurality of dry construction boards comprise a first layer of dry construction board connected to a second layer of dry construction board.

20. The drywall construction system of claim 17, wherein a cavity is formed between the first plurality of dry construction boards and the second plurality of dry construction boards and the cavity is filled with up to eight percent by volume of an insulation material.

Description

(1) The invention will now be described in more detail by way of an exemplary embodiment, in which:

(2) FIG. 1A shows an airborne sound reduction index in dependence of the frequency for various drywall construction systems

(3) FIG. 1B shows a schematic cross-section through a drywall construction system according to the invention

(4) FIG. 1C shows a schematic cross-section through a commonly used drywall construction system with sound insulation properties

(5) FIG. 1D shows a schematic cross-section through a drywall construction system built of lightweight steel

(6) FIG. 2 shows an oblique top view onto a part of a spring rail

(7) FIG. 3 shows a schematic section through an installed situation according to the invention.

(8) FIG. 1 shows the sound reduction index R in dependence of the frequency for different drywall construction systems. In FIGS. 1B to 1D the respective drywall construction systems are shown schematically in horizontal section. FIG. 1C shows a commonly used drywall construction system optimised for sound insulation, which consists of metal profiles as commonly used in drywall construction systems with double-sided, two-layer panelling (profiles with a sheet thickness of 0.6 mm). The inner cavity between the metal profiles is filled to 80% by volume with mineral wool. All gypsum plasterboards (raw density >1000 kg/m.sup.3) are screwed directly to the flanges of the metal profiles. The arrows point to the resulting respectively associated sound reduction graph for such a drywall construction system, see graph with circles.

(9) FIG. 1D shows the same system setup as for the embodiment described for FIG. 1C, but here with lightweight steel profiles comprising a sheet thickness of 1.5 mm. The arrow points to the associated sound reduction graph, see graph with filled triangles. Compared to the sound insulation system of FIG. 1C it becomes clear that the sound insulation properties of the drywall system are diminished due to the use of lightweight steel profiles.

(10) FIG. 1B shows an embodiment of a drywall construction system according to the invention, which is different from the embodiment shown in FIG. 1D due to the presence of spring rails extending perpendicularly to the metal profiles. The spring rails are arranged between the 1.5 mm thick lightweight steel profiles and the one side, which is panelled. The spring rails are screwed to the metal profiles at the intersecting points, whilst the gypsum plasterboards are screwed solely to the spring rails. The panelling is decoupled from the metal profiles, so that only a very small proportion of the sound energy can actually be transferred via the system to the other side. The arrow points to the sound reduction graph associated with this drywall construction system, see graph with crosses. It is evident that this system is superior especially in the high frequency range even to the sound insulation system shown in FIG. 1C. This also becomes evident when looking at the sound reduction index Rw, which is 66.4 dB for the inventive embodiment, 63.2 dB for the sound insulation variant of FIG. 1C, and only 51.1 dB for the lightweight steel variant without further measures (FIG. 1D). The negative influence of the 1.5 mm lightweight steel profiles upon the sound insulation is not just compensated for by the integration of the spring rails, but distinctly overcompensated for. Such a positive result had not been expected.

(11) FIGS. 2 and 3 show a possible embodiment of the spring rails in the form of a top-hat profile. In the region of the flanks the spring rail has oval holes which make the rail more elastic. The bevelled flanges also comprise holes which can be used for screwing to the metal profile.

(12) In FIG. 3 an exemplary installed situation is depicted in longitudinal section. The metal profile 1 has a top-hat rail or spring rail 2 fastened to it with screws via the two flanges 2b. Two construction boards 3, in this case gypsum plasterboards, are fastened with screws in a single layer to the base 2a of the spring rail 2. The screws for fastening the gypsum plasterboards fix the plasterboards to the spring rail 2 only, not to the metal profile 1.