Dry construction system for making partition walls, suspended ceilings or the like, carrier profile therefor, and use of this dry construction system

Abstract

The invention relates to a dry construction system for making partition walls (1), suspended ceilings or the like, with a support structure (2), a cladding (3) arranged on at least one side of this, and an insulation layer (4), wherein the support structure (2) comprises a plurality of carrier profiles (22), to which at least one cladding (3) is secured, and wherein the carrier profiles (22) are formed from a sheet material and exhibit in cross-section a basic section and two limb sections arranged perpendicular thereto, and comprise an embossing with regularly distributed elevations and depressions. In this situation, the centre-to-centre distance between two adjacent elevations of the embossing on one side of the sheet material is less than six times the rated sheet thickness, and the base section is connected to the adjacent limb section in each case by a curved section with an outer radius which amounts to at least three times the rated sheet thickness. The invention further relates to a carrier profile (22) for such a dry construction system and uses of such a dry construction system. In this way a generic dry construction system is further improved in respect of the sound insulation properties.

Claims

1. Dry construction system for making partition walls (1) or suspended ceilings comprising: a support structure (2) in the form of a metal load-bearing structure, the support structure having a plane, at least one cladding (3) arranged on at least one side of the support structure (2), and an insulation layer (4), which is arranged in the plane of the support structure (2), wherein the support structure (2) comprises a plurality of carrier profiles (22), to which the at least one cladding (3) is secured, wherein the carrier profiles (22) are formed from a sheet material having a rated sheet thickness and comprise in the cross-section a base section (22a) as well as two adjacent limb sections (22b, 22b) arranged perpendicular to the base section (22a), and wherein the limb sections (22b, 22b) of the carrier profiles (22) comprise an embossing with regularly distributed elevations on a first surface and corresponding depressions on a second, opposing surface, characterised in that the base section (22a) of the carrier profile (22) also comprises the said embossing with regularly distributed elevations on a first surface and corresponding depressions on a second, opposing surface, said elevations and depressions regularly distributed in an orthogonal array, so as to provide a pattern that repeats in two dimensions, the elevations having centre-to-centre distances, wherein the centre-to-centre distance between two adjacent elevations of the embossing on the first surface of the sheet material is between three and six times the rated sheet thickness, and that the base section (22a) is connected to the adjacent limb section (22b, 22b) in each case by means of a curved section (22c) with an outer radius (R1) which amounts to between three and ten times the rated sheet thickness.

2. Dry construction system according to claim 1, characterised in that the centre-to-centre distance between the two adjacent elevations of the embossing on one side of the sheet material amounts to three times the rated sheet thickness.

3. Dry construction system according to claim 2, characterised in that the centre-to-centre distance between two adjacent elevations of the embossing on one side of the sheet material lies between four times and 5.5 times the rated sheet thickness.

4. Dry construction system according to claim 1, characterised in that the curved section (22c) with an outer radius (R1) amounts to ten times the rated sheet thickness.

5. Dry construction system according to claim 4, characterised in that the outer radius (R1) of the curved section (22c) is between six times and seven times the rated sheet thickness.

6. Dry construction system according to claim 1, characterised in that the base section (22a) comprises at least one beading (22e) running longitudinally.

7. Dry construction system according to claim 6, characterised in that the beading (22e) of the base section projects to an inner side of the carrier profile cross-section.

8. Dry construction system according to claim 6, characterised in that a depth of the beading (22e) of the base section amounts to one to six times the rated sheet thickness.

9. Dry construction system according to claim 6, characterised in that the beading (22e) exhibits a triangular cross-section with an apex, wherein the apex encloses an inner angle of approximately 90.

10. Dry construction system according to claim 6, wherein precisely one beading (22e) is arranged in the middle in the base section (22a).

11. Dry construction system according to claim 1, characterised in that the two limb sections (22b, 22b) comprise in each case a beading (22f) running longitudinally.

12. Dry construction system according to claim 11, wherein in each case precisely one beading (22f) is arranged in the middle in each limb section (22b, 22b).

13. Dry construction system according to claim 11, wherein the carrier profile cross-section includes an inner side and wherein the beading (22f) of the two limb sections projects to the inner side of the carrier profile cross-section.

14. Dry construction system according to claim 11, characterised in that a depth of the beading (22f) of the two limb sections amounts to one to six times the rated sheet thickness.

15. Dry construction system according to claim 1, characterised in that the embossing in the carrier profiles (22) is applied on both sides of the sheet material.

16. Dry construction system according to claim 1, wherein the limb sections (22b, 22b) have free ends and characterised in that the carrier profiles (22) at the free ends of the limb sections (22b, 22b) in each case comprise inclinations (22d) facing inwards.

17. Dry construction system according to claim 1, characterised in that a total thickness (D) derived from the embossing depth of the base section (22a) and of the limb sections (22b, 22b) respectively is 1.2 times to 3 times the rated sheet thickness.

18. Dry construction system according to claim 17, characterised in that a total thickness (D) derived from the embossing depth of the base section (22a) and of the limb sections (22b, 22b) respectively amounts to about 1.6 times the rated sheet thickness.

19. Carrier profile (22) for a dry construction system which is formed from a sheet material having a rated sheet thickness and in cross-section comprises a base section (22a) as well as two adjacent limb sections (22b, 22b) arranged perpendicular thereto, wherein the limb sections (22b, 22b) comprise an embossing with regularly distributed elevations and depressions, characterised in that the base section (22a) of the carrier profiles (22) also comprises an embossing with regularly distributed elevations on a first side and corresponding depressions on a second, opposite side, said elevations and depressions regularly distributed in an orthogonal array, so as to provide a pattern that repeats in two dimensions, that the centre-to-centre distance between two adjacent elevations of the embossing on the first side of the sheet material is between three and six times the rated sheet thickness, and that the base section (22a) is connected to the adjacent limb section (22b, 22b) in each case by a curved section (22c) with an outer radius (R1) which amounts to between three and ten times the rated sheet thickness.

Description

(1) The invention is explained in greater detail hereinafter by way of embodiments, based on the figures in the drawings. These show:

(2) FIG. 1. a perspective view of a partition wall in dry construction format, shown in a partial sectional view;

(3) FIG. 2. a section from a horizontal section through the partition wall in FIG. 1;

(4) FIG. 3. a perspective view of a carrier profile;

(5) FIG. 4. an enlarged detail representation of the surface of the carrier profile according to FIG. 3;

(6) FIG. 5. a transverse view of a carrier profile according to the invention;

(7) FIG. 6. a side view of a section of the surface of an embossing roller; and

(8) FIG. 7. a view from above onto the section of the embossing roller according to FIG. 6.

(9) According to the representation in FIG. 1, a partition wall 1, which is designed as a single-plank wall with simple facing, comprises a support structure 2 in the form of a metal carrying structure, which is faced on both sides with a cladding 3. The cladding 3 on both sides encloses between it an insulation layer 4 made of mineral wool, located in the plane of the support structure 2.

(10) The support structure 2 exhibits an essentially U-shaped floor profile 21, which is secured beforehand on the floor side when the partition wall 1 is produced. A correspondingly designed ceiling profile, not shown here, extends parallel to and perpendicular above the floor profile 21, at the ceiling of the room, not shown here. Arranged between the floor profile 21 and the ceiling profile are a plurality of carrier profiles 22, made of galvanised steel, which in each case extend upright at predetermined distance intervals.

(11) The carrier profiles 22 serve to secure the cladding 3. This comprises a plurality of gypsum plasterboard panels 31, which in each case are secured by means of screws 32 to the carrier profile 22. In this situation, self-tapping screws 32 are used. As can be seen from FIG. 1, the gypsum plasterboard panels 31 exhibit a length which corresponds to double the distance between two carrier profiles 22. As a result, an offset arrangement of the gypsum plasterboard panels 31 is possible, in the manner shown.

(12) Shown in FIG. 2 is a horizontal section through the partition wall 1 according to FIG. 1. As can be seen from this, the gypsum plasterboard panels 31 are screwed directly to the carrier profiles 22. These are formed as single pieces, and comprise a base section 22a as well as two limb sections 22b and 22b respectively, located essentially perpendicular to this, as can be seen in greater detail from FIGS. 3 and 5. The base section 22a in this situation extends transverse to the plane of the wall, and connects the two claddings 3. These are connected, in the manner shown in FIG. 2, in each case to a limb section 22b and 22b respectively, by the screws 32. Inasmuch as two gypsum plasterboard panels 31 abut one another in the region of a carrier profile 22, their edges are secured in each case by means of screws to the same limb section 22b and 22b respectively. Inasmuch as a limb section 22b or 22b respectively comes to lie in the middle region of a gypsum plasterboard panel 31, as a rule one single screw in the horizontal direction is sufficient for the securing.

(13) In FIG. 2 it can further be seen that the joints between two abutting plasterboard panels 31, in the same way as the screw holes with the screw heads slightly sunk in the conventional manner, can be filled out with a filler compound 33. This results in a flat outer surface of the partition wall 1.

(14) In FIGS. 3 to 5 a carrier profile 22 is shown in greater detail.

(15) As can be seen in particular from the cross-sectional view in FIG. 5, the two limb sections 22b and 22b respectively are connected in each case by a curved section 22c to the base section 22a. The carrier profile 22 further exhibits a tilt inclination 22d, which is likewise connected by a curved section 22c to the free end of the respective limb section 22b and 22b respectively. The carrier profile 22 therefore exhibits an essential C-shaped design.

(16) In the embodiment shown, the entire surface of the carrier profile 22 is provided with embossing of regularly distributed elevations and depressions. In FIG. 4 these are shown in an enlarged representation. The embossing is in this situation applied from both sides, such that the elevations and depressions are arranged offset to one another on two large surfaces of the carrier profile 22.

(17) The carrier profile 22 further exhibits a beading 22e in the base section 22a. This beading 22e is arranged in the middle in the base section 22a. In addition, the carrier profile 22 in each limb section 22b and 22b respectively comprises a beading 22f which is likewise arranged in the middle.

(18) In the embodiment shown, a limb length L.sub.1 of a limb section 22b is dimensioned at 48.5 mm. A limb length L.sub.2 of the other limb section 22b, by contrast, exhibits a dimension of 47 mm. Due to these differently dimensioned limb lengths of the limb sections 22b and 22b respectively, two such carrier profiles 22 fit inside one another for transport, as a result of which transport volume is saved.

(19) A base length L.sub.3 of the base section 22a exhibits in this case a dimension of 48.8 mm. An inclination dimension L.sub.4 of the inclinations 22d is in each case dimensioned at 6 mm. A radius R.sub.1 of the curved section 22c in the embodiment shown here exhibits in each case a value of 4 mm. This is the outer radius of the curved section 22c between the base section 22a and the respective limb section 22b and 22b respectively and a limb section 22b and 22b respectively, and the tilting inclination 22d allocated in each case.

(20) The beading 22e in the base section 22a exhibits in this case a depth T.sub.1 of 2.5 mm. The beading 22e has in this situation an essentially triangular-shaped cross-section, wherein the flanks of this extend opposite the base section 22a at an angle of 135. The angle enclosed by the triangular formation of the beading 22e accordingly amounts to 90. The flanks of the beading 22e are additionally tilted with a radius R.sub.2 of 1 mm from the base section 22a. A width B.sub.1 of the beading 22e in the base section 22a has a dimension of 4.7 mm.

(21) The beading 22f, which in each case is formed in the middle in the limb section 22b and 22b respectively, exhibits a width B.sub.2 of 3.5 mm. This is in each case formed less deep than the beading 22e in the base section 22a.

(22) The beadings 22e and 22f in this situation project in the manner shown in FIG. 5 towards the inner side of the profile cross-section of the carrier profile 22.

(23) The carrier profile 22 shown in FIG. 5 corresponds to what is referred to as a CW50 profile. In this situation, carrier profiles with other standard dimensions are usual, wherein the difference relates in particular to the base length L.sub.3. With a profile CW75, for example, this can have a dimension of 73.8 mm, with a profile CW100 a dimension of 98.8 mm, with a profile CW125 a dimension of 123.8 mm, and with a profile CW150 a dimension of 148.8 mm.

(24) As can be seen in particular from FIG. 4, the embossing also extends over the curved sections 22c and, despite the bending process, continues to be embossed there. This is particularly associated with the fact that the distance interval between two adjacent elevations of the embossing is relatively small in comparison with the radius R.sub.1 of the curved section 22c. In the embodiment shown, the centre-to-centre distance between two adjacent elevations is 2.7 mm. With the rated sheet thicknesses in the embodiment shown, i.e. the thickness of the unfinished sheet before the embossing step, of 0.6 mm, a factor of 4.5 is derived, i.e. the centre-to-centre distance between two adjacent elevations of the embossing is 4.5 times the rated sheet thickness.

(25) A total thickness D of the profiled sheet material of the carrier profile 22 in the embodiment shown is about 1 mm.

(26) In FIGS. 6 and 7, by way of illustration, a section from the surface of a suitable embossing roller 7 is shown. As can be seen from this, embossing teeth 8 essentially exhibit the shape of a truncated pyramid. The embossing teeth 8 in this situation exhibit a width P.sub.1 of the base, which in the embodiment shown amounts to 2.20 mm. A width P.sub.2 of the embossing teeth level at the upper end of the truncated pyramid is dimensioned here at 0.20 mm. A distance interval A between two embossing teeth 8 is 2.70 mm, from which is derived on the embossed surface of the carrier profile 22 the centre-to-centre distance referred to heretofore, with a dimension of 2.70 mm. A height H of an embossing tooth 8 is dimensioned here at 1.00 mm. A flank angle of the embossing tooth 8 in the embodiment shown is 90.

(27) The embossing teeth 8, of which, for easier overview, only one single tooth is shown in FIGS. 6 and 7 respectively, are arranged regularly on the surface of the embossing roller 7, and therefore create regularly distributed indentations in the carrier profile 22. In this situation, for the embossing of the carrier profile 22, two such embossing rollers 7 with a slight gap between them are moved in counter-rotation to each other in such a way that the sheet material is drawn between them and subjected to an essentially full-surface press-embossing. As a result, not only is the simultaneous formation of elevations and indentations of the embossing achieved, but also that a part of the surface of the sheet material which is not subjected directly to the embossing teeth 8 continues to remain parallel to the original orientation of the non-embossed material. The embossing process used in the course of the present invention corresponds essentially to the method derived from WO 94/12294 A1.

(28) Practical tests with partition walls 1 according to the invention have revealed that insulation values can be achieved which are better than the prior art. For example, with the use of a profile in the design according to FIG. 5, but with a base length L.sub.3 of 73.8 mm, i.e. a CW75 profile, with a rated sheet thickness of 0.6 mm and a centre-to-centre distance of 2.7 mm, in each case with a beading 22e and 22f arranged in the middle and a cladding made of RB panels of Rigips with a weight per unit area of approx. 8.7 kg/m.sup.2 with a thickness of 12.5 mm of the cladding, a calculated value RWJR for the sound insulation of 43 dB is achieved. If a double facing is used, i.e. a two-layer cladding 3 on both sides of the partition wall 1, and otherwise the same structure, a calculated value R.sub.W,R for the sound insulation of 54 dB is even achieved.

(29) A partition wall 1 designed according to the invention therefore exhibits excellent sound insulation properties.

(30) The invention also allows for further design formulations in addition to the embodiment explained.

(31) For example, the centre-to-centre distance between two adjacent elevations of the embossing on one side of the sheet material is not restricted to the value referred to heretofore of 2.70 mm. Rather, it can lie in particular in the range between three times and six times the rated sheet thickness without any substantial deterioration with regard to the sound insulation effect being anticipated.

(32) Moreover, the outer radius of the curved section need not necessarily amount to 4 mm, as in the embodiment shown. As has been shown, a radius here of between three times and ten times the rated sheet thickness is, as a rule, suitable for achieving good sound insulation properties.

(33) As well as this, it is not necessary for the base section 22a to comprise only one single beading 22e running longitudinally. In a number of exemplary embodiments, such as, in particular, with the use of a U-shaped profile, two or more beadings may also be provided in the base section 22a.

(34) It is accordingly not necessary for the inclinations 22d to be provided in the carrier profile 22. This then exhibits the essentially U-shaped form referred to heretofore.

(35) The total thickness of the profiled carrier profile 22 does not necessarily amount to 1 mm, as in the embodiment shown. In particular, with the use of a U-shaped profile, a total thickness of, for example 0.8 mm, can be sufficient in this situation. In general it has been shown that this total thickness should exhibit between 1.2 times and three times the rated sheet thickness.

(36) In simplified embodiments, it is also possible to do without the beading in the base section and/or in the two limb sections.

(37) The dimensions of the beadings can additionally vary from those illustrated. They may be identical, or, as shown in FIG. 5, they may exhibit different dimensions. In general, a depth of the beading of between one to six times the rated sheet thickness has proved favourable.

(38) The cross-section formation and the width or a possible interior angle at the apex of the respective beading can be adjusted in a suitable manner to the respective application situation. In particular, it is therefore possible for the beading to be designed not as triangular but as a semi-circle.

(39) In addition, it is not absolutely necessary for the die embossing in the carrier profiles 22 to be introduced on both sides. In a simplified embodiment, it would also be possible for the embossing to be applied only on one side, for example in the form of knurling.

(40) As well as this, the embossing need not necessarily be formed as full-surface on the carrier profile. For example, it is possible for a structuring of the surface of the inclinations to be done without.

(41) Moreover, the regular structure of the embossing can also lead to a repeating pattern being embossed.

(42) As cladding 3, as well as the RB gypsum plasterboard panels referred to, use may also be made, for example, of a Duraline panel, exhibiting a weight per unit area of approx. 13 kg/m.sup.2 at a thickness of 12.5 mm. This allows for the sound insulation effect to be again perceptibly improved.

(43) Alternatively, for the cladding 3, other construction panels can be used, such as, for example, wood fibre panels etc.

(44) The insulation layer 4 can also be formed from a material other than mineral wool. Fibre insulation materials of other kinds may be used, or also foamed plastics, etc.

(45) With the system according to the invention, not only can partition walls 1 be produced, but also other dry construction elements, such as, in particular, suspended ceilings or the like. In this case, the cladding 3 is done away with on one side. Such suspended ceilings are used not only in the horizontal ceiling region, but also on roof pitches or the like.