RESILIENT WALLBOARD MOUNTING CHANNEL ACCOMMODATING STANDARD FASTENERS

Abstract

An improved resilient wallboard channel constructed and arranged for attachment to a surface of a framing member and accommodating standard fasteners. Included on the present channel is a first, generally planar surface having an elongate edge, an inclined web disposed along the elongate edge and projecting at an oblique angle relative to the first surface, a web edge of the inclined web opposite the first surface is shared with a second, generally planar surface, a stop flange, which is shorter than the inclined web, projects from a stop flange edge of the second surface opposite the inclined web, and the first surface and the web edge are separated by at least -inch measured normally from the framing member surface.

Claims

1-3. (canceled)

4. (canceled)

5-7. (canceled)

8. A resilient wallboard support channel constructed and arranged for attachment to a surface of a framing member and for holding a wallboard panel suspended away from the framing member, comprising: a first, generally planar surface having an elongate edge, and an opposite free edge which is folded over; an inclined web disposed along said elongate edge and projecting at an obtuse angle ranging from 110-115 relative to said first surface, said inclined web is provided with a plurality of linearly spaced cutouts for increasing resiliency when mounted to the frame member; a web edge of said inclined web opposite said first surface is shared with a second, generally planar surface; an arched support rib formed between adjacent edges of said inclined web and said second surface to provide enhanced structural rigidity; a stop flange, which is shorter than said inclined web, projects from a stop flange edge of said second surface opposite said inclined web a distance of at least inch, a second arched support rib spaced from said arched support rib and formed between adjacent edges of said second surface and said stop flange, said stop flange projects from said second surface at an angle of 90-110; and said first surface and said web edge being separated by at least -inch measured normally from the framing member surface, said distance achieved by a length of said inclined web, said channel being constructed and arranged so that sufficient spacing is created between the wallboard panel and the frame so that when an installer uses 1-inch fasteners to install the wallboard panel to said channel, the fasteners will not reach the frame, thus preserving the desired spacing and reducing acoustic transmission from the wallboard panel to the frame.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0013] FIG. 1 is a perspective view of an interior room under construction and employing prior art RC-1 channels;

[0014] FIG. 2 is a front perspective view of the present RC-1 channel;

[0015] FIG. 3 is a front perspective view of an alternate embodiment of the present RC-1 channel;

[0016] FIG. 4 is an end view of the present RC-1 channel; and

[0017] FIG. 5 is a fragmentary perspective view of the present RC-1 channel being installed on a frame member, and a wallboard panel shown attached to the RC-1 channel.

DETAILED DESCRIPTION

[0018] Referring now to FIG. 1, a portion of a room is illustrated, generally designated 10, and includes a pair of walls 12 and 14, each supported by a frame 16 including at least one footer or base 18, at least one header or upper support member 20, and a plurality of vertical members or studs 22 joining the header(s) to the footer(s). As is well known in the art, the studs 22 are placed at a regular spacing such as 16-inch on center, or other spacing depending on the local building code. Also, while the frame 16 is typically made of wooden members, preferably 24 planks, other sizes of lumber, as well as alternate construction techniques are contemplated that employ metal members made of steel or the like, as well as other materials. Ceiling joists 24 are secured to the header(s) 20, and are used to support a roof or an upper floor, depending on the desired height of the building. As is known in the art, the frame 16 is assembled using fasteners such as nails or screws. The footers 18, the headers 20, the studs 22 as well as joists 24 are collectively referred to as frame members or framing members.

[0019] In applications where transmission of sound between rooms is intended to be suppressed, it is common to install RC-1 channel or runners 26 in spaced, parallel orientation directly to the studs 22 or other framing members using suitable fasteners (not shown), so that the channels 26 extend transversely to the framing members. Wallboard panels 28, made of gypsum wallboard or the like, are then secured to the RC-1 channels using conventional fasteners, such as screws, nails or chemical adhesives. Thus, the wallboard panels 28 are held a spaced distance from the frame 16 by the RC-1 channel 26, thus interrupting the path of acoustical transmission from the panels to the frame, and thus reducing room-to-room noise transmission.

[0020] A problem addressed by the present disclosure is that Underwriters' Laboratories (UL) standards, as well as many local building codes, specify that 1-inch long fasteners are used to install the panels 28 to the frame 16. However, since 1-inch fasteners are not a common inventory item on building sites, and many installers believe that such fasteners are unsuitable for a positive attachment of the panels 28 to the frame 16, installers typically use 1-inch screws when installing the wallboard panels 28 to the RC-1 channel. Unfortunately, the 1-inch fasteners are long enough to pass through the wallboard panel 28, the RC-1 channel 26 and even reach the frame 16, thus acoustically connecting the wallboard panel to the frame, and significantly reducing or negating the sound-reducing properties of the channel 26.

[0021] Referring now to FIGS. 2-5, to address this problem, an improved RC-1 channel is provided, and generally designated 40. A main feature of the present channel 40 is that it is constructed and arranged to create sufficient spacing between the wallboard panel 28 and the frame 16 so that even if the installer uses 1-inch fasteners to install the channel, they will not reach the frame, thus preserving the spacing for enhanced reduction of sound transmitted from the room 10.

[0022] Included in the present RC-1 channel 40 is a first, generally planar surface 42 having an elongate edge 44, and an opposite free edge 46. An inclined web or wall 48 is disposed along the elongate edge 44 and projects at an oblique angle relative to the first surface 42. In the preferred embodiment, the angle is obtuse, and it is further preferred that the angle is approximately 110-115. A web edge 50 of the inclined web 48 opposite the first surface 42 is shared with a complementary edge of a second, generally planar surface 52. An important feature of the inclined web 48 is that it is dimensioned to separate the web edge 50, which contacts the wallboard panel 28 (FIG. 5), from the frame 16 a distance D of at least -inch measured normally from a surface 54 of the frame 16, preferably the stud 22 or other framing member, so that even if relatively longer 1-inch fasteners 56 are used to secure the wallboard panel 28 to the RC-1 channel, they will not contact the frame, as seen in FIG. 5. In other words, tips of the fasteners 56 will not reach the respective member, such as the stud 22 or other framing member of the frame 16. In this manner, the acoustical separation, discussed above as an important factor in installing RC-1 channels, is preserved when the system is installed using the longer fasteners.

[0023] A stop flange edge 58 is located on the second planar surface 52 and is generally horizontally aligned with the web edge 50. Also, the stop flange edge 58 is located at an intersection of adjacent or complementary edges of a stop flange 60 and the second planar surface 52, and forms the base from which projects the stop flange, which is shorter than the inclined web 48, and projects from the second surface 52 opposite the inclined web 50.

[0024] Referring now to FIGS. 2-4, the support channel 40 is preferably produced by roll forming and stamping the entire structure from a strip of steel, preferably galvanized or otherwise corrosion-protected as is well known in the art, which is then formed into the shape as illustrated. During the manufacturing process, the inclined web 48 is preferably provided with a plurality of linearly spaced cutouts 62 for increasing resiliency when mounted to the vertical frame member 22. As is seen in FIGS. 2 and 3, the shape of the cutouts 62 may vary to suit the application, but is contemplated as being circular, oval, ovoid, elongate slot, or the like. In addition, enhanced structural rigidity is provided to the channel 40 by preferably forming arched support ribs 64 at the web edge 50 as well as the stop flange edge 56, however fewer ribs are contemplated depending on the application.

[0025] As seen in FIG. 4, the stop flange 58 projects from the second planar surface 52 at an angle which is similar to an angle defined between the second planar surface and the inclined web 48. In the preferred embodiment, the angle is approximately 90-110, however variations are contemplated. To further enhance the strength of the support channel 40, the free edge 46 is folded over upon itself. Also, as best seen in FIGS. 2, 3 and 5, the first planar surface 42 is preferably provided with linearly spaced mounting apertures 66 used to secure the RC-1 channel 40 to the frame 16. It is also preferred that the stop flange 60 extends a distance E in FIG. 4 at least -inch from the stop flange edge 58 to prevent bending of the channel 40 relative to the frame member so that the fastener can more easily penetrate the channel. However other dimensions are contemplated depending on the application.

[0026] While a particular embodiment of the present resilient wallboard channel accommodating standard fasteners has been described herein, it will be appreciated by those skilled in the art that changes and modifications may be made thereto without departing from the invention in its broader aspects and as set forth in the following claims.