GYPSUM STUDS ASSEMBLED BY ROLLING SCORED SEGMENTS

Abstract

A gypsum stud is provided, including a gypsum wallboard panel having first and second facing sheets sandwiching a core therebetween, a series of cuts formed on at least one of the first and second facing sheets and extending into the core, retaining intact an opposing one of said first and second facing sheets to form a hinge point, the panel being rolled from a first side to a second side into a rolled condition so that a rolled up stud is formed.

Description

BACKGROUND

The present invention relates generally to the construction of interior walls involving the attachment of gypsum wallboard panels to wood or metal framing elements, and more specifically to improved techniques implemented to enhance desired sound transmission through such walls.

Conventional interior walls are often constructed by attaching gypsum wallboard panels to framing members made of wood or U-shaped steel. The frames include horizontally positioned header (top track) and footer (bottom track) members, respectively secured to the ceiling and floor. Vertically positioned stud members are secured between the headers and footers using fasteners as is well known in the art. Spaces between opposing wallboard panels and also between respective vertical stud members are optionally filled with bats of insulation.

For US-based customers, there is an expectation by customers that the interior wall needs to be sufficiently sturdy to define the room circumscribed by the walls, and that the wall will support shelving or wall hangings as needed to satisfy the customer's decorating preferences.

Another factor that US-based customers focus on when evaluating interior wall construction is the sound transmission of the wall. In other words, how quiet is the room defined by the interior walls when the doors are closed? An important property of interior walls is the ability of the wall to isolate the individuals within a room defined by the walls from outside noise.

In technical terms, the sound transmission property of an interior wall is quantified by what is known in the industry as an STC value. STC values for interior wall assemblies made of single sheets of ⅝-inch wallboard secured to metal studs range from 38-40 without insulation and 43-44 with insulation in the form of fiberglass bats or the like. Walls made with metal studs have higher (quieter) STC ratings than walls made with wooden studs. Sound rated floors are typically evaluated by ASTM Standard E492 and are rated as to impact insulation class (IIC). The greater the IIC rating, the less impact noise will be transmitted to the area below. Floors may also be rated as to Sound Transmission Class (STC) per ASTM E90. As is the case with wall assemblies, the greater the STC rating, the less airborne sound will be transmitted to the area below. Sound rated floors typically are specified to have an IIC rating of not less than 50 and an STC rating of not less than 50.

It is commonplace for customers of residential or commercial construction in Mexico to focus on the stability of the interior construction in a different way compared with US customers. In Mexico, the focus is more on the solid feel of the interior wall, rather than on the resulting quiet character of the room. Mexican customers are more focused on obtaining sturdy interior walls, and consider structural sturdiness more significant than the sound absorbing qualities. To this end, customers in Mexico often knock on the wall with their knuckles to obtain a sense of the solidity of the relevant wall, with a muffled, solid sound upon knocking being more favorable to a hollow sound.

Accordingly, there is a need for an interior wall construction system that provides acoustical properties that are acceptable to both US and Mexican customers.

SUMMARY

The above-listed need is met or exceeded by the present building framing stud fabricated from a gypsum wallboard panel that replaces conventional wood or metal studs. During assembly, the panel is scored on at least one face to have a plurality of parallel score cut lines defining segments. A spacing between the score lines determines the width of the segment. In the present panel, the score lines are spaced so that the panel is rolled from an outer edge, which forms a central core, and following segments are dimensioned so that upon completion of the rolling process, a solid roll of interconnected segments is formed. Adhesive is applied as needed during the rolling process to hold the respective segments together. In a preferred embodiment, a thickness of the rolled-up gypsum stud is in the range of 2.5 inches (6.35 cm), or the width of a track of a top or bottom track.

In an embodiment, the score lines were created by forming 90° V-cuts or score cuts in the conventional wallboard panel, preferably on the “back” or craft paper face, as opposed to the “front” or finished face. The cuts extend into the board, penetrating and extending through the back face and the core, but leave the face paper intact to enable folding/rolling up. Segments measured in order from the outer edge: 1″ (2.5 cm), 1″ (2.5 cm), 1.5″ (3.8 cm), 1.5″ (3.8 cm), 2.0″ (5.0 cm), 2.0″ (5.0 cm), 2½″ (6.35 cm), 2½″ (6.35 cm), and 2½″ (6.35 cm). Rolling begins at the 1″ edge so that the final, solid rolled stud has a width of 2½″ (6.35 cm).

In an alternate embodiment, a gypsum rolled stud is formed in two main pieces. The first piece is a small, square-shaped insert stud made of rolled gypsum that fits into a central or axial opening of a larger stud tube also made of rolled, scored gypsum. In an embodiment, the smaller, insert stud is formed from four segments measuring 1.5″ (3.8 cm). Linear 90° V-cuts or score cuts are formed in the back face as in the first embodiment. The outer tube is formed by segments formed by 90° V-cuts or score cuts in the back face of the panel and having dimensions of 2.5″ (6.35 cm). The insert tube is inserted into the central axial opening of the larger stud tube. Adhesive is applied as needed to secure the rolled up components in their designated shapes, both the outer tube and the insert tube and the assembled stud.

In still another embodiment, multiple components, meaning outer tubes and smaller insert studs are made from a standard 4 foot×8 foot gypsum wallboard panel. Linear score cuts are made on both the back face and the front or finished face. In some cases, the score cuts are formed through the entire panel. In a preferred embodiment, to create the desired gypsum stud components, the score cut lines are formed in both faces of the panel, so that a clean separation is achieved.

In the present application, the terms linear cuts, score cuts, cuts are considered interchangeable and refer to cuts made in a wallboard panel from one end to another in a linear fashion to form a stud of sufficient height to be suitable for wall construction. Also, while certain dimensions are provided for preferred applications, it will be understood that dimensions of particular components of the present stud may vary to suit the application, and the particular cuts may alternately be provided on one or the other of the panel facing sheet. Further, while certain sequences of dimensions of stud segments are provided re a direction of rolling, it will also be understood that the direction of rolling may vary to suit the application.

More specifically, a gypsum stud is provided, including a gypsum wallboard panel having first and second facing sheets sandwiching a core therebetween, a series of cuts formed on at least one of the first and second facing sheets and extending into the core, retaining intact an opposing one of said first and second facing sheets to form a hinge point, the panel being rolled from a first side to a second side into a rolled condition so that a rolled up stud is formed.

In an embodiment, a layer of adhesive is applied to at least one of the first and second facing sheets so that the panel is held in the rolled condition. In an embodiment, the cuts are 90° cuts, and preferably the cuts extend vertically up to but not into the opposite facing sheet from where they begin. In an embodiment, the cuts are made in the following sequence: 1″ (2.5 cm), 1″ (2.5 cm), 1.5″ (3.81 cm), 1.5″ (3.81 cm), 2.0″ (5.0 cm), 2.0″ (5.0 cm), 2½″ (6.35 cm), 2½″ (6.35 cm), 2½″ (6.35 cm). In the previous embodiment, the rolling preferably begins at the 1″ end so that the resulting stud has a width of 2½″ (6.35 cm).

In another embodiment, the wallboard panel is a full-size, standard panel, and said cuts are made into the first and second facing sheets in a specialized pattern to form multiple wallboard studs. In such an embodiment, the cuts are preferably made in multiple groups of the following sequence: 3.8 (1.5 in.), 6.9 (2.7 in.), 3.8 (1.5 in.), 6.9 (2.7 in.), 6.4 (2.5 in.), 6.4 (2.5 in.), 6.4 (2.5 in). In such an embodiment, three gypsum studs, including three tubular outer portions and three insert portions are created from the standard wallboard panel.

In an embodiment, the stud is made of two portions, an outer portion defining a central opening, and an insert portion dimensioned to fit within the central opening. In such an embodiment, the insert portion is formed by creating the cuts in an alternating fashion on the first and second facing sheets.

In still another embodiment, a method of making a gypsum stud is provided, including, providing a gypsum wallboard panel having first and second facing sheets sandwiching a core therebetween; generating a series of cuts formed on at least one of the first and second facing sheets and extending into a core located between the sheets, retaining intact an opposing one of the first and second facing sheets to form a hinge point; and rolling the panel from a first side to a second side into a rolled condition so that a rolled up stud is formed.

In an embodiment, a first spacing of the cuts on the first facing sheet is different from a second spacing of the cuts on the second facing sheet. In an embodiment, the method includes generating the series of cuts to form a first outer portion defining a central opening, and generating the series of cuts to form a second, insert portion dimensioned to fit inside the opening.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top view of the present rolled gypsum stud;

FIG. 2 is a vertical cross-section of a gypsum panel scored to obtain the rolled gypsum stud of FIG. 1;

FIG. 3 is a top view of an alternate embodiment of the rolled gypsum stud of FIG. 1;

FIG. 4 is a vertical cross-section of a gypsum panel scored to obtain the rolled gypsum stud of FIG. 3;

FIG. 5 is a top view of another alternate embodiment of the present rolled gypsum stud;

FIG. 6 is a partial exploded view of the rolled gypsum stud of FIG. 5;

FIG. 7 is a vertical cross-section of the components of the rolled gypsum stud of FIG. 6;

FIG. 8 is a top view of still another alternate embodiment of the present rolled stud;

FIG. 9 is a vertical cross-section of a standard gypsum wallboard panel scored to produce multiple studs of the embodiment of FIG. 8 in a single foldable piece;

FIG. 10 is a vertical cross-section of a standard gypsum wallboard panel scored to produce multiple studs of the embodiment of FIGS. 8 and 11; and

FIG. 11 is an exploded view of the present rolled stud of FIG. 8.

DETAILED DESCRIPTION

Referring now to FIGS. 1 and 2, a first embodiment of the present rolled gypsum stud is generally designated 10. The stud 10 is formed from a standard gypsum wallboard panel 12, or a portion of such a panel. Included on the panel is a first facing sheet 14, commonly referred to as the face paper which is finished upon installation in a room, a second facing sheet 16, commonly referred to as the backing paper, which is made of a relatively coarser grade of paper, and a set gypsum core 18 sandwiched between the facing sheets 14, 16 as a unit as is well known in the art. It is contemplated that the thickness of the panel 12 may vary with the application, but standard thicknesses are 0.5 inch (1.27 cm) or ⅝ inch (1.58 cm). Also, a full or standard sized panel 12 has a dimension of 4 feet (1.22M)×8 feet (2.44 M). It is also contemplated that the present stud 10 is made either from standard panels, or segments of such panels, also referred to as dunnage.

Generally, the present gypsum stud 10 is formed in a first embodiment by creating a series of cuts 20, preferably 90° V-shaped cuts, also referred to as score cuts or linear cuts, on at least one of the first and second facing sheets 14, 16 and extending into the core 18, up to and retaining intact an opposing one of the first and second facing sheets (at the end opposite the direction of the cut) to form a hinge point. Thus, the uncut facing sheet 14, 16 enables the panel to be held together and creates a hinge or folding point. It will be understood that the cuts 20 extend a full length of the wallboard panel 12, to provide the resulting stud 10 having a height suitable for use in building frame construction.

Upon forming the cuts 20, the panel is then rolled from a first side to a second side, or in from a first direction to a second direction, so that the panel is folded upon itself by hinge action at the cuts. The resulting rolled stud 10 is useful for wall construction between opposing wallboard panels, and has a preferred width of 2.5 inches (6.3 cm). This dimension also is configured to suitably fit within a channel formed by conventional steel frame members forming top and bottom tracks in a wall frame.

Referring now to FIG. 2, the panel 12 is shown with the cuts marked 20A, 20B, 20C, 20D, 20E, 20F, 20G and 20H. As described above, the cuts 20 are preferably 90° V-shaped, which provides a series of right angle folds upon rolling. Note that the cuts 20A-20H do not extend into the first facing sheet 14. Once the cuts 20A-20H are made, a plurality of segments 22, designated 22A-221 are defined, having axial lengths when viewed from right to left in FIG. 2 of: 1″ (2.5 cm), 1″ (2.5 cm), 1.5″ (3.8 cm), 1.5″ (3.8 cm), 2.0″ (5.0 cm), 2.0″ (5.0 cm), 2½″ (6.3 cm), 2½″ (6.3 cm), and 2½″ (6.3 cm). Preferably a layer of chemical adhesive 24 is applied to the segments on at least one of the first and second facing sheets 14, 16 to retain the panel 12 in the rolled up condition. To assemble the gypsum stud 10, the panel in FIG. 2 is rolled from right to left, or smallest segment to largest. Upon assembly, the stud 10 has the appearance as seen in FIG. 1.

Referring now to FIGS. 3 and 4, a modified version of the present gypsum stud is generally designated 30. Features shared with the stud 10 are designated with identical reference numbers. A main difference of the stud 30 is that it has a rectangular profile of 2.0 inches (5.0 cm)×2.5 inches (6.3 cm), while the stud 10 has a profile of 2.5″ (6.3 cm)×2.5″ (6.3 cm) square. Cuts 20A-20G are made as before, while the segments 32A-321 measure 1″ (2.5 cm), 1″ (2.5 cm), 1.5″ (3.8 cm), 1.5″ (3.8 cm), 2.0″ (5.0 cm), 2.0″ (5.0 cm), 2.5″ (6.3 cm) and 2.0″ (5.0 cm). Adhesive 24 is applied as before, and the direction of rolling is right to left, or starting with the smallest segment to the largest. Upon rolling the stud 30, it has the appearance shown in FIG. 3.

Referring now to FIGS. 5-7, another modified version of the present gypsum stud is generally designated 40. Components shared with the studs 10 and 30 are designated with identical reference numbers. A main feature of the stud 40 it is made of two portions, an outer portion 42 defining a central opening 44, preferably polygonal in shape, and an insert portion 46 dimensioned to fit matingly within the central opening. Both the outer portion 42 and the insert portion 46 are constructed by folding segments of the gypsum panel 12. Preferably, the outer portion 42 has a square shape with 2.5 inch (6.3 cm) sides 48, and the insert portion 46 is also square, having 1.5 inch (3.8 cm) sides 50. As seen in FIG. 6, the insert portion 46 also has an opening 52.

Referring now to FIG. 7, the panels 12 used to make the stud 40 are shown in the cutting position. 90° V-cuts 54A-54C are formed in the panel 12 forming the outer portion 42, and define segments 56A-56D of 2.5 inches long. Also, 90° V-cuts 58A-58C in the panel 12 forming the insert portion 46 define segments 60 A-D of 1.5 inches long. It will be seen that in the studs 10, 30 and 40, the cuts 20, 54 and 58 are all made in the same direction, and the first facing sheet 14 defines the hinge or folding point, which is not cut. Depending on the application, the second facing sheet 16 optionally defines the hinge or folding point. Unlike the other embodiments, in this case since the segments 56, 60 are all the same length, the rolling can start in either direction. Also, as needed, the adhesive 24 is applied. Upon completion of the rolling, the outer portion 42 and the insert portion 46 have the appearance shown in FIG. 6. Then, as assembled, with the insert portion 46 inserted into the outer portion 42, the completed stud 40 is shown in FIG. 5.

Referring now to FIGS. 8 and 11, an alternate embodiment to the stud 40 is generally designated 70. Components shared with the previous embodiments 10, 30, and 40 are designated with identical reference numbers. Both studs 40 and 70 are made of two components, an insert portion 46, 72 and an outer portion 42, 74. A main difference between the embodiments 40 and 70 is that the latter adopts a distinctive cut and folding pattern such that the insert portion 72 lacks the opening 52. In addition, the insert portion 72 is created using a “zig-zag” cutting pattern using cuts 20 alternating on both first and second facing sheets 14, 16. Also, the outer portion 74 is formed with cuts on only one facing sheet 14 or 16, but the segments 76 A-D alternating between 1.5″ (3.8 cm) and 2.7″ (6.9 cm) are formed by folding backwards so that the facing sheet closest to the cut is facing outward. As in the other embodiments, adhesive 24 is applied as needed to maintain the folded shape.

In a preferred embodiment, the insert portion 72 has segments 78A-C of 2.5″ (6.4 cm) formed by cuts 80 A-C (FIG. 9) alternating on the first and second facing sheets 14, 16. Upon assembly, it is inserted into the central opening 44 of the outer portion 74. Adhesive 24 is applied as needed to maintain the desired shapes. The entire length (as opposed to the height, which is equal to wall frame height) of the stud 70 is 3.7″ (9.4 cm).

Referring now to FIGS. 9 and 10, another feature of the present rolled stud 10, 40, 70 is that multiple studs are optionally manufactured from a single standard wallboard panel 12 dimensioned at 4′×8′ (128 cm×244 cm) depending on the arrangement of the cuts 20. The cuts 20R located adjacent both the first and second facing sheets 14, 16 mark a full cut or cleave through the panel 12, defining three studs 70. Moving from left to right, the insert segments 78A-C are rolled first, with the zig-zag cuts 80A-C forming the stacked orientation seen in FIG. 8. Then, as rolling progresses, the outer portion 74 is formed. The segments 76A-D and 78 A-C are thus made in multiple groups of the following sequence: 3.8 (1.5 in.), 6.9 (2.7 in.), 3.8 (1.5 in.), 6.9 (2.7 in.), 6.4 (2.5 in.), 6.4 (2.5 in.), 6.4 (2.5 in.).

In FIG. 9, each stud 70 of the three studs formed from the panel 12 is formed in a single piece, with the insert portion 72 joined to the outer portion 74. In FIG. 10, each of the three studs 70 are created in two pieces, with cuts 20 S cleaving the insert portion 72 from the outer portion 74.

While particular embodiments of the present gypsum studs assembled by rolling scored segments have 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.

Claims

1. A gypsum stud, comprising: a gypsum wallboard panel having first and second facing sheets sandwiching a core therebetween;a series of cuts formed on at least one of said first and second facing sheets and extending into a core located between said sheets, retaining intact an opposing one of said first and second facing sheets to form a hinge point;said panel being rolled from a first side to a second side into a rolled condition so that a rolled up stud is formed.

2. The gypsum stud of claim 1 further including a layer of adhesive applied to at least one of said first and second facing sheets so that said panel is held in said rolled condition.

3. The gypsum stud of claim 1, wherein said cuts are 90° cuts.

4. The gypsum stud of claim 3, wherein said cuts extend up to the opposite facing sheet from where they begin.

5. The gypsum stud of claim 1, wherein said cuts are made in the following sequence: 1″ (2.5 cm), 1″ (2.5 cm), 1.5″ (3.8 cm), 1.5″ (3.8 cm), 2.0″ (5.0 cm), 2.0″ (5.0 cm), 2½″ (6.35 cm), 2½″ (6.35 cm), and 2½″ (6.35 cm).

6. The gypsum stud of claim 5, where the rolling begins at the 1″ end so that the resulting stud has a width of 2½″.

7. The gypsum stud of claim 1, wherein said cuts are made in multiple groups of the following sequence: 3.8 (1.5 in.), 6.9 (2.7 in.), 3.8 (1.5 in.), 6.9 (2.7 in.), 6.4 (2.5 in.), 6.4 (2.5 in.), 6.4 (2.5 in.).

8. The gypsum stud of claim 1, wherein said gypsum wallboard panel is a full-size, standard panel, and said cuts are made into said first and second facing sheets to form multiple wallboard studs.

9. The gypsum stud of claim 8, wherein said cuts are made in multiple groups of the following sequence: 3.8 (1.5 in.), 6.9 (2.7 in.), 3.8 (1.5 in.), 6.9 (2.7 in.), 6.4 (2.5 in.), 6.4 (2.5 in.), 6.4 (2.5 in.).

10. The gypsum stud of claim 8, wherein three said gypsum studs, including three tubular outer portions and three insert portions are created from said panel.

11. The gypsum stud of claim 1, wherein said stud is made of two portions, an outer portion defining a central opening, and an insert portion dimensioned to fit within said central opening.

12. The gypsum stud of claim 10, wherein said insert portion is formed by creating said cuts in an alternating fashion on said first and second facing sheets.

13. A method of making a gypsum stud, comprising: providing a gypsum wallboard panel having first and second facing sheets sandwiching a core therebetween;generating a series of cuts formed on at least one of said first and second facing sheets and extending into a core located between said sheets, retaining intact an opposing one of said first and second facing sheets to form a hinge point;rolling said panel from a first side to a second side into a rolled condition so that a rolled up stud is formed.

14. The method of claim 13, wherein a first spacing of said cuts on said first facing sheet is different from a second spacing of said cuts on said second facing sheet.

15. The method of claim 13, further including generating said series of cuts to form a first outer portion defining a central opening, and generating said series of cuts to form a second, insert portion dimensioned to fit inside said opening.