Patent Grant
8136320
The present invention relates to building constructions and acoustic control therein. More specifically, the present invention relates to a spacer assembly adapted to prevent an acoustic short circuit in a building ceiling, floor or wall assembly.
Acoustic short circuits are a commonly-encountered problem in buildings resulting from faulty construction practices. Short circuiting refers to the situation where building structural elements become linked, often through a fastener (e.g., a screw), in such a manner that vibrational energy, particularly sound energy, affecting one of the structural elements is transmitted to the linked structure. Vibrations are typically manifested as noise, especially low-frequency noise. The effects of acoustic short circuiting are extremely noticeable and objectionable in multi-unit buildings, such as condominiums, apartment buildings, and the like where people are present near others or near electrical or mechanical equipment. For example, if two units of the multi-unit building, such as a first dwelling area and a second dwelling area located immediately above the first dwelling area, are short circuited, vibrations generated in the first area are transmitted to the second area as noise or other sounds, thereby disturbing the enjoyment of the second area.
Acoustic short circuiting often occurs in flooring assemblies. As is known, a flooring assembly typically includes a plurality of horizontally extending, parallel placed joists that provide support for the building itself and for an intermediate substrate for other features of the flooring assembly. The joists provide a structural substrate for installation of finished flooring elements, i.e., a subfloor, finished flooring and related components, to thereby complete the flooring of a first building unit and/or room. The joists also provide a substrate for installation of ceiling elements to thereby complete the ceiling of a unit and/or room disposed below the first unit and/or room. With regard to the ceiling elements, one or more support elements are fastened to the bottoms of the joists. The support elements may include channels and are typically elongate, horizontally extending and placed on the bottoms of the joists perpendicularly thereto. The supporting elements provide a supporting structure or substrate for installation of finished ceiling or wall elements, such as gypsum board, also known as dry wall. In practice, fasteners, typically screws, are passed through the gypsum board into the supporting elements, thereby completing installation of the ceiling, flooring or wall assemblies.
By error, the fasteners used to secure gypsum board to the supporting elements are often driven into the joists. This error physically couples the gypsum board and the supporting element to the joists and results in the creation of an acoustic short circuit that will allow vibrational energy present in the joists to be transmitted to the gypsum board and, ultimately to the unit or room below as sound. Similarly, vibrations can be transmitted horizontally or vertically upward. The transmission of vibrational energy in the form of vibrations or sound can lead to significant discomfort. For example, if individuals reside in a certain unit of a multi-unit dwelling structure that is acoustically short circuited to a second unit through the ceiling, floor or wall, the noise they generate will be readily observable by individuals in the second unit, likely to their displeasure. For contractors and developers, this can also cause building code violations since the national code requires that certain levels of noise control between room units of a building be achieved and maintained.
In one exemplar aspect, the present invention is directed to a spacer assembly for preventing the formation of an acoustical coupling or short circuit between rooms or units through a ceiling, floor or wall assembly having at least one structural member, at least one finished interior element, and at least one support element that includes a U-shaped channel, the support element serving to space the finished interior element from the structural members to achieve acoustic isolation of the structural and finished elements. The spacer assembly generally includes a J-shaped spacer that resists penetration by fasteners and an engagement means adapted for enabling the U-shaped channel support to be operatively associated with and supported by the J-shaped spacer and a structural member engagement means adapted for enabling the spacer assembly to be connected to the structural member.
In another exemplar aspect, the present invention is directed to a building construction having a ceiling, floor or wall assembly that displays improved acoustic characteristics. The assembly generally includes at least one structural member; at least one finished interior element; at least one support element including a generally U-shaped channel disposed between the finished interior element and the structural member; and a penetration resistant spacer disposed at least partially between the channel and the finished interior element. The spacer generally includes a support element engaging means for retaining the support element with respect to the spacer and a structural member engagement means engaging the structural member. The spacer preferably has a hardness suitable for preventing a fastener holding the finished interior element from contacting the structural member.
In yet another exemplar aspect, the present invention is directed to a spacer for preventing the formation of an acoustical short circuit in a building construction ceiling, floor or wall assembly having at least one structural member, at least one finished interior element, and at least one supporting element having a generally: U-shaped channel for spacing the finished interior element from the structural member and preventing fasteners retaining the finished interior element from engaging the structural member. The spacer generally includes an engagement means adapted for enabling the supporting element to be engaged and supported by the spacer; a structural member engagement means adapted for enabling the spacer to be connected to the structural member; and a fastener blocking means adapted for preventing a fastener from passing therethrough, and wherein the fastener blocking means is adapted to be positioned between the structural member and the channel in the supporting element. The fastener blocking means of the spacer is preferably of a dimension suitable for preventing a fastener extending upward from the finished ceiling element from contacting the structural member.
The above and other features and a more thorough understanding of the present invention may be achieved by referring to the following description and claims, taken in conjunction with the accompanying drawings, wherein:
Disclosed is a spacer assembly for preventing an acoustic short circuit in building assembly and uses thereof. Acoustic short circuiting is a commonly encountered problem in building assembly construction that frequently results from imprecise or incorrect installation techniques in the installation of ceiling, floor or wall assemblies. For example, acoustic short circuits are commonly created between a ceiling assembly and a joist structure to which such ceiling is secured. The bottoms of ceiling joists typically are fitted with elongate resilient supporting elements having generally U-shaped channels to which gypsum board for a ceiling is fastened. During installation, the fasteners are driven through the gypsum board and anchored into the supporting elements for securely suspending the gypsum board as a ceiling. The intention is for the fasteners to intersect the U-shaped channel and stop short of the structural member. However, due to human error or the use of fasteners of incorrect length (e.g., any length greater than 1″), the fasteners are often driven through the channel and into the joist located above the channel. If the fastener passes through the gypsum board and into the joist, an acoustic short circuit is created between these two elements and permits the transfer of vibrational energy (e.g., noise, especially low-frequency noise) therebetween. In multi-unit dwellings or offices, the short-circuited joists usually support flooring materials thereon that define a finished floor of an adjacent building unit space. Therefore, noise or vibrations generated in one space adjacent to the location of the acoustic short circuit are transmitted to a second building unit space or spaces which are also adjacent to said short circuit, often to the annoyance and discomfort of the individuals residing or working in the second unit space.
As will be more fully explained hereinafter, the spacer assembly of the present invention prevents the formation of such a short circuit by preventing fasteners from engaging the joists. The spacer is adapted to be associated with the channel in the supporting element and/or joist and suitably eliminates the fastening of the finished interior element directly to the structural element. First, by being disposed between the joist and the ceiling gypsum board, the spacer maintains a fixed distance therebetween. This distance is preferably of a dimension greater than that which could be spanned by the recommended fastener. Second, the spacer is preferably constructed of a material that is impenetrable to a fastener. Accordingly, by being disposed between the ceiling gypsum board and the joist, the spacer provides a physical barrier and prevents the fastener from passing into the joist. These and other aspects of the invention will be more fully described hereinafter.
Turning now to
As best shown in
The joists 202 suitably also provide a substrate for installation of various ceiling elements to bottom portions thereof. As also shown in
Prior to the invention of this application, conventional installation of gypsum board to the bottom of structural joists typically included one or more elongate sheet metal, usually steel, support elements 208 having generally U-shaped channels therein. In the construction trades, the support elements 208 are commonly called “channels” and for the sake of convenience will be referred to as channels hereinafter. The channels 208 are disposed between the ceiling element 204 and perpendicular to the joists 202. The channels 208 are intended to improve the acoustic properties of flooring assemblies 200 by physically separating and acoustically decoupling the finished ceiling, i.e., the gypsum board 204, from the joists 202. By decoupling the gypsum board from the joists, the likelihood of creating an acoustic short circuit therebetween is reduced. However, as mentioned above, unintended installation errors frustrates the intent of using channels 208 when fasteners are driven completely through the channels 208 and into the joists 202. Fasteners passing through the channels into the joists create an acoustic short circuit that is prevented by the present invention.
Channels 208 are typically provided in one of two configurations, a hat channel and a resilient channel. With reference to
Prior to the invention of this application, during installation of the channel 208′, the channel 208′ is typically secured directly to bottom portions of the joists 202 with threaded fasteners, and then the gypsum board 204 is fastened to the channel 208′. More specifically, upper faces of the flanges 212′ are positioned flush against bottom portions of the joists 202 and fasteners are passed through the flanges 212′ and into the joists 202 to secure the channel 208′ to the joists 202. In this configuration, the fastening portion 214′ is spaced apart from the joist 202. Accordingly, gypsum board 204 is then positioned horizontally and flush against the channel 208′ fastening portion 214′, and fasteners are driven through the gypsum board 204 and into the fastening portion 214′, thereby securing the gypsum board 204 to the channel 208′ and, in turn, joist 202.
Turning now to a discussion of the example spacer 100 disclosed according to the present invention, and with best reference to
Turning now to
With best reference to
The corner 110 suitably continues to extend downward away from the spacer 100 arcuately and terminates in the lip 112. The lip 112 is preferably a terminal portion of the channel interface portion 102 that extends generally co-planar with the spacer 100, particularly the extended portion 104 thereof. In this manner, the lip 112 suitably provides a feature that is adapted to underlie the channel 208 flange 212 when disposed in the channel interface portion 102, and suitably also provides a funnel-like effect to facilitate the insertion of the channel 208 flange 212 into the channel interface portion 102. In this regard, the lip 112 may suitably also downwardly flare to increase the funnel-like characteristics of the lip 112.
The channel interface portion 102 suitably also includes the slot 114 into which the channel 208 flange 212 is received. As previously mentioned, the channel interface portion 102 corner 110 suitably extends arcuately from an end of the spacer 100 and curved around into the lip 112. The extension of the corner 110 and lip 112 suitably define the slot 114 that is configured for the channel 208 flange 212.
Turning now to the spacer 100 intermediate portion 108, the intermediate portion 108 is preferably a substantially planar element that extends between the channel interface portion 102 and the extended portion 104. As previously mentioned and as best shown in
The extended portion 104 is preferably a substantially planar member that extends from an edge of the intermediate portion 108 that is opposite the channel interface portion 102. In a preferred configuration, the extended portion 104 is disposed along a plane that is generally parallel to the longitudinal axis of the spacer 100, and extends from the intermediate portion 108 with an initial slight curvature.
The spacer 100 suitably also includes the flange 106. In a preferred embodiment, the flange 106 extends generally perpendicularly from an end of the extended portion 104 that is opposite the intermediate portion 108.
The spacer 100 may suitably include additional features for increasing the grip it exerts on the channel 208. As best shown in
The spacer 100 may be constructed of any material suitable to the aims of the present invention. In a preferred embodiment, the spacer 100 is constructed of sheet steel, such as a 10 AWG to 24 AWG, 0.050″ thick steel sheet that is both structurally sound and impenetrable to a fastener. The use of steel is also advantageous in connection with permitting the spacer 100 to pass a burn test as required by the building construction codes. However, as stated, it is to be appreciated that any suitable material may be employed in the construction of the spacer, such as a polymeric material, a polymeric material featuring a flame-resistant additive, a suitable metal, and the like provided that the necessary penetration resistance is achieved to prevent penetration of fasteners into the joists during installation of the channel.
Despite the foregoing discussion of the structure of the spacer 100, it is to be appreciated that the present invention is not to be construed to the example embodiments discussed and/or illustrated herein. Physically decoupling the channel 208 from the joist 102 is one of the primary objectives and advantages of the present invention, and the spacer 100 may be provided in any suitable configuration capable of achieving this result, such as a substantially planar member adapted to be positioned between the joist 202 and channel 208, a washer-like material so disposed, a rubber material, and the like.
A discussion of installation and positioning of the spacer 100 will now be provided in connection with
Once this preferred configuration is achieved, the assembly of the channel 208 and spacer 100 is fastened to the joist 202. As best shown in
At this point, the channel 208 is prepared to have the gypsum board 204 fastened thereto. Accordingly, the gypsum board 204 is brought flush against the channel 208, and one or more fasteners 222 are driven through the gypsum board 204 and into the channel 208, particularly the fastening portion 214 thereof. It is to be appreciated that the presence of the spacer 100 between the channel 208 and the joist 202 prevents the fastener 222 from extending into the joist 202. First, the extended portion 104 of spacer 100 provides a physical barrier that blocks advance of the fastener 222 and prevents it from extending vertically beyond the spacer 100 and penetrating the joist 202. Second, the spacer 100 also spaces the joist 202 and the channel 208 apart. The increased separation is preferably a distance that the recommended conventional fasteners 222 are incapable of crossing. If the use of improperly long fasteners is attempted, the progress of the fastener will be stopped and the installer will be provided with a visual indication of having used a fastener of an incorrect length.
It is to be appreciated that the presence of the spacer 100 flange 106 provides certain advantages relative to the installation. In one aspect, the presence of the flange 106 ensures proper channel 208 and gypsum board 204 installation. More specifically, the flange 106 suitably prevents the channel 208 angular arm 216 from coming into contact with the joist 202, especially in connection with a resilient channel 208. As the gypsum board 204 is fastened to the channel 208, it applies pressure that tends to bend the channel 208 angular arm 216 upward and into contact with the joist 202. The presence of the spacer 100 flange 106 provides an impediment to the continued bending of the channel 208 angular arm 216 thereby helping to prevent an acoustic short circuit.
Although the invention has been described with regard to certain preferred example embodiments, it is to be understood that the present disclosure has been made by way of example only, and that improvements, changes and modifications in the details of construction and the combination and arrangement of parts may be resorted to without departing from the spirit and scope of the invention. Such improvements, changes and modifications within the skill of the art are intended to be covered by the scope of the appended claims.
| Number | Name | Date | Kind |
|---|---|---|---|
| 2115238 | Stevens | Apr 1938 | A |
| 3067323 | Kember | Dec 1962 | A |
| 5718095 | Kemeny | Feb 1998 | A |
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| 7478787 | Bankston et al. | Jan 2009 | B2 |
| Number | Date | Country | |
|---|---|---|---|
| 20090283658 A1 | Nov 2009 | US |
