Isolated Resilient Channel

Abstract

A resilient channel for joining a board to a support such as a stud, joist or truss in building construction, has a mounting flange and a face flange joined by a web. The mounting flange has a first foot and a second foot disposed at ends of the flange, the first foot bent back toward the support to be disposed between the mounting flange and the support, the second foot bent toward the support, such that the first foot and second foot are disposed to bridge the mounting flange over the support to define a gap between at least a portion of the mounting flange and the support. The face flange has a first bend and a second bend disposed at ends of the flange, and corrugations between the first bend and the second bend.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No. 29/785,098, filed May 24, 2021, and is incorporated herein by reference in its entirety for all purposes.

BACKGROUND OF THE SUBJECT TECHNOLOGY

The subject technology relates to resilient channels. Resilient channels are members used in building construction and framing for attaching wall panels, for example gypsum boards, to wall supports, for example, wooden or metal studs. Additionally, resilient channels are used to attach ceiling panels to ceiling supports such as trusses and/or joists. The subject technology applies to both uses, but for brevity, this disclosure will focus on the wall use-case with gypsum boards.

Resilient channels are installed between studs and gypsum boards to provide a space between the boards and studs and to provide acoustical dampening, thereby attenuating the transmission of sound through the resulting wall.

BRIEF SUMMARY OF THE SUBJECT TECHNOLOGY

A resilient channel for joining boards to studs, joists or trusses in building construction, and thereby provide acoustic attenuation of sound passing through the structure, is further isolated from the studs, joists or trusses by a bridged mounting flange, and is further isolated from the boards by a bridged face flange. The bridged mounting flange is bridged over the studs, joists or trusses by a pair of feet disposed at opposite ends of the mounting flange and connected by respective bends to the flange. The bridged face flange is bridged over the board by bends disposed at opposite ends of the face flange and/or by corrugations formed in the face flange. Due to the bridged structures of the mounting flange and face flange, the area of contact between the resilient channel and the studs, joists or trusses, and the boards, respectively, is reduced. Thereby the acoustic isolation provided by the resilient channel is improved, resulting in improved sound transmission characteristics of the overall construction.

According to an aspect of the subject technology, a resilient channel for joining a board to a support such as a stud, joist or truss in building construction, has a mounting flange, a face flange, and a web joining the mounting flange and face flange; the mounting flange having a first foot disposed on a first end of the mounting flange and a second foot disposed on a second end of the mounting flange and joined to the web, the first foot and second foot disposed to contact the support and bridge the mounting flange over the support to define a gap between at least a portion of the mounting flange and the support. The first foot is disposed at the end of a bend (which may be a 180-degree bend, so that the first foot is doubled back and under the mounting flange) formed in the mounting flange such that the first foot is disposed between the mounting flange and the support. The face flange is joined by a first bend to the web, and in an embodiment is joined by a second bend to a stiffener on an end of the face flange opposite the web, and has corrugations formed therein between the first bend and second bend. In another embodiment, the second bend joins the face flange to a second web and second mounting flange which is a mirror-image of the first mounting flange.

Moreover, according to an aspect of the subject technology, a resilient channel for joining a board to a support such as a stud, joist or truss in building construction, is in the form of a single piece of steel, and comprises a mounting flange having a first foot and a second foot, the first foot disposed at a first end of the mounting flange and bent back toward the support to be disposed between the mounting flange and the support, the second foot disposed at a second end of the mounting flange and bent toward the support, such that the first foot and second foot are disposed to bridge the mounting flange over the support to define a gap between at least a portion of the mounting flange and the support. The channel also comprises a face flange having a first bend, a second bend, and corrugations, the first bend disposed at a first end of the face flange and the second bend disposed at a second end of the face flange and the corrugations disposed between the first bend and the second bend; and a web joining the second foot of the mounting flange and the first bend of the face flange.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an isometric view of a resilient channel according to an embodiment of the subject technology, with non-limiting dimensions.

FIG. 2 shows an installation of a prior-art resilient channel, connecting a board to studs.

The resilient channel of the subject technology may be installed in a similar fashion.

FIG. 3 is an end view or cross-sectional view of a resilient channel according to the embodiment of FIG. 1.

FIG. 4 is an end view or cross-sectional view of a resilient channel according to an embodiment of the subject technology.

DETAILED DESCRIPTION OF THE SUBJECT TECHNOLOGY

According to an aspect of the subject technology, in an embodiment, resilient channel 1 has a body made of steel using methods known to the art, for example, by cold rolling. As shown in the Figures, and as best seen in FIG. 3, resilient channel 1 has a board-facing side (the top of the figure) and a stud-facing side (the bottom of the figure). Resilient channel 1 has mounting flange 12 for mounting resilient channel 1 to a wooden or steel stud (in the case of wall construction), or a joist or truss (in the case of ceiling construction). Resilient channel 1 has face flange 16 for mounting gypsum board, ceiling panels, or other construction elements. Mounting flange 12 and face flange 16 are joined by web 14. Mounting flange 12 incorporates bend 10, in this embodiment a 180-degree bend, terminating in first foot 11. Mounting flange 12 is joined to web 14 via second foot 13. Mounting flange 12 optionally has through-going holes for passage of fasteners (e.g., screws or nails) for fastening resilient channel 1 to a stud.

According to another aspect of the subject technology, in an embodiment, face flange 16 is disposed between bends 15 and 18. Bend 15 joins face flange 16 to web 14. Bend 18 joins face flange 16 to stiffener 19. Face flange 16 incorporates corrugations 17 which rise above the plane of face flange 16.

In the embodiment shown, corrugations 17 take the form of triangle-wave corrugations formed in face flange 16, extending from point 20 to point 21, rising to peaks above the plane of face flange 16 approximately as high as bends 15 and 18. In other embodiments the corrugations may take the form of trapezoids, rounded domes, or other protruding shapes. In other embodiments the corrugations may rise to peaks above the plane of face flange 16 but lower, or higher, than bends 15 and 18. In other embodiments, the corrugations may extend above the plane of face flange 16 in the board-facing direction but not in the stud-facing direction. In the embodiment shown, corrugations 17 have the same height above the plane of face flange 16, however in other embodiments, corrugations may have different heights.

When in use, resilient channel 1 is fastened to metal or wooden studs via fasteners (e.g., nails or screws) passing through mounting flange 12, as shown for example in FIG. 2 (which depicts the installation of a prior-art resilient channel of the assignee of the present application). Mounting flange 12 may be formed with pre-formed holes for this purpose. Feet 11, 13 are disposed to contact the studs. Mounting flange 12 is bridged over the studs owing to the contact of feet 11, 13 with the studs, except where fasteners may deflect mounting flange 12 and bring its stud-facing surface into contact with the studs, local to the fasteners. In this way, according to an aspect of the subject technology, the contact area between mounting flange 12 and the studs is reduced, which is expected to improve the sound transmission properties of the overall construction.

Additionally, when in use, gypsum boards or the like are fastened to face flange 16 with fasteners (e.g., screws). Bends 15, 18 are disposed to contact the boards. Face flange 16 is bridged over the boards, except where the peaks of corrugations 17 may contact the boards, as for example when face flange 16 is deflected by fasteners toward the board. In this way, according to an aspect of the subject technology, the contact area between face flange 16 and the boards is reduced, which is expected to improve the sound transmission properties of the overall construction.

In embodiments of the subject technology, the mounting flange structure 12 may be used with a conventional face flange, or the corrugated face flange 16 may be used with a conventional mounting flange structure.

In another embodiment, for example as shown in FIG. 4, resilient channel 2 is symmetrical about a central plane, and has mounting flanges 12, etc., duplicated on both sides of resilient channel 2. Resilient channel 1 may be referred to as a “single-leg” channel, while resilient channel 2 may be referred to as a “double-leg” channel. The foregoing description of resilient channel 1 and its variations, installation and use also applies to resilient channel 2.

While a specific embodiment of the subject technology has been shown and described in detail to illustrate the application of the principles of the subject technology, it will be understood that the subject technology may be embodied otherwise without departing from such principles. It will also be understood that the present subject technology includes any combination of the features and elements disclosed herein and any combination of equivalent features. The exemplary embodiments shown herein are presented for the purposes of illustration only and are not meant to limit the scope of the subject technology.

Claims

1. A resilient channel for joining a board to a support such as a stud, joist or truss in building construction, the resilient channel comprising:

a mounting flange, a face flange, and a web joining the mounting flange and face flange;

the mounting flange having a first foot disposed on a first end of the mounting flange, and a second foot disposed on a second end of the mounting flange and joined to the web, the first foot and second foot disposed to contact the support and bridge the mounting flange over the support to define a gap between at least a portion of the mounting flange and the support.

2. The resilient channel of claim 1 wherein the first foot is disposed at the end of a bend formed in the mounting flange such that the first foot is disposed between the mounting flange and the support.

3. The resilient channel of claim 2 wherein the bend is a 180-degree bend.

4. The resilient channel of claim 1 wherein the mounting flange has through-going holes for passage of fasteners for fastening the resilient channel to the support.

5. The resilient channel of claim 1 wherein the face flange is joined to the web by a bend.

6. The resilient channel of claim 1 wherein the face flange has corrugations formed therein.

7. The resilient channel of claim 1 wherein the face flange is joined by a bend to a stiffener on an end of the face flange opposite the web.

8. The resilient channel of claim 1 wherein the face flange is joined by a first bend to the web, and is joined by a second bend to a stiffener on an end of the face flange opposite the web.

9. The resilient channel of claim 1 wherein the face flange is joined by a first bend to the web, and is joined by a second bend to a stiffener on an end of the face flange opposite the web, and has corrugations formed therein between the first bend and second bend.

10. The resilient channel of claim 9 wherein the first bend, corrugations, and second bend rise to peaks above a plane of face flange.

11. The resilient channel of claim 10 wherein the peaks of the first bend, corrugations, and second bend all rise to approximately the same height above the plane of the face flange.

12. The resilient channel of claim 9 wherein the first bend, second bend, and corrugations are disposed to contact the board and bridge the face flange over the board to define a gap between at least a portion of the face flange and the board.

13. The resilient channel of claim 1 wherein the resilient channel further comprises a second mounting flange joined by a second web to the face flange on a side of the face flange opposite the web.

14. The resilient channel of claim 6 wherein the corrugations are in the form of a triangle-wave, trapezoids, or rounded domes.

15. The resilient channel of claim 6 wherein the corrugations extend above the plane of the face flange in a board-facing direction but not in a stud-facing direction.

16. A resilient channel for joining a board to a support such as a stud, joist or truss in building construction, the resilient channel in the form of a single piece of steel, the channel comprising:

a mounting flange having a first foot and a second foot, the first foot disposed at a first end of the mounting flange and bent back toward the support to be disposed between the mounting flange and the support, the second foot disposed at a second end of the mounting flange and bent toward the support, such that the first foot and second foot are disposed to bridge the mounting flange over the support to define a gap between at least a portion of the mounting flange and the support;

a face flange having a first bend, a second bend, and corrugations, the first bend disposed at a first end of the face flange and the second bend disposed at a second end of the face flange and the corrugations disposed between the first bend and the second bend;

a web joining the second foot of the mounting flange and the first bend of the face flange.

17. The resilient channel of claim 16 wherein through-going holes are formed in the mounting flange for passage of fasteners for fastening the resilient channel to a support.

18. The resilient channel of claim 16 wherein the face flange is joined by the second bend to a stiffener.

19. The resilient channel of claim 16 wherein the first bend, corrugations, and second bend rise to peaks above a plane of face flange.

20. The resilient channel of claim 16 wherein the face flange is joined by the second bend to a second web and the second web is joined to a second mounting flange.

21. The resilient channel of claim 20 wherein the second mounting flange comprises a first foot and a second foot, the first foot disposed at a first end of the second mounting flange and bent back toward the support to be disposed between the second mounting flange and the support, the second foot disposed at a second end of the second mounting flange and bent toward the support, such that the first foot and second foot are disposed to bridge the second mounting flange over the support to define a gap between at least a portion of the second mounting flange and the support.