SOUND DAMPING AND VIBRATION ISOLATION STRUCTURAL SUPPORT

Abstract

A channel strut includes a support member with a first tab and a second tab coupled to the support member. A layer of material, such as foam, is disposed on the channel strut. The support member has a low profile and is configured to be attached to successive wall studs via the first and second tabs. The channel strut is attached to wall studs proximate a location with frequent occurrences of sound and vibration, such as studs behind kitchen cabinets, behind door stops, or behind dresser drawings. The layer of material is configured to provide a damping force to reduce sound and vibration at the installed location.

Description

BACKGROUND

Technical Field

The present disclosure relates to structural supports, and more particularly, to structural supports with a layer of material for sound damping and vibration isolation.

Description of the Related Art

Structural supports are generally known. Examples of common structural supports include wall studs, brackets, beams, and headers, among others. Common structural supports do not mitigate sound and vibration in typical building applications. For example, in single family homes, common structural supports allow for noise and vibration from closing doors, cabinets, and drawers, among other common activities, to permeate throughout the structure. These problems are exacerbated in high occupancy buildings with common walls between units or spaces, such as apartment or office buildings. The noise and vibration from common activities proves to be an annoyance for other occupants of most structures.

Some products and construction methods have been developed to address this issue. For example, insulation materials have been developed with enhanced soundproofing properties. In addition, alternative wall construction methods have been developed to reduce sound transmission. However, these materials and methods can be prohibitively expensive for homeowners and developers. Further, these materials and methods are typically utilized throughout the entire structure, which is inefficient when sound and vibration issues are typically localized to certain areas of a building.

BRIEF SUMMARY

The present disclosure is directed to a structural support with sound damping and vibration isolation properties that can be selectively applied in areas of a building that experience frequent occurrences of sound and vibration. More specifically, the present disclosure describes embodiments of a channel strut, which is a bracket with a flat and planar base plate and first and second flanges coupled to the base plate. The flanges are also flat and planar and extend from the base plate substantially perpendicularly to give the channel strut a “U” shaped cross-section. A first tab and a second tab are coupled to the base plate at opposite ends of the base plate. In some examples, the length of the channel strut is selected to correspond to a distance between wall studs. A layer of material, which may be foam, is applied to the channel strut. The layer of material may be on any portion of the channel strut, such as on either surface of the base plate, on either of the tabs, and on either of the flanges.

The channel strut is designed to be inserted between studs with minimal thickness extending from the wall studs, such that the channel strut can be coupled to wall studs without impacting drywall, sheetrock, or other finishes applied over the studs and the strut. The channels struts can be installed in locations that correspond to frequent vibration or noise in a building, such as in locations in the wall that correspond to cabinets, drawers, door openings, and others. The layer of material on the channel struts provides sound damping and vibration isolation to reduce the impacts of sound and vibration on other occupants of the building from common activities.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

For a better understanding of the embodiments, reference will now be made by way of example only to the accompanying drawings. In the drawings, identical reference numbers identify similar elements or acts. In some figures, the structures are drawn to scale. In other figures, the sizes and relative positions of elements in the drawings are not necessarily drawn to scale. For example, the sizes, shapes of various elements and angles may be enlarged and positioned in the figures to improve drawing legibility.

FIG. 1 is a perspective view of an embodiment of a channel strut according to the present disclosure.

FIG. 2 is a bottom plan view of the channel strut of FIG. 1.

FIG. 3 is a right side elevational view of the channel strut of FIG. 1.

FIG. 4A is a rear elevational view of the channel strut of FIG. 1.

FIG. 4B is a detail view of window A in FIG. 4A.

FIG. 5 is a front elevational view of the channel strut of FIG. 1 illustrating the strut installed to successive wall studs.

FIG. 6 is a cross-sectional view of the channel strut of FIG. 5 along line 6-6 in FIG. 5 illustrating the strut secured to a wall stud with a fastener.

FIG. 7 is a cross-sectional view of the channel strut of FIG. 5 along line 7-7 in FIG. 5 illustrating the low profile of the strut relative to the wall studs.

FIG. 8 is a side elevational view of the channel strut of FIG. 1 coupled to wall studs in locations corresponding to hinges of cabinets and closures of a dresser.

FIG. 9 is a perspective view of the channel of FIG. 1 coupled to wall studs proximate a door opening and in a location corresponding to a door stop.

FIG. 10 is a perspective view of an embodiment of a channel strut according to the present disclosure.

FIG. 11 is a perspective view of an embodiment of a channel strut according to the present disclosure.

FIG. 12 is a bottom plan view of the channel strut of FIG. 11.

FIG. 13A is a perspective view of an embodiment of a wall support system according to the present disclosure.

FIG. 13B is a detail view of a bracket interface of the wall support system of FIG. 13A.

FIG. 13C is a perspective view of a bracket of the wall support system of FIG. 13A.

FIG. 14A is a perspective view of an embodiment of an extendable channel strut in a retracted configuration according to the present disclosure.

FIG. 14B is a perspective view of the channel strut of FIG. 14A in an extended configuration.

FIG. 14C is a cross-sectional view of the channel strut of FIG. 14A along line 14-14 in FIG. 14A.

FIG. 15A is a perspective view of an embodiment of an extendable channel strut in a retracted configuration according to the present disclosure.

FIG. 15B is a perspective view of the channel strut of FIG. 15A in an extended configuration.

FIG. 15C is a cross-sectional view of the channel strut of FIG. 15A along line 15-15 in FIG. 15A.

DETAILED DESCRIPTION

Although the present disclosure describes and illustrates certain non-limiting examples of a channel strut or other support member to be coupled to wall studs, it is to be understood that embodiments of the present disclosure include all structural supports and support members. In other words, the concepts presented in the disclosure can be applied to any other beam, column, header, strut, bracket, joist, stud, or other like support members used in building construction. As such, the present disclosure is not limited solely to channel struts.

FIG. 1 illustrates a perspective view of one or more embodiments of a channel strut 100 according to the present disclosure. FIG. 2 illustrates a rear elevational view of the channel strut 100 and FIG. 3 is a side elevational view of the channel strut 100. FIG. 4A is a rear elevational view of the channel strut 100 and FIG. 4B is a detail view of window A in FIG. 4A.

With reference to FIGS. 1-4B, the channel strut 100 includes a base plate 102. The base plate 102 is flat and planar and has a length 104 that is greater than a width 106, in some embodiments. The length 104 of the base plate 102 is selected according to the distance between wall studs in construction of a building. For example, where the channel strut 100 is used with standard wall studs that are spaced 16 inches on center, the length 104 of the base plate 102 may be between 12 and 16 inches, such that the strut 100 has a length that corresponds to the distance between studs. When the distance between the studs is different, such as 24 inches on center, the length 104 may be adjusted accordingly. Of course, the strut 100 may also be selected to be longer or shorter depending on the distance between studs. For example, the length 104 may be as small as 3 to 5 inches, or more or less, if the strut 100 is to be installed in a corner where the first wall stud from the corner is only a few inches from the corner stud.

The width 106 is also selected based on the desired support properties of the channel strut 100. In other words, in applications where the base plate 102 is relied upon for structural support, the width 106 may be changed to vary the load capacity, stiffness, and other structural properties of the base plate 102. Further, the width 106 can be selected based on the desired amount of sound and vibration damping from the channel strut 100 because the sound and vibration damping efficacy of the strut 100 will increase with the surface area of the strut 100, which is based in part on the width 106. The width 106 can therefore be greater than the length 104 or the length 104 and the width 106 may be equal in some embodiments.

The channel strut 100 further includes a first flange 108 and a second flange 110 coupled to the base plate 102. The first flange 108 and the second flange 110 are the same and are spaced from each other across the width 106 of the base plate 102, in some embodiments. The first flange 108 and the second flange 110 are flat and planar and have a length that is the same as the length 104 of the base plate 102. However, in one or more embodiments, a length of either or both of the first and second flanges 108, 110 is greater than or less than the length 104 of the base 102. As shown in FIG. 1 and FIG. 4A, the first and second flanges 108, 110 extend from the base plate 102 perpendicularly, in some embodiments, to give the channel strut 100 a “U”-shaped cross section. The flanges 108, 110 are substantially perpendicular (e.g., within 5 degrees of perpendicular) from the base plate 102 in one or more embodiments, or can extend from the base plate 102 at any angle not equal to 0 degrees and not equal to 90 degrees in one or embodiments.

A first tab 112 and a second tab 114 are coupled to the base plate 102. The first tab 112 and the second tab 114 may also be referred to herein as protrusions, flanges, extensions or as part of the base plate 102. The first tab 112 is spaced from the second tab 114 across the length 104 of the base plate 102, such that the tabs 112, 114 are on opposite sides of the base plate 102. In some embodiments, the tabs 112, 114 are aligned and planar with the base plate 102. More specifically, the base plate 102 includes a first surface 116 and a second surface 118 opposite the first surface 116 (see FIG. 4B). The first surface 116 is a front outermost surface and the second surface 118 is a rear outermost surface of the base plate 102, in one or more embodiments. The tabs 112, 114 further include a front outermost surface 120 and a rear outermost surface 122, wherein the front surface 120 of each of the tabs 112, 114 is aligned and coplanar with the front surface 116 of the base plate 102, in some embodiments. In one or more embodiments, the front surface 120 of at least one or both tabs 112, 114 is recessed relative to the front surface 116 of the base plate 102 or extends beyond the front surface 116 of the base plate 102. The rear surfaces 122 of the tabs 112, 114 may also be aligned and coplanar, recessed, or extend beyond the rear surface 118 of the base plate 102. Further, the surfaces 120, 122 of the tabs 112, 114 can be flat and planar, such that the front surface 116 of the base plate 102 includes the front surface 120 of each of the tabs 112, 114, in one or more embodiments.

In some embodiments, the tabs 112, 114 each further include at least one hole 124 through the respective tab 112, 114 to assist with securing the strut 100 to a wall stud, as further explained below. However, in one or more embodiments, there are no holes 124 through the tabs 112, 114, as shown in FIGS. 10-12. A thickness of the tabs 112, 114 may be the same as a thickness of the base plate 102, in some embodiments, while in one or more embodiments, the thicknesses of the tabs 112, 114 and the base plate 102 are different. The tabs 112, 114 can include rounded edges or rectilinear edges, among other selected shapes.

The strut 100 further includes a layer of material 126 on the strut 100. The layer of material 126 may be foam, in some embodiments, such as a specific type of soundproof foam or acoustic foam in some non-limiting examples. The layer of material 126 may also include vibration isolation foam. In some embodiments, the layer of material 126 is foam with both sound damping and vibration isolation properties. Thus, the layer of material 126 has a composition and structure to dissipate vibrational energy before the energy builds up and is released as audible sound and to absorb and damp mechanical waves associated with vibration to reduce or eliminate vibration.

As shown in FIG. 1, the layer of material 126 is only disposed on the base plate 102 of the strut 100 and more specifically, is only disposed on the front surface 116 of the base plate 102 and not on the front surface 120 of the tabs 112, 114. FIG. 2 illustrates, via dashed lines 128, that the layer of material 126 can also be disposed on the rear surface 118 of the base plate 102, or the rear surface 122 (FIG. 3) of the tabs 112, 114, or both. However, the layer of material 126 can also be disposed only on the rear surface 118 of the base plate 102 or only on the rear surface 122 (FIG. 3) of the tabs 112, 114, in some embodiments. FIG. 3 illustrates, via dashed lines 130, that the layer of material 126 can be disposed on the first flange 108. While only first flange 108 is illustrated in FIG. 3, it is to be appreciated that the second flange 110 can be a mirror image and can also include the layer of material 126. The layer of material 126 can be on any surface of the flanges 108, 110 and can be only on both flanges 108, 110 or only on one flange 108, 110, including on only one surface of the flanges 108, 110, in some embodiments.

FIG. 4A and FIG. 4B illustrate the low profile of the strut 100. As will be explained in more detail below, the strut 100 is attached to wall studs or other structural supports via the tabs 112, 114 with the flanges 108, 110 received in the space between studs. As such, the only portion of the strut 100 that extends beyond an outer surface of the wall studs is the base plate 102, the tabs 112, 114, and the layer of material 126 in some embodiments. The layer of material 126 is attached to the base plate 102 with a thin layer of adhesive 132. The adhesive 132 may be glue, tape, or an adhesive backing on layer of material 126. Further, the layer of material 126 has a thickness 134, the adhesive 132 has a thickness 136, and the base plate 102 has a thickness 138. As shown in FIG. 4B, the thickness 136 of the adhesive 132 is less than the thicknesses 134, 138 of the layer of material 126 and base plate 102, respectively. In some embodiments, the thickness 134 of the layer of material 126 is equal to the thickness 138 of the base plate 102. However, in one or more embodiments, the thicknesses 134, 138 are different, such as the thickness 134 of the layer of material 126 being more or less than the thickness 138 of the base plate 102.

Further, FIG. 4A illustrates that the base plate 102 and flanges 108, 110 form a channel 109 extending along the length 104 of the base plate 102. The channel 109 allows the strut 100 to be installed with wires, pipes, or other conduits in typical construction projects passing through channel 109. In other words, the channel 109 prevents strut 100 from interfering with the design and installation of other aspects of a construction project. Further, each of the flanges 108, 110 include a ridge 111 extending from the respective flange 108, 110 into channel 109. The ridges 111 provide structural support for the flanges 108, 110.

In some embodiments, the thickness 134 of the layer of material 126 is between less than 1 millimeter (“mm”) and 10 mm. The thickness 136 of the adhesive layer 136 is between less than 1 mm and 5 mm. The thickness 138 of the base plate 102 is between less than 1 mm and 10 mm. As such, the total thickness of the base plate 102, the layer of material 126, and the adhesive 132 may be between 1 mm or less to 25 mm or more. Preferably, the total thickness of the base plate 102, the layer of material 126, and the adhesive 132 is 10 mm or less so that the strut 100 does not impact the appearance of dry wall, sheet rock, or other materials installed over the strut 100. However, the thickness of the base plate 102, the layer of material 126, and the adhesive 132 can be selected according to the application of the strut 100.

FIG. 5 is an elevational view of the strut 100 coupled to wall studs 140. Specifically, FIG. 5 shows the tabs 112, 114 of the strut 100 coupled to successive wall studs 140. In one or more embodiments, there is a distance 142 between the studs 140 that is the same as the length 104 of the base plate 102 of the strut 100. Further, the layer of material 126 extends across the entirety of the distance 142, in some embodiments (e.g., extends all the way between successive studs 140). The total length of the strut 100, including the tabs 112, 114 is greater than the distance 142 between the studs 140, such that the tabs 112, 114 overlap the studs 140 and can be coupled to the studs 140. Moreover, FIG. 5 illustrates that holes 124 through the tabs 112, 114 are aligned with the studs 140 to facilitate coupling the tabs 112, 114 to studs 140 with fasteners, as in FIG. 6.

FIG. 6 is a cross-sectional view of the strut 100 and wall stud 140 along line 6-6 in FIG. 5. FIG. 6 illustrates that the tab 112 is secured to stud 140 with fastener 144. The fastener 144 may be a nail, screw, bolt, or any other type of fastener. In FIG. 6, the fastener 144 is inserted through hole 124 in tab 112 and coupled to stud 140. However, in some embodiments, the tab 112 does not include hole 124 and the fastener 144 is inserted directly through the tab 112. More than one fastener 144, with or without corresponding holes 124 may also be used. The second tab 114 can be coupled to the second wall stud 140 in a similar manner.

FIG. 7 is a cross-sectional view of the strut 100 along line 7-7 in FIG. 5. FIG. 7 illustrates that the flanges 108, 110 of the strut 100 are structured to be received in the gap or space between the wall studs 140. As such, only the base plate 102, the tabs 112, 114 and the layer of material 126 extend beyond wall studs 140. As noted above, a thickness of this portion of the strut 100 may only be a few millimeters, such as between 1 and 5 mm or between 1 and 10 mm. Thus, the strut 100 does not interfere with installation of dry wall, sheet rock, panels, or other materials over the strut 100. Put a different way, the strut 100 does not bulge out of the material installed over studs 140 when observed in the orientation shown in FIG. 5. Further, the flanges 108, 110 of the strut 100 have a width that is less than a width of industry standard studs 140 such that the flanges 108, 110 do not protrude from the studs 140 and interfere with materials installed over studs 140 on the opposite side from the strut 100.

FIG. 8 is a side elevational view illustrating several channel struts 100 coupled to wall stud 140 in an installed, use configuration. The channel struts 100 are labeled as 100A, 100B, 100C, 100E, and 100E for clarity with respect to the following description. Wall stud 140 corresponds in this non-limiting example to a shared wall between two rooms, which may be part of the same residence, such as in a single family home, or may be separate units or rooms of an apartment, hotel, condo, or office building, among other high occupancy configurations. Sheet rock 146 is installed to the wall stud 140 and over the channel struts 100A-E. As explained above, the thin configuration of the struts 100A-E prevents bulging or deformation of the sheet rock 146. Further, the struts 100A-E can provide additional support for the sheet rock 146 between successive wall studs 140. On the right side of the wall stud 140 is a cabinet 148, which is one non-limiting example of an item that may cause localized sound and vibration issues in a room.

Cabinet 148 includes a base 150 and a door 152 attached to the base 150 with hinges represented by dashed lines 154. The door 152 is manipulatable to access the base 150 via pull or knob 156 and hinges 154. Noise and vibration are common when the user closes the door 152 or when the user manipulates items within the cabinet 148. Channel struts 100A, 100B, 100C are installed on the wall stud 140 behind the cabinet 148 to reduce the noise and vibration impacts of the cabinet 148. Specifically, FIG. 8 illustrates that struts 100A, 100C are installed in locations corresponding to the hinges 154 and the pull 156, such that the struts 100A, 100C provide sound damping and vibration isolation at the source of sound and vibration from the cabinet 148.

In other words, sound and vibration emanate from the hinges 154 and the pull 156 because the closing force on the door 152 is localized in these locations. As such, the struts 100A, 100C are installed aligned with these locations, in some embodiments on center with these elements of cabinet 148, to reduce sound and vibration from cabinet 148. Strut 100B is provided to reduce vibration from manipulating items within cabinet 148. For example, a user may generate noise and vibration by placing several plates or bowls in a stacked configuration inside cabinet 148. The strut 100B reduces the noise and vibration impacts of such activities by the user inside cabinet 148. Each of the struts 100A, 100B, 100C are installed with the layer of material 126 facing the cabinet 148. However, in some embodiments, each of the struts 100A, 100B, 100C are installed with the layer of material 126 facing away from the cabinet 148, in addition to, or instead of, the layer of material facing the cabinet 148.

A dresser 158 is on the left side of wall stud 140. The dresser 158 includes a base 160 with drawers 162 that slide in and out of the base 160 via user manipulation of pulls or knobs 164 on each drawer 162. The dresser 158 causes noise and vibration as a result of drawers 162 sliding into contact with base 160. As such, the struts 100D, 100E are installed in locations on wall stud 140 corresponding to pulls 164. In some embodiments, the struts 100D, 100E are installed aligned with drawers 162, such as on center with drawers 162. Moreover, there may be more than one strut 100 per drawer 162, such as a first strut 100 at the top of a first drawer 162 and a second strut 100 at the bottom of the drawer 162. As with the cabinet 148, the struts 100D, 100E are installed on wall stud 140 with the layer of material 126 facing the dresser 158. In some embodiments, each of the struts 100D, 100E are installed with the layer of material 126 facing away from the dresser 158 in addition to, or instead of, the layer of material facing the cabinet 158. Further, additional struts beyond struts 100A-100E may be installed to studs 140 behind the cabinet 148 and dresser 158 and in any selected location relative to the cabinet 148 and dresser 158.

FIG. 9 is a perspective view illustrated several channel struts 100 in a further use configuration. For FIG. 9, the channel struts 100 are labeled 100F, 100G, 100H, and 100I for clarity in the following description. Another common source of noise or vibration in a building is the closing of doors or the banging of doorknobs into walls behind doors. FIG. 9 illustrates the wall studs 140 around a door opening 166. The door is illustrated here installed in door opening 166 with dashed lines 168. The door 168 has a handle or knob 170. One of the struts 100F is installed to wall studs 140 in a location corresponding to a location of a doorstop on the wall behind the door 168. In other words, one of the struts 100F is located where knob 170 of door 168 would contact a wall behind the door 168 when the door 168 is opened.

The remaining struts 100G, 100H, 100I are installed around door opening 166 to dampen sound and vibration from closing the door 168 into opening 166. Although only three struts 100G, 100H, 100I are shown around opening 166 in FIG. 9, additional struts may be installed around an entirety of door opening 166 or only select sides of the opening 166 such as the top, left, or right side of opening 166, in some embodiments. Further, each of the struts 100F, 100G, 100H, 100I are installed with the layer of material 126 facing into the room. In some embodiments, the struts 100F, 100G, 100H, 100I include the layer of material 126 on a surface facing away from the room instead of, or in addition to, the layer of material 126 facing into the room, as illustrated. Further, the struts described herein can be installed in other locations in a building beyond those illustrated in FIG. 8 and FIG. 9. For example, the struts could be installed to floor or ceiling joists or other supports, as well as in other rooms where there are frequent occurrences of sound and vibration.

FIG. 10 illustrates one or more embodiments of a channel strut 200 according to the present disclosure. The channel strut 200 includes a base plate 202 and protrusions 204. The channel strut 200 also includes a layer of material 206 disposed on the base plate 202 and protrusions 204. The layer of material 206 is a single, continuous layer of material extending across the entirety of base plate 202 and both protrusions 204, in some embodiments. In one or more embodiments, the layer of material 206 is only on the base plate 202 and the protrusions 204. Further, the layer of material 206 can be on any surface of the base plate 202 and the protrusions 204. In still further embodiments, the layer of material 206 can be on the base plate 202 and only one of the protrusions 204. The layer of material 206 may have the same properties as the layer of material 126, except as otherwise described. Further, the protrusions 204 do not include holes for installing fasteners. Rather, fasteners are punched through protrusions 204 for securing the strut 200 to a wall stud. Moreover, the protrusions 204 have a trapezoidal shape, in some embodiments, although the shape of the protrusions 204 can be selected from among any number of different shapes.

FIG. 11 illustrates a channel strut 300 with a base plate 302 and tabs 304 coupled to the base plate 302. A layer of material 306, which may be similar to layer of material 126, is disposed on the tabs 304. In other words, the base plate 302 does not include the layer of material 306, and instead, the material 306 is only on the tabs 304, in some embodiments.

FIG. 12 is a bottom plan view of the channel strut 300. The tabs 304 each have a bottom surface 308 that in some embodiments, is also covered with the layer of material 306. In other words, the layer of material 306 is on the front or top surface of each of the tabs 304 and on the back surface 308 of each of the tabs 304, in one or more embodiments. In some embodiments, the layer of material 306 is only on one surface of the tabs 304, or the layer of material 306 can be on both surfaces of the tabs 304 as shown in FIG. 12. The bottom surface 308 is a surface that faces wall studs when the channel strut 300 is installed, as described herein. The top or front surface would then be a surface facing away from the wall studs, in some embodiments.

The channel strut 300 further includes an adhesive 310 on the bottom surface 308 of each tab 304 for attaching the strut 300 to wall studs 140. More specifically, the adhesive 310 is on the layer of material 306 on the bottom surface 308 of each tab 304, such that the adhesive 310 can be secured to wall studs. In other words, in one or more embodiments, screws, nails, or other fasteners are not used to secure the struts described herein to wall studs. Rather, adhesive 310 is used to increase the efficiency of installation. Once sheet rock 146 or other materials are coupled to wall studs, the friction between the sheet rock 146, the wall stud 140, the tabs 304, and the layer of material 306 will hold the strut 300 in place. As such, the adhesive 310 secures the strut 300 to wall studs while construction continues to provide permanent coupling of the strut 300 to the wall studs. The adhesive 310 may be glue, tape, foam, or a preformed adhesive with a removable backing layer, such as a peel and stick adhesive layer.

FIG. 13A and FIG. 13B are views of a sound and vibration damping structural support system 400. Beginning with FIG. 13A, the system 400 includes a wall stud structure with a horizontal base channel 402 and vertical wall studs 404 coupled to the base channel 402. Although not shown, a second base channel may be coupled to the vertical wall studs 404 at the top of the studs 404, in some embodiments. The system 400 further includes brackets 406 coupled to the studs 404, as explained further herein. The brackets 406 receive supports 408 that extend between studs 404 to provide backing for mounting cabinets 410 or other items to the system 400. In some embodiments, the supports 408 are dimensional structural grade lumber, such as 2×4 s, 2×6 s, 1×4 s, or 1×6 s, among others.

As shown in FIG. 13A, the supports 408 include a layer of material 412 on a surface of the supports 408 facing drywall 414 and cabinet 410. In other words, the supports 408 are installed with a major surface facing drywall 414 and cabinet 410, wherein the major surface includes the layer of material 412. The layer of material 412 can have the same structure and composition as the other layers of material descried herein. Further, FIG. 13A shows variations of the placement of the layer of material 412 within the system 400. For example, the layer of material 412 can be only on the surface of the supports 408 facing drywall 414, or the layer of material 412 can be on a surface of each of the brackets 406 facing the drywall 414. In some embodiments, the layer of material 412 is also on one or more surfaces of the studs 404, such as on a surface of a flange of the studs 404 facing the cabinet 410 and drywall 414.

In one or more embodiments, the layer of material 412 is also on any surface of the studs 404, brackets 406, and supports 408. In some embodiments, the layer of material 412 is a single, continuous layer over the brackets 406 and the supports 408. In yet further embodiments, the layer of material 412 is discontinuous and is only applied to individual brackets 406 and supports 408. In general, the layer of material 412 reduces noise and vibration from opening and closing doors of the cabinet 410, or other activities, and may be selectively located (such as behind cabinet 410, as shown) where noise and vibration are an issue.

FIG. 13B is a detail view of an interface between one of the brackets 406, two of the supports 408, and one of the wall studs 404 in FIG. 13A. FIG. 13C is a view illustrating additional detail of the bracket 406. With reference to FIG. 13B and FIG. 13C, the bracket 406 includes a web 416 coupled to two flanges 418. The flanges 418 are perpendicular to the web 416 in some embodiments. Further, the flanges 418 are spaced across the web 416 by space or opening 420. The wall stud 404 is received in the opening 420, such that the flanges 418 extend on opposite sides of the wall stud 404, as shown in FIG. 13B. The web 416 further includes a plurality of holes 422 through the web 416, which receive fasteners to secure the bracket 406 to the stud 404 as well as the supports 408. For example, in FIG. 13B, the bracket 406 is coupled to the stud 404 and supports 408 with fasteners 424 through holes 422 (FIG. 13C), which may be screws, bolts, or other like fasteners. In the installed configuration shown in FIG. 13B, the supports 408 rest on the flanges 418 of the bracket 406 and are secured to the web 416 with fasteners 424.

FIG. 13B further illustrates the layer of material 412 on the supports 408. The layer of material 412 may be added to the supports 408 before coupling with the bracket 406, or may be added after installation of the supports 408 to the bracket 406, such as a layer of material 412 over the brackets 406 and the supports 408 as in FIG. 13A. The layer of material 412 is on a surface of the supports 408 facing the bracket 406, in some embodiments, which in turn, faces the drywall after further installation. In some embodiments, the layer of material 412 is only on this one surface facing the brackets 406, while in one or more embodiments, the layer of material 412 is on any of the surfaces of the supports 408 as well as the brackets 406 and the studs 404, as described herein. Further, in embodiments where the supports 408 are wood and the studs 404 are metal, such as steel, the wood supports 408 have worse sound damping and vibration isolation properties than the steel studs 404, such that vibration and noise are likely to occur through use of anything installed to supports 408, such as cabinet 410 in FIG. 13A. As such, the layer of material 412 can significantly improve the sound damping and vibration isolation properties of the supports 408 to reduce noise and vibration in the system 400 (FIG. 13A).

FIG. 13C further illustrates that in some embodiments, the bracket 406 includes the layer of material 412 on a surface of the bracket 406 that faces the stud 404. In particular, the layer of material 412 on the bracket 406 is only on a portion of the bracket 406 that is aligned with a vertical center of the bracket 406 and that corresponds to walls of the stud 404, as shown in FIG. 13C. In operation, the stud 404 is received in opening 420 and the layer of material 412 is on the surface of the web 416 that corresponds to the stud 404 such that the layer of material 412 contacts the stud 404, but does not extend beyond outer edges of the side of the stud 404 illustrated in FIG. 13B. However, in some embodiments, the layer of material 412 is on all of the web 416 facing the stud 404, or may be on less or a different portion of the web 416 than the illustrated portion, such as an area with less width or less height than the layer 412 illustrated or portion that is to the left or right of the center of the web 416. The layer of material 412 in this location further attenuates sound and vibration from passing through the interface between the studs 404, the brackets 406, and the supports 408.

FIG. 14A illustrates one or more embodiments of a channel strut assembly 500 with a length that is extendable. In particular, the channel strut assembly 500 includes a first channel strut 502 and a second channel strut 504 where the second channel strut 504 is nested or telescopes within the first channel strut 502. FIG. 14A illustrates the channel strut assembly 500 in a retracted configuration with a majority of the second channel strut 504 received in the first channel strut 502 in a telescoping manner. In some embodiments, the second channel strut 504 is received completely within the first channel strut 502, except for tab 506 coupled to the second channel strut 504, which may extend from the first channel strut 502 in the retracted configuration of the assembly 500. However, in one or more embodiments, in the retracted configuration, 50%, 60%, 70%, 80%, 90% or more or less of a length of the second channel strut 504 is received in the first channel strut 502. Further, in some embodiments, the first channel strut 502 is received in the second channel strut 504 instead of the illustrated arrangement.

FIG. 14B illustrates the assembly 500 in an extended configuration where the second channel strut 504 slides along the first channel strut 502 to extend from the first channel strut 502 and extend an overall length of the assembly 500. The assembly 500 has a first length 508 in the retracted configuration and a second length 510 in the extended configuration. The second length 510 is greater than the first length 508 and in some embodiments, the second length 510 may be 50%, 60%, 70%, 80%, 90% or more or less greater than the first length 508. Further, it is to be appreciated that the assembly 500 has a length range from a minimum length in the fully retracted configuration with second strut 504 received in the first strut 502 a maximum amount to a maximum length in the fully extended configuration with the second strut 504 extending from the first strut 502 a maximum amount without uncoupling from the first strut 502.

The minimum and maximum length of the assembly 500, which may be the lengths 508, 510 in some embodiments, can be selected according to design preference. For example, the minimum length may be any value in the range of 8 to 36 inches, or more or less, and the maximum length may any value in the range of 14 to 70 inches, or more or less, in some embodiments. In one or more embodiments, the minimum and maximum ranges are selected based on industry standard spacing between wall studs, such as 16 inches on-center or 24 inches on-center, where the adjustable length of the assembly 500 can account for variations from the standard 16 or 24 inches on center during installation. For example, in some embodiments, the minimum length is 14 inches and the maximum length is 26 inches, such that the same assembly 500 can be used with studs that are installed 16 inches on center or 24 inches on center. In other embodiments, the assembly 500 is sold in different units that are designed for standard stud spacing, namely one for 16 inch on center studs and one for 24 inch on center studs, with the extendable nature of the assembly 500 accounting for variation in installation.

The channel strut assembly 500 further includes a layer of material 512 on both of the struts 502, 504. The layer of material 512 can have the same composition and attenuation of sound and vibration characteristics as other layers of material described herein. Further, the layer of material 512 may be only on the surface of the struts 502, 504 that faces drywall in the installed configuration, or the layer of material 512 may be on all of, or any portion of, any surface of the struts 502, 504 of the assembly 500 in some embodiments.

FIG. 14C is a cross-sectional view of the assembly 500 along line 14-14 in FIG. 14A and illustrates additional detail of the nesting or telescoping arrangement of the struts 502, 504. In particular, the first strut 502 includes a channel 514 defined by walls of the first strut 502. The second strut 504 is received in the channel 514 and slides along the channel 514. Further, the second strut 504 is held in place in the channel 514 by flanges 516 of the first strut 502, which extend into the channel 514 to prevent the second strut 504 from falling out of the channel 514. As such, the outer dimensions of the second strut 504 are less than the interior dimensions of first strut 502 such that the second strut 504 is received in the channel 514 of the first strut 502 in a clearance fit. In some embodiments, the outer dimensions of the second strut 504 are equal to or greater than the interior dimensions of the first strut 502 that define the channel 514 such that the second strut 504 is received in the first strut 502 in a friction fit.

FIG. 15A illustrates one or more embodiments of a channel strut assembly 600 with an extendable length, similar to the assembly 500 described above. However, instead of two struts in the assembly as with assembly 500, the channel strut assembly 600 includes three struts to further extend the length range of the assembly 600. More specifically, the channel strut assembly 600 includes a central strut 602 as well as extension struts 604A, 604B that are received in, and slide along central strut 602 to extend from opposite sides of the central strut 602, as shown. In FIG. 15A, the assembly 600 is illustrated in a retracted configuration where the assembly 600 has a length 606. In some embodiments, the length 606 is a minimum length with a majority of the extension struts 604A, 604B received in the central strut 602.

FIG. 15B illustrates the assembly 600 in the extended configuration. In operation, the extension struts 604A, 604B slide to extend from the central strut 602 until tabs 608 on the extension struts 604A, 604B reach wall studs. The tabs 608 are then secured to wall studs as described herein. In the extended configuration, the assembly 600 has a length 610, which may be as much as three times the length 606 in the retracted configuration of FIG. 15A. In other words, in some embodiments, each of the struts 602, 604A, 604B have the same length with the extension struts 604, 604B nested or telescoping relative to each other, such that the length 610, which may be a maximum length, is three times or approximately three times the length 606 in the retracted configuration. In one or more embodiments, the extension studs 604A, 604B may have a length that is less than the length of the central strut 602, such that the length 610 is two times the length 606.

However, because the extended length 610 of the assembly 600 is as much as three times the retracted length 606, the assembly 600 can be used with a wider range of stud arrangements. In one non-limiting example, the central strut 602 may have a length that is 12 inches and each of the extension struts 604A, 604B may have a length that is 10 inches. As such, the assembly 600 can be used for studs that are 16 inches on center as well as studs that are 24 inches on center. Further, the assembly 600 can be installed in any length within the range from the minimum, fully retracted length to the maximum, fully extended length, such that the assembly 600 can account for variations in actual installation dimensions between studs. Further, each of the struts 602, 604A, 604B may have a layer of material 612 on a surface of the strut that faces drywall installed over the assembly 600, as described herein, to attenuate sound and vibration.

FIG. 15C is a cross-sectional view of the assembly 600 along line 15-15 in FIG. 15A. FIG. 15C shows the nesting or telescoping arrangement between the struts 602, 604A, 604B. In particular, the central strut 602 receives both of the extension struts 604A, 604B, and the extension struts 604A, 604B are nested or telescoped relative to each other in order to increase the extension range of the assembly 600. In some embodiments, the extension struts 604A, 604B are not nested, but rather, have a length that is equal to or less than half of the length of the central strut 602, such that there may be a gap or space between ends of the extension struts 604A, 604B in the retracted configuration. As shown, the extension strut 604A is received in the central strut 602 in a clearance or friction fit and the extension strut 604B is similarly received in the extension strut 604A in a clearance or friction fit, as described herein. Flanges 614 of the central strut 602 extend to hold the extension strut 604A in place and similarly, flanges 616 of the extension strut 604A extend to hold the extension strut 604B in place.

As such, the embodiments of the present disclosure provide for sound damping and vibration isolation structural supports that can be selected for use in areas with noise and vibration issues. The cost of the supports described herein is considerably less than the cost of sound proof insulation or sound proof wall construction in a building. Moreover, the supports are quicker to install and their arrangement can be customized to more effectively reduce noise and vibration from common activities. Further, some embodiments of the supports described herein have an adjustable length to account for variations in the installed width between wall studs.

In the above description, certain specific details are set forth in order to provide a thorough understanding of various disclosed embodiments. However, one skilled in the relevant art will recognize that embodiments may be practiced without one or more of these specific details, or with other methods, components, materials, etc. In other instances, well-known structures associated with structural supports, sound damping, and vibration isolation devices, systems, and methods have not been shown or described in detail to avoid unnecessarily obscuring descriptions of the embodiments.

Unless the context requires otherwise, throughout the specification and claims which follow, the word “comprise” and variations thereof, such as, “comprises” and “comprising” are to be construed in an open, inclusive sense, that is as “including, but not limited to.” Further, the terms “first,” “second,” and similar indicators of sequence are to be construed as interchangeable unless the context clearly dictates otherwise.

Reference throughout this specification to “one embodiment” or “an embodiment” means that a particular feature, structure or characteristic described in connection with the embodiment is included in at least one embodiment. Thus, the appearances of the phrases “in one embodiment” or “in an embodiment” or other like phrases, such as “in one or more embodiments” or “in some embodiments” in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments.

As used in this specification and the appended claims, the singular forms “a,” “an,” and “the” include plural referents unless the content clearly dictates otherwise. It should also be noted that the term “or” is generally employed in its broadest sense that is as meaning “and/or” unless the content clearly dictates otherwise.

The relative terms “approximately” and “substantially,” when used to describe a value, amount, quantity, or dimension, generally refer to a value, amount, quantity, or dimension that is within plus or minus 5% of the stated value, amount, quantity, or dimension, unless the context clearly dictates otherwise. It is to be further understood that any specific dimensions of components or features provided herein are for illustrative purposes only with reference to the various embodiments described herein, and as such, it is expressly contemplated in the present disclosure to include dimensions that are more or less than the dimensions stated, unless the context clearly dictates otherwise.

The various embodiments described above can be combined to provide further embodiments. All of the U.S. patents, U.S. patent application publications, U.S. patent applications, foreign patents, foreign patent applications and non-patent publications referred to in this specification and/or listed in the Application Data Sheet are incorporated herein by reference, in their entirety. Aspects of the embodiments can be modified, if necessary to employ concepts of the various patents, applications and publications to provide yet further embodiments.

These and other changes can be made to the embodiments in light of the above-detailed description. In general, in the following claims, the terms used should not be construed to limit the claims to the specific embodiments disclosed in the specification and the claims, but should be construed to include all possible embodiments along with the full scope of equivalents to which such claims are entitled. Accordingly, the claims are not limited by the disclosure.

Claims

1. A device, comprising:

a support member having a first surface and a second surface opposite the first surface;

a first tab coupled to the support member;

a second tab coupled to the support member; and

a foam layer on at least one of the first surface, the second surface, the first tab, and the second tab of the support member,

wherein the support member is configured to be coupled to wall studs in a location of a storage device with the foam layer configured to dampen sound or vibration from the storage device.

2. The device of claim 1 wherein the first tab and the second tab are coplanar with the first surface of the support member.

3. The device of claim 1 wherein the foam layer is only on the first surface of the support member.

4. The device of claim 1 wherein the foam layer is only on the first tab and the second tab of the support member.

5. The device of claim 1 wherein the foam layer is only on the second surface of the support member.

6. The device of claim 1 wherein the location corresponds to a position of a hinge of the storage device.

7. The device of claim 1 further comprising:

at least one extension strut received within the support member, the extension strut structured to slide relative to the support member.

8. An assembly, comprising:

a channel strut assembly, including: a channel strut; an extension strut received in the channel strut and structured to slide relative to the channel strut; a first protrusion coupled to the channel strut; a second protrusion coupled to the extension strut; and a layer of material on the channel strut and the extension strut configured to dampen sound or vibration,

wherein the channel strut assembly is configured to be coupled to wall studs via the first protrusion and the second protrusion.

9. The assembly of claim 8 wherein the layer of material is foam.

10. The assembly of claim 8 wherein the channel strut assembly is configured to be coupled to wall studs in a location corresponding to hinges of a cabinet.

11. The assembly of claim 8 wherein the channel strut assembly is configured to be coupled to wall studs in a location corresponding to one or more closures of a dresser.

12. The assembly of claim 8 wherein the channel strut assembly is configured to be coupled to wall studs in a location corresponding to a door stop.

13. The assembly of claim 8 wherein the channel strut assembly is configured to be coupled to wall studs proximate a door opening.

14. The assembly of claim 8 wherein the first protrusion is planar with a surface of channel strut and the second protrusion is planar with a surface of the extension strut.

15. An assembly, comprising:

a channel strut assembly, including: a central strut; a first extension strut received in the central strut and structured to slide relative to the central strut; a second extension strut received in the central strut and structured to slide relative to the central strut; a first protrusion coupled to the first extension strut; a second protrusion coupled to the second extension strut; and a layer of material on at least one of the central strut, the first extension strut, and the second extension strut configured to dampen sound or vibration,

wherein the channel strut assembly is configured to be coupled to wall studs via the first protrusion and the second protrusion.

16. The assembly of claim 15 wherein the second extension strut is telescopically received in the first extension strut and structured to slide relative to the first extension strut.

17. The assembly of claim 15 wherein the channel strut assembly has a minimum length in a retracted configuration, an end of the first extension strut spaced from an end of the second extension strut in the retracted configuration of the channel strut assembly.

18. The assembly of claim 17 wherein the channel strut assembly has a maximum length in an extended configuration, the maximum length being at least twice the minimum length.

19. The assembly of claim 15 wherein the layer of material is foam and is on only the central strut.

20. The assembly of claim 15 wherein the layer of material is on the central strut, the first extension strut, and the second extension strut.