WALL SYSTEM USING GYPSUM STUDS HAVING MEP ACCOMMODATION

Abstract

An interior wall system includes a frame including a lower support member, an upper support member, and at least two vertical support members securing the lower and upper support members together, the frame having a first side and a second side, at least one first panel secured to the first frame side by attachment to at least the upper and lower support members, each first panel having an interior surface facing the frame, at least one shortened gypsum stud having a length shorter than the vertical support members, and being secured to the interior surface of the first panels to create upper and lower passages between respective ends of each stud and the respective upper and lower support members, and at least one second panel secured to the second frame side by attachment to the upper and lower support members, and also to the shortened gypsum studs.

Description

RELATED APPLICATION

The present application is a Non-Provisional of, and claims 35 U.S.C. 119 priority from, US Patent Application Serial No 63/744,999, filed January 14, 2025, the entire contents of which are incorporated by reference herein.

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, while accommodating utility infrastructure.

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 (upper) and footer (lower) 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 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 5/8-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 being more favorable to a hollow sound.

The use of gypsum studs in wall construction for enhanced acoustic properties is disclosed in US Serial No.18/485,005, filed October 11, 2023 and Published as US 2024/0167281, the contents of which are incorporated by reference herein. A related design consideration in constructing interior walls using gypsum studs is the need to maintain desirable sound properties while accommodating required plumbing, electrical, data and other infrastructure. Due to their construction, gypsum studs lack the customary passages for such conduits, cabling and/or piping found in conventional steel studs.

Accordingly, there is a need for an interior wall construction system using gypsum studs, that provides acoustical properties that are acceptable to both US and Mexican customers, and also accommodates the passage of infrastructure conduits.

SUMMARY

The above-listed need is met or exceeded by the present wall system using gypsum studs having a clearance or allowance for mechanical, electrical and/or plumbing lines, cables or conduits, collectively referred to in this application as MEP. The gypsum studs have a thickness or width extending fully between the associated wall panels, preferably also being gypsum wallboard or the like. A main distinction from prior wall construction is that in the present system, the vertical studs are not only made of gypsum, but have a length significantly shorter than the height of the wall. As such, upon assembly, upper and lower passages are created in the wall for accommodating the insertion of MEP structures.

Interior wall installation is accomplished by first securing a first wallboard panel to a wall frame including conventional top members or headers, and bottom members or footers, made of wood or steel channels formed in a “C”-shape. Once the first panel is secured, the present, shortened, vertical gypsum studs are secured to an interior surface of the wallboard panel, preferably using an adhesive to hold the studs in place until the installer secures the studs to the first panel. Preferably, the shortened studs are placed at 12 inches on center spacing as one progresses horizontally from one edge of the wallboard panel to an opposite edge. Once the studs are in place, mid-way between the upper and lower margins of the panel, any required MEP conduits, lines cables or other structures are installed in upper and lower passages or channels defined by the ends of the shortened studs. Then, a second panel is secured to the frame on an opposite side, by fastening the panel to the upper and lower members, and also to the shortened vertical gypsum studs. The use of adhesive for holding the second panel in place is optional. The shortened studs do not carry the load, but instead are used to stiffen the wall and make it feel more solid. Instead, the first and second wallboard panels carry the weight of the wall. Tests have shown only a 3-5% reduction in stiffness of the wall using the present, shortened studs, compared with standard, full-height studs.

More specifically, an interior wall system is provided, including a frame including at least one lower support member, at least one upper support member, and at least two vertical support members securing the lower and upper support members together, the frame having a first side and a second side, at least one first panel secured to the first side of the frame by attachment to at least the upper and lower support members, each first panel having an interior surface facing the frame. At least one shortened gypsum stud has a length shorter than the vertical support members, and is secured to the interior surface of at least one of the first panels to create upper and lower passages between respective ends of the at least one stud and the respective upper and lower support members. At least one second panel is secured to the second side of the frame by attachment to the upper and lower support members, and also to the shortened gypsum studs.

In an embodiment, the present wall system includes at least one MEP structure located in at least one of the passages and extending at least between the vertical support members. In a preferred embodiment the at least one first and second panels are gypsum wallboard.

In an embodiment, each shortened gypsum stud is secured to the interior surface of each first panel using adhesive prior to the application of fasteners. In an embodiment, the adhesive is gypsum joint compound.

In a preferred embodiment, the shortened gypsum studs are placed at 12 inches on center spacing as one progresses horizontally between the vertical supports.

In another embodiment, a method of assembling an interior wall system is provided, including assembling a frame having at least one lower support member, at least one upper support member, and at least two vertical support members securing the lower and upper support members together, the frame having a first side and a second side. The method includes securing at least one first panel to the first side of the frame by attachment to at least the upper and lower support members, each first panel having an interior surface facing the frame. Next, securing at least one shortened gypsum stud having a length shorter than the vertical support members to the interior surface of at least one first panel to create upper and lower passages between respective ends of the at least one stud and the respective upper and lower support members. Then, installing at least one MEP structure in at least one of the upper and lower passages, and, lastly, securing at least one second panel to the second side of the frame by attachment to the upper and lower support members, and to the shortened gypsum studs.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a fragmentary perspective view of a prior art wall system;

FIG. 1A is a perspective view of three gypsum studs;

FIG. 2 is a perspective view of a first step in constructing the present wall system, namely constructing the frame;

FIG. 3 is a perspective view of a second step in constructing the present wall system, namely adding a first set of panels to the frame;

FIG. 4 is a perspective view of a third step in constructing the present wall system, namely fastening the shortened gypsum studs to an interior surface of the first set of panels;

FIG. 5 is a perspective view of a fourth step in constructing the present wall system, namely inserting the MEP structures in upper and lower passages defined by the shortened gypsum studs;

FIG. 6 is a perspective view of a fifth step in constructing the present wall system, namely adding a second set of wallboard panels to the frame and to the installed shortened gypsum studs; and

FIG. 7 is a horizontal cross-section of the frame taken along the line 7-7 of FIG. 2 and in the direction generally designated.

DETAILED DESCRIPTION

Referring now to FIGS. 1 and 1A, a conventional wall or wall system, is generally designated 10 and refers to an interior wall in a residential or commercial building that is not load bearing. The wall 10 is mounted on a substrate 12 such as a poured concrete floor or the like, and reaches to a ceiling 14, which may or may not be finished.

Included in the wall 10 is a frame 16 including at least one footer, base member or lower support member 18 fastened to the substrate 12 by specialized fasteners as known in the art. The footers 18 usually are installed in 8 foot lengths, and multiple footers are often positioned end-to-end, depending on the size of the wall 10 to be constructed. Also included is at least one header or upper support member 20 defining an upper margin of the frame 16. Similar to the footer 18, the header 20 is provided in 8 foot lengths and multiple headers are often installed end-to-end. At least one vertical support member 22 connects the footer 18 to the header and the members 18, 20 and 22 are secured to each other with fasteners such as nails or screws (not shown) as known in the art. Also, the headers 18, the footers 20 and the vertical support members 22 are contemplated as being made of wood or “[”-channel steel construction as is also known in the art, but the “[“-channel is considered preferred. An interior frame space 24 is defined by the footer 18, the header, 20 and the vertical support members 22.

A feature of the wall 10 is the use of gypsum wallboard studs, also referred to as gypsum studs 26 as substitution for many of the vertical support members 22. At least one gypsum stud 26 is secured in the interior frame space 24, and is fastened to the frame 16. As seen in FIG. 1A, in the present application, the wallboard stud 26 is assembled from a plurality of layers or thicknesses 28 of conventional wallboard that has been cut into appropriate lengths, such as 8 feet (2.44 meters) long, in similar fashion to the vertical frame members 22. The multiple layers 28 are secured into a unitary mass using chemical adhesive or the like. Further, in the preferred embodiment, the wallboard studs 26 have a width of 100 mm, (about 4 inches) and a thickness of 64 mm (about 2.5 inches). In other words, the wallboard stud 26 has a thickness that extends from a first frame side 30 to a second frame side 32.

In conventional construction, the vertical frame members 22 are installed at a predetermined spacing, such as 16-inch on center spacing. In the present application, the frame 16 is provided with the first frame side 30 corresponding to an exterior of a room defined by the wall 10, and the second frame side 32 corresponding to an interior of the room defined by the wall.

While the frame 16 is contemplated as being made either of wood studs or metal “[“-shaped channel, in a preferred embodiment, the frame is made of metal channel and the footer 18 defines an upwardly-projecting U-shape defining a cavity 34 between walls 36 (FIGS. 2 and 3). A feature of the wallboard stud 26 is having a thickness that extends between the walls 36 or from the first side 30 to the second side 32, which is considered to be substantially the same dimension.

A first wallboard panel 38 is secured to the first side 30. Preferably, the panel 38 is a sheet of gypsum wallboard or the like having a 4 by 8 foot (1.22 meter X 2.44 meter) (dimension and a thickness of ½ inch, 5/8 inch or even 1 inch ( 1.27 cm, 1.6 cm or 2.5 cm) depending on the application. Other known construction panels used in interior construction are contemplated as the first wallboard panel 38. It will be understood that the first wallboard panel 38 represents a plurality of such panels secured to the frame 16 by fasteners to close off the wall 10 as is known in the art.

Once the first wallboard panel 38 is secured to the frame 16 and to the wallboard studs 26, a second wallboard panel 40 is fastened to the wallboard studs and also to the other frame members 18, 20, 22 similarly to the first wallboard panel 38. As is the case with the first wallboard panel 38, the second wallboard panel 40 is a sheet of gypsum wallboard or the like having a 4 by 8 foot dimension and a thickness of ½ inch, 5/8 inch or even 1 inch depending on the application. Other known construction panels used in interior construction are contemplated.

Once the second wallboard panel 40 is in place, the wall 10 is finished in a conventional manner, using wallboard joint compound to fill the seams between adjacent panels. Upon assembly, the second wallboard panel 40 creates a continuous acoustic connection between the first wallboard panel 38, the wallboard stud 26 and the second wallboard panel.

As stated above, a drawback of the prior art wall 10 is the difficulty in feeding plumbing, electrical and/or data conduits, piping or cables, collectively referred to in this application as MEP structures 50 (FIG. 6) in the interior frame space 24. Unlike the conventional “[“- channel vertical supports 22, which are provided with stamped cutouts for the passage of MEP structures 50, gypsum studs 26 are solid. Accordingly, accommodation of the MEP structures 50 is accomplished in gypsum studs 26 by tedious, customized cutting of each gypsum stud as needed.

Referring now to FIGS. 2-7, to address the above-identified problem of wall construction using gypsum studs 26, the present wall or wall system is provided, generally designated 60. Also, the present wall system 60 is assembled in an unconventional way so that the MEP structures 50 are easily accommodated. Components shared by the present wall system 60 with the wall system 10 are designated with identical reference numbers.

To create the present wall system 60, and as seen in FIG. 2, first the frame 16 is assembled, including at least one lower support member 18, at least one upper support member 20, and at least two vertical support members 22 securing the lower and upper support members together. As discussed above, the frame 16 has the first frame side 30 and the second frame side 32.

Referring now to FIG. 3, a difference in the assembly of the present wall 60 is that the first panel 38 is secured to the first side 30 of the frame by attachment to at least the upper and lower support members 18, 20 prior to installation of a majority of the vertical support members 22, and particularly prior to the installation of the gypsum studs 26. As is the case with the wall system 10, each first panel 38 has an interior surface 62 facing the frame 16. Since the wall 60 is not load bearing and is an interior wall, the panels 38 perform no load bearing function, and only need to be secured in place, as by the use of conventional fasteners securing the panel along upper and lower perimeter edges 64. Endmost panels 38e are also secured to the adjacent vertical support 22 using fasteners as known in the art.

Referring now to FIG. 4, another unconventional step in assembling the wall 60 is that at least one, and preferably a plurality of shortened gypsum studs 66 are provided, having a length shorter than a length of the vertical support members 22, which are typically 8 feet in length (height) (2.44 meters). Instead, the shortened gypsum studs 66 are about 6 feet in length (1.83 meters) and have upper and lower ends 68, 70 that create or define upper and lower passages 72, 74 between respective stud ends and the respective upper and lower support members 20, 18. During installation or assembly of the wall 60, the shortened gypsum studs 66 are secured to the inner wallboard surface 62 of the first wallboard panel 38.

Preferably, the shortened gypsum studs 66 are initially secured in place on the panel 38 using an adhesive composition, such as but not restricted to gypsum joint compound or a chemical adhesive 76. While the use of gypsum joint compound is preferred in this application, a suitable chemical adhesive 76 will have relatively fast setting and strong bonding qualities. One acceptable type of adhesive 76 is polyurethane-based. Suitable chemical adhesives 76 are manufactured by Sika Corporation, Lyndhurst, New Jersey. As the adhesive 76 becomes suitably set to hold the shortened gypsum studs 66 in place, the installer then fully secures the studs 66 in place using conventional fasteners installed through an exterior surface of the panel 38 on the frame side 30. As seen in FIG. 4, the shortened gypsum studs 66 are preferably installed at least on seams 78 defined between adjacent panels 38 by corresponding abutting edges. In a preferred embodiment, the shortened gypsum studs 66 are placed at 12 inches on center spacing as one progresses horizontally between the vertical supports 22, so not all the studs will be located on the seams 78.

Referring now to FIG. 5, the MEP structures 50 are then installed in at least one of the upper and lower passages 72, 74 as needed, depending on the particular application. Preferably, the MEP structures 50 extend at least between the vertical supports 22, also depending on the requirements of the particular application. By using the shortened gypsum studs 66, assembly of the wall 60 is considerably more efficient, and the gypsum studs have sufficient length to substantially dampen noise transmitted through the wall 60.

Referring now to FIG. 6, after installation of the MEP structures 50, the second wallboard panel 40 is secured to the second side 32 of the frame 16 by attachment to the upper and lower support members 20, 18, and also to edges 80 of the shortened gypsum studs 66.

Accordingly, a method of assembling the interior wall system 60, includes assembling the frame 16 having at least one lower support member 18, at least one upper support member 20, and at least two vertical support members 22 securing the lower and upper support members together, the frame having the first side 30 and a second side 32, securing at least one first panel 38 to the first side 30 of the frame 16 by attachment to at least the upper and lower support members 20, 18, each first panel 38 having the interior surface 62 facing the frame 16, securing at least one shortened gypsum stud 66 having a length shorter than the vertical support members 22 to the interior surface 62 of the at least one first panel 38 to create the upper and lower passages 72, 74 between respective ends 68, 70 of the at least one stud 66 and the respective upper and lower support members 20, 18, installing MEP structures 50 in at least one of the upper and lower passages 72, 74, and securing at least one second panel 40 to the second side 32 of the frame 16 by attachment to the upper and lower support members 20, 18, and to the shortened gypsum studs 66.

While a particular embodiment of the present wall system using gypsum studs having MEP accommodation has been described herein, it will be appreciated by those skilled in the art that changes and modifications may be made thereto without departing from the invention in its broader aspects and as set forth in the following claims.

Claims

1. An interior wall system, comprising:

a frame including at least one lower support member, at least one upper support member, and at least two vertical support members securing said lower and upper support members together, said frame having a first side and a second side;

at least one first panel secured to said first side of said frame by attachment to at least said upper and lower support members, each said first panel having an interior surface facing said frame;

at least one shortened gypsum stud having a length shorter than said vertical support members, and being secured to said interior surface of said at least one first panel so as to create upper and lower passages between respective ends of said at least one stud and the respective upper and lower support members;

at least one second panel secured to said second side of said frame by attachment to said upper and lower support members, and also to said shortened gypsum studs.

2. The wall system of claim 1, further including at least one MEP structure located in at least one of said passages and extending at least between said vertical support members.

3. The wall system of claim 1, wherein said at least one first panels and said at least one second panels are gypsum wallboard.

4. The wall system of claim 1, wherein each said gypsum stud is secured to said interior surface of said at least one first panel using adhesive prior to the application of fasteners.

5. The wall system of claim 4, wherein said adhesive is gypsum joint compound.

6. The wall system of claim 1, wherein said shortened gypsum studs are placed at 12 inches on center spacing as one progresses horizontally between said vertical supports.

7. A method of assembling an interior wall system, comprising:

assembling a frame having at least one lower support member, at least one upper support member, and at least two vertical support members securing said lower and upper support members together, said frame having a first side and a second side;

securing at least one first panel to said first side of said frame by attachment to at least said upper and lower support members, each said first panel having an interior surface facing said frame;

securing at least one shortened gypsum stud having a length shorter than said vertical support members to said interior surface of said at least one first panel to create upper and lower passages between respective ends of said at least one stud and the respective upper and lower support members;

installing at least one MEP structure in at least one of said upper and lower passages; and

securing at least one second panel to said second side of said frame by attachment to said upper and lower support members, and to said shortened gypsum studs.

8. The method of claim 7, further including securing said shortened gypsum studs to said interior surface of said at least one panel using chemical adhesive.

9. The method of claim 7, wherein said adhesive includes polyurethane.

10. The method of claim 7, further including placing said shortened gypsum studs at 12 inches on center spacing as one progresses horizontally between said vertical supports.