RESILIENT CONSTRUCTION MEMBER

Abstract: A construction beam (100, 100a-c, 200, 300) includes a pair of lateral members (102, 102a-c, 202, 302, 104, 104a-c, 204, 304) and a resilient web (106, 106', 106'', 106''', 206, 306a-b) extending therebetween, so as to present a cross-sectional profile corresponding to commonly used construction beam members (for example, 2" x 4" or 2" x 6"). The resilience of the web (106, 106', 106'', 106''', 206, 306a-b) helps to attenuate sound transmission through the beam (100, 100a-c, 200, 300) from one lateral member (102, 102a-c, 202, 302, 104, 104a-c, 204, 304) to the other. In particular, in a wall frame, the lateral members (102, 102a-c, 202, 302, 104, 104a-c, 204, 304) are mounted at opposite ends thereof to end plates consisting of other construction beams (100, 100a-c, 200, 300) according to the present invention (that is, a pair of lateral members (102, 102a-c, 202, 302, 104, 104a-c, 204, 304) with a resilient web (106, 106', 106'', 106''', 206, 306a-b) extending therebetween). When the wall frame is used in a building structure, the lateral members (102, 102a-c, 202, 302, 104, 104a-c, 204, 304) of the end plates on the same side are attached to the surrounding structure, leaving the other side of the frame resiliently free floating. A wall is mounted on the free floating side of the wall frame so as to provide a resiliently free floating wall that acts as a sound attenuating "diaphragmatic" absorber.

Description: RESILIENT CONSTRUCTION MEMBER TECHNICAL FIELD AND INDUSTRIAL APPLICABILITY OF THE INVENTION The present invention relates to members used in construction, especially in applications where the importance of sound attenuation and isolation is significant. In particular, the present invention relates to construction members used to construct building structures in which sound transmission from one room to another is to be prevented or reduced. BACKGROUND OF THE INVENTION In general, it is conventionally known to resiliently mount a wall or ceiling in order to isolate sound or attenuate transmission therethrough. U.S. Patent No. 3,445,975 to Nelsson discloses a partition in which first and second lath panels are held against a metallic stud, channel, or furring member by a clip fastener. One portion of the stud, channel, or furring member is cantilevered away from the portion at which the lath panels are clipped thereto. According to Nelsson, this permits the free portion of the stud, channel, or furring member to flex as the lath panels mechanically respond to sound waves incident thereon. The remainder of the structure dampens this surface movement, reducing sound transmission to the opposite surface of the partition. U.S. Patent No. 3,324,615 to Zinn discloses a construction member having a plurality of laterally extending supporting tabs by which wallboard segments are resiliently mounted. U.S. Patent No. 3,046,620 to Tvorik et al. discloses a ceiling hanger member whereby a furring strip (to which a ceiling member is attached) is resiliently attached to a joist, such that the weight of the furring strip and ceiling member resiliently separates the furring strip from the joist. Another known method of sound attenuation is to build a wall frame in which studs are laterally staggered relative to a toe plate and head plate. Therefore, alternate studs are used to mount wall board on respective sides of the frame so that a given stud is spaced away from one of wall boards. Unfortunately, the foregoing conventional methods of noise attenuation are problematic in that they generally move away from basic construction methods and thereby increase complexity and cost. For example, they require additional parts (such as Tvorik et al. and Nelsson) or specially made parts (such as the channel member with specially formed support tabs, as in Zinn). The staggered stud arrangement necessarily results in a thicker wall partition which reduces the area of the room whose walls are framed in this manner, and increases the cost of the toe and head plates. In addition, nail fasteners generally cannot be used with metal members, thereby undesirably restricting available construction methods. In addition to the devices for sound attenuation described hereinabove, a wood I- beam is commercially available (for example, under the brand name "BCI Advantage" from Boise Cascade Corporation) that comprises a pair of wood members with a rigid wooden panel extending therebetween. However, because the wooden panel is essentially non-resilient, this I-beam offers little or no sound attenuation benefit. SUMMARY OF THE INVENTION The present invention is therefore directed to a construction member that relies on resilient flexibility in order to attenuate sound transmission therethrough, but also more closely conforms to conventional building members in order to minimize or eliminate the need for any special handling or the like in use. In particular, the present invention is directed to a construction beam member sized comparably to conventional wood beams (for example, 2" x 4" or 2" x 6"). The beam comprises a pair of spaced of lateral members having a resilient web extending therebetween. The web is preferably relatively stiff, but permits a slight flexure between the lateral members. The lateral members are preferably made from an easily workable material such as wood. BRIEF DESCRIPTION OF THE DRAWINGS The present invention will be described in detail hereinbelow, with reference to the drawings appended hereto, in which: Figure 1 is a partial perspective view of an end of a construction beam according to the present invention; Figure 2 is an end view of a beam according to the present invention; Figure 3 is a plan view of a beam according to a different embodiment of the present invention; Figure 4 is a perspective view of an example of a linkage for linking lateral members in a beam according to the present invention; Figure 5 is a partial perspective view of a framework for mounting wallboard or the like, utilizing beams according to the present invention; Figure 6 is a partial perspective view of a beam according to yet another embodiment of the present invention; Figure 7 is a plan view of a beam according to the embodiment of the present invention shown in Figure 6; and Figure 8 is a plan view of a variant of the beam shown in Figure 7. DETAILED DESCRIPTION AND PREFERRED EMBODIMENTS OF THE PRESENT INVENTION Figures 1 and 2 illustrate a portion of a beam 100 according to the present invention. In general, beam 100 comprises lateral members 102 and 104 with a web 106 spanning therebetween. Lateral members 102, 104 are generally squared in cross-sectional profile and have at least the same thickness y (see Figure 2). Moreover, lateral beams 102, 104 are preferably identical so that each has the same width, proportionately spaced with web 106 therebetween so as to present an overall beam width x. Lateral members 102, 104 are preferably (but not necessarily) identical in shape so as to facilitate manufacture of beam 100 from one source of stock. Accordingly, beam 100 presents a cross section having a major dimension x and minor dimension y corresponding to any standard beam size (for example, 2" x 4", 2" x 6", and so on, without limitation). According to the present invention, lateral members 102, 104 are elongate rigid members. Accordingly, a variety of suitably rigid materials could be used. However, lateral members 102, 104 are preferably (but not exclusively) made from wood, (in part, in keeping with an intent of the present invention to present a construction member very similar to those conventionally used in the art). Wood is also desirable because it can be worked, generally, in more ways than comparable metal members (for example, it can be easily cut, driven with nails or screws, etc.). Not only can continuous lumber be used, but composite materials, such as plywood or wood particle board can be used. In addition, finger jointed wood members can be used according to the present invention. A plastic material reinforced with glass fibers may also be used in accordance with the present invention. Web 106 is made from a relatively rigid material that has some flexibility. If web 106 is relatively too flexible, lateral members 102, 104 have too much relative freedom of movement and beam 100 is no longer, overall, a rigid member. If web 106 is relatively too stiff, then the benefits of sound isolation/attenuation are lost. Generally, web 106 may be made from any suitably stiff and resilient material, including (without limitation) rubber, asphalt, plastic or other resilient polymeric material. In one example of the present invention, web 106 is made from galvanized 22 gauge steel. As seen in Figure 4, web 106 includes edge portions 106a and an intermediate portion 106b. Edge portions 106a are embedded in lateral members 102, 104, and intermediate portion 106b extends obliquely between lateral members 102, 104. However, intermediate portion 106b may, most generally, extend between lateral members 102, 104 in any orientation so long as flexure between lateral members 102, 104 is relatively easy (compared to, for example, an intermediate portion extending straight across the gap between lateral members 102, 104, which does not readily flex). It is noted that the use of galvanized steel as described here may offer additional ancillary benefits, such as improved fire safety protection. Edge portions 106a are embedded in lateral members 102, 104 in any conventional manner. One possible method (not illustrated) is to form grooves in lateral members 102, 104 that are wider than the thickness of edge portions 106a. Once edge portions 106a are suitably disposed in the respective grooves, additional strips of material (such as wood) are pressed into the remaining space in the grooves, such that edge portions 106a are wedged into place and retained in the grooves. Web 106 may extend continuously substantially the entire length of lateral members 102, 104. However, when beams 100 are used in construction, it is useful to provide a plurality of spaced apart webs 106, such that piping, wiring and the like can be passed through the openings between webs 106 (see Figure 3). Whether one or a plurality of webs 106 are provided, it is specifically contemplated that beams 100 are provided in standardized lengths (for example, 8') as seen in Figure 3 and can be cut down as required. As mentioned above, it is an important feature of the present invention to provide a construction member that can be used like conventional construction beams. Accordingly, Figure 5 is a partial perspective view of a frame work (as might be used for walls in a building). As seen in Figure 5, beams 100a, 100b are mounted as studs on a laterally extending beam (that is, a head plate or toe plate) 100c. (Another laterally extending beam (not shown) is provided at the other end of beams 100a, 100b.) The structure of each of beams 100a- 100c is in accordance with the description of the present invention hereinabove, and will not be repeated here. Attention is drawn to the manner in which lateral members 102a and 102b and 104a and 104b are mounted with respect to lateral members 102c and 104c, respectively, with nails, screws or any other conventional fasteners (not shown here). Accordingly, it can be appreciated that one side of the frame (that is, lateral members 102a- 102c) are resiliently separated by way of respective webs 106', 106", and 106'" from the other side of the frame (that is, lateral members 104a- 104c). Accordingly, sound impinging on a wall member mounted on one side of the frame is attenuated upon transmission to the other side of the frame because of the resilience of webs 106', 106", and 106"'. Furthermore, it is possible to resiliently mount a wall so that it acts like a diaphragmatic sound absorber. In particular, only one "side" of the frame assembly (for example, lateral member 104c and/or lateral members 104a, 104b) is fixed to the surrounding structure, and the other side of the frame assembly has wall board or the like mounted thereon (that is, on lateral members 102a, 102b), without attachment to the surrounding structure. The wall is therefore mounted on the "free" or "floating" side of the studs. In order to enhance the effect of decoupling the one side of the wall frame from the surrounding structure, it is desirable to provide a soft gasket (made from, for example, foam rubber) between the lateral beam 100c and the surrounding structure (that is, the ceiling and/or floor). This promotes relatively free movement of the one side of the frame that is not fixed to the surrounding building structure. To further enhance the effect of decoupling the wall from the surrounding structure, it is preferable to provide flexible joint material at junctions between wall board segments, including at corners of rooms. Therefore the wall surface is visually continuous, but physically decoupled, in order to take advantage of the resultant sound attenuation effects. Also, it is very desirable to provide additional sound and/or thermal insulation in the spaces defined by the studs and end plates. Such insulation can be of any conventional type, including blown, rolled or batting, foam board, etc. The addition of such insulation enhances sound attenuation effects resulting from the present invention. Figures 6 and 7 are a partial perspective view and a partial plan view, respectively, of beam 200, in accordance with another embodiment of the present invention. The design concept underlying beam 200 is fundamentally similar to that of beam 100. Like before, lateral members 202 and 204 are provided, and are resiliently spaced apart from each other by web 206. Unlike web 106 in beam 100, however, web 206 is not embedded in lateral members 202, 204. Instead, web 206 is fixed (by any conventional means, such as nails, as shown in Figures 6 and 7) relative to opposite faces of lateral members 202, 204 along the major dimension of the beam cross section. As in the first embodiment, a plurality of spaced apart webs 206 may be provided along the length of beam 200 (see, for example, Figure 7). Web 206 is preferably made from a material that is slightly more flexible than that used for web 106, such as 24 gauge galvanized steel. Initial comparative testing has been undertaken comparing the sound attenuation characteristics of conventional construction members versus beam 100 and beam 200. Initial results indicate that beam 100 has greater than expected attenuation characteristics, and that beam 200 should have even better attenuation performance than beam 100. This latter effect is thought to be caused by the shape and orientation of web 206, which more easily permits a normal compression between lateral members 202, 204. In addition, as a variation of the embodiment illustrated in Figure 7, the plurality of webs are alternately arranged so that the portion of the webs extending obliquely thereacross alternates (thereby crossing each other, as seen from an end of beam 200) (see Figure 8). In Figure 8, beam 300 comprises lateral beams 302 and 304, and includes a plurality of first webs 306a which are spaced from and alternate with a plurality of second webs 306b. Accordingly, respective intermediate portions of webs 306a and 306b crisscross as seen from an end of beam 300. Inasmuch as sound that one seeks to attenuate or isolate is typically physically unique relative to particular environments (for example, a home theater room, a movie theater, a machine shop, a recording studio, a concert hall), it is an important feature of the present invention to provide a construction member that can be "tuned" in order to tailor its sound attenuation properties for a specific environment. In other words, a beam according to the present invention can be specifically manufactured so that its resilient properties (in terms of, for example, spring constant) are made to correspond to a particular kind of sound (especially in terms of its frequency) so that sound attenuation can be maximized. Such "tuning" can be accomplished by varying the thickness of web 106, 206, either uniformly or variably over the entire area of web 106, 206. In addition, notches, slits, or other openings can be formed in web 106, 206 to control the resilience of web 106, 206 in accordance with known principles of physics. In addition, suitably sized perforations or openings in a continuous web can be formed so as to create a tunable Helmholtz resonator effect between adjacent cavities defined between studs in the framework illustrated in Figure 5. By altering the number and/or size of the perforations or openings, a resultant Helmholtz resonant frequency can be controlled, at which attenuation of sound at that frequency is maximized. It should be noted that this is different from reference to a plurality of webs as shown in Figures 3, 7, and 8. It can therefore be appreciated that adjoining rooms may be constructed (for example, adjoining musical studios) such that each room can be tuned in accordance with its respective mode of use. In particular, this may be accomplished by constructed "double wall" framework, where two frames of the structure illustrated in Figure 5 are constructed face-to-face, such that the respective opposing sides of the frames are fixed to the surrounding building structure and their respective opposite sides are left free floating in the manner discussed above. Although construction members according to the present invention have been described hereinabove for wall frames and the like, they are also contemplated for use in mounting floating ceilings which are acoustically isolated from a building structure. In addition, construction members according to the present invention may also be used in floor construction. In particular, a construction member for mounting a floating ceiling may be used by fixing one of the lateral members to the building structure and fixing a ceiling member to the free floating lateral member (that is, the lateral member not fixed to the building structure). Although the use of substantially identical lateral members is contemplated according to the present invention, it is expressly within the scope of the present invention to use dissimilar lateral members. For example, one of the lateral members 102, 104 shown in Figure 2 may be replaced by a conventional wood I-beam of the type described above. In particular, web 106 may be embedded in one of the flange portions of the wood I-beam, in the manner disclosed above. Although the present invention is directed primarily to construction members made from non-metal materials, the design concepts may be of interest in the manufacture of metal studs comprising a pair of metal members with a resilient web extending therebetween in accordance with the foregoing description. In particular, a metal stud using the inventive principles disclosed herein could be made from a single piece of sheet metal, formed into shape. The present invention being thusly described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art are intended to be included within the scope of the following claims.

Claims: WHAT IS CLAIMED IS: 1. A beam (100, lOOa-c, 200, 300) member comprising: a plurality of spaced apart lateral members (102, 102a-c, 202, 302, 104, 104a-c, 204, 304); and a resilient web (106, 106'-'", 206, 306a-b) extending between respective pairs of said lateral members (102, 102a-c, 202, 302, 104, 104a-c, 204, 304) and having respective edge portions fixed to respective ones of said lateral members (102, 102a-c, 202, 302, 104, 104a-c, 204, 304). 2. The beam (100, lOOa-c, 200, 300) member according to claim 1, wherein said lateral members (102, 102a-c, 202, 302, 104, 104a-c, 204, 304) are squared in cross- section. 3. The beam (100, lOOa-c, 200, 300) member according to claim 1, wherein said web (106, 106'-"', 206, 306a-b) extends obliquely between said lateral members (102, 102a-c, 202, 302, 104, 104a-c, 204, 304). 4. The beam (100, lOOa-c, 200, 300) member according to claim 1, wherein said web (106, 106'-'", 206, 306a-b) is made from metal. 5. The beam (100, lOOa-c, 200, 300) member according to claim 4, wherein said web (106, 106'-'", 206, 306a-b) is made from galvanized steel. 6. The beam (100, lOOa-c, 200, 300) member according to claim 4, wherein said web (106, 106'-'", 206, 306a-b) is made from 22 gauge stock or thinner. 7. The beam (100, lOOa-c, 200, 300) member according to claim 5, wherein said web (106, 106'-'", 206, 306a-b) is made from 22 gauge stock or thinner. 8. The beam (100, lOOa-c, 200, 300) member according to claim 1, wherein said lateral members (102, 102a-c, 202, 302, 104, 104a-c, 204, 304) are made from wood. 9. The beam (100, lOOa-c, 200, 300) member according to claim 1, wherein said lateral members (102, 102a-c, 202, 302, 104, 104a-c, 204, 304) are made from wood particle board. 10. The beam (100, lOOa-c, 200, 300) member according to claim 8, wherein said lateral members (102, 102a-c, 202, 302, 104, 104a-c, 204, 304) are made from finger jointed wood segments. 11. The beam (100, lOOa-c) member according to claim 1, wherein said respective edge portions (106a) are embedded in respective ones of said lateral members (102, 102a- c, 104, 104a-c). 12. The beam (100, lOOa-c) member according to claim 11, wherein said edge portions (106a) are fixed in grooves formed in said lateral members (102, 102a-c, 104, 104a-c), respectively. 13. The beam (100, lOOa-c) member according to claim 1, wherein said edge portions (106a) are fixed to respective facing sides of said lateral members (102, 102a-c, 104, 104a-c). 14. The beam (100, lOOa-c, 200, 300) member according to claim 1, comprising a plurality of spaced apart said web (106, 106'-'", 206, 306a-b)s extending between respective pairs of said lateral members (102, 102a-c, 202, 302, 104, 104a-c, 204, 304). 15. The beam (100, lOOa-c) member according to claim 14, wherein said respective edge portions (106a) are embedded in respective ones of said lateral members (102, 102a- c, 104, 104a-c). 16. The beam (100, lOOa-c) member according to claim 15, wherein said edge portions (106a) are fixed in grooves formed in said lateral members (102, 102a-c, 104, 104a-c), respectively. 17. The beam (200, 300) member according to claim 14, wherein said edge portions (206) are fixed to respective opposite sides of said lateral members (202, 302, 204, 304). 18. A wall frame in a building construction comprising: a first end plate comprising a first pair of lateral members (102a, 104a) and a resilient web (106') extending therebetween; and a stud comprising a second pair of lateral members (102b, 104b) and a resilient web (106") extending therebetween; wherein said stud is orthogonally mounted on said end plate. 19. The frame according to claim 18, wherein both lateral members of said second pair of lateral members (102b, 104b) are fixed to respective lateral members of said first pair of lateral members (102a, 104a). 20. The frame according to claim 18, wherein said stud comprises a plurality of spaced apart said resilient webs (106") extending between said second pair of lateral members (102b, 104b). 21. The frame according to claim 18, further comprising a second end plate, comprising a third pair of lateral members (102c, 104c) and a resilient web (106'") extending therebetween, an opposite end of said stud from said first end plate being mounted on said second end plate. 22. In a building structure, a frame for mounting a wall comprising: a first end plate comprising a first pair of lateral members (102a, 104a) and a resilient web (106') extending therebetween; a second end plate generally parallel to said first end plate and comprising a second pair of lateral members (102b, 104b) and a resilient web (106") extending therebetween; and a stud comprising a third pair of lateral members (102c, 104c) and a resilient web (106'") extending therebetween; wherein said stud is orthogonal to said first and second end plates with respective ends thereof being fixed to said first and second end plates. 23. The frame according to claim 22, wherein respective lateral members of said third pair of lateral members (102c, 104c) are fixed to respective lateral members of said first pair of lateral members (102a, 104a) and said second pair of lateral members (102b, 104b), respectively. 24. The frame according to claim 23, wherein lateral members of said first, second, and third pairs of lateral members (102, 102a-c, 202, 302, 104, 104a-c, 204, 304) on the same side of the frame are attached to the building structure, such that the lateral members of the first, second, and third pairs of lateral members (102, 102a-c, 202, 302, 104, 104a-c, 204, 304) on the other side of the frame are left resiliently free. 25. The frame according to claim 24, wherein wall board is mounted on at least some of the lateral members (102, 102a-c, 202, 302, 104, 104a-c, 204, 304) on said other side of the frame so as to define a resiliently mounted wall acting as a diaphragmatic sound damper. 26. The beam (100, lOOa-c, 200, 300) member according to claim 1, wherein said web (106, 206) includes at least one opening therein sized in accordance with Helmholtz resonator principles so as to correspond to a predetermined sound frequency. 27. The frame according to claim 21, wherein said web (106, 206) of said stud includes at least one at least one opening therein sized in accordance with Helmholtz resonator principles so as to correspond to a predetermined sound frequency. 28. The frame according to claim 22, wherein said web (106, 206) of said stud includes at least one opening therein sized in accordance with Helmholtz resonator principles so as to correspond to a predetermined sound frequency. 29. The beam (100, lOOa-c, 200, 300) member according to claim 1, wherein said web (106, 106'-'", 206, 306a-b) is made from a resilient polymeric material. 30. The frame according to claim 18, wherein said resilient webs (106, 106'-'", 206, 306a-b) of said first end plate and said stud are made from one of a resilient polymeric material and a metal. 31. The frame according to claim 21, wherein said resilient web (106, 106'-'", 206, 306a-b) of said second end plate is made from one of a resilient polymeric material and a metal. 32. The frame according to claim 22, wherein resilient webs (106, 106'-'", 206, 306a- b) of said first and second end plates and said stud are made from one of a resilient polymeric material and a metal. 33. The beam (100, lOOa-c, 200, 300) member according to claim 1, comprising two said spaced apart lateral members (102, 102a-c, 202, 302, 104, 104a-c, 204, 304) with said resilient web (106, 106'-'", 206, 306a-b) extending therebetween. 34. The beam (100, lOOa-c, 200, 300) member according to claim 1, wherein one of said lateral members (102, 104) is an I-beam, a respective said edge portion of said resilient web (106, 106'-'", 206, 306a-b) being fixed to a flange portion of said I-beam. 35. A beam (100, lOOa-c, 200, 300) member comprising: an I-beam comprising a pair of flange portions and a rigid web (106, 106'-'", 206, 306a-b) extending therebetween; a secondary member; and a resilient web (106, 106'-'", 206, 306a-b) extending between said I-beam and said secondary member, an edge portion of said resilient web (106, 106'-'", 206, 306a-b) being fixed to a flange portion of said I-beam. 36. The beam (100, lOOa-c, 200, 300) member according to claim 35, wherein said rigid web (106, 106'-'", 206, 306a-b) and said resilient web (106, 106'-'", 206, 306a-b) have generally parallel directions of extension. 37. A frame member for hanging a ceiling in a building structure, comprising: a beam (100, lOOa-c, 200, 300) comprising a pair of lateral members (102, 102a-c, 202, 302, 104, 104a-c, 204, 304) and a resilient web (106, 106'-'", 206, 306a-b) extending therebetween, wherein one of said lateral members (102, 102a-c, 202, 302, 104, 104a-c, 204, 304) is fixed to the building structure, and the other of said lateral members (102, 102a-c, 202, 302, 104, 104a-c, 204, 304) is left resiliently free-floating, the other of said lateral members (102, 102a-c, 202, 302, 104, 104a-c, 204, 304) being adapted to have a ceiling member fixed thereto. 38. The frame member according to claim 37, wherein said lateral member fixed to said building structure is an I-beam comprising a pair of flange portions and a rigid web (106, 106'-'", 206, 306a-b) extending therebetween. 39. The frame member according to claim 38, wherein one of said flange portions is fixed to the building structure and the other of said flange portions is connected to said resilient web (106, 106'-'", 206, 306a-b). 40. The frame member according to claim 39, wherein said I-beam is made from wood. 41. The frame member according to claim 37, wherein said lateral member fixed to said building structure is a truss comprising a plurality of rigid members. 42. The frame member according to claim 41 wherein said truss is a ceiling joist.

Inventors: MCGRATH RALPH D, O'BRIEN-BERNINI FRANK C, MCGRATH, RALPH, D., O'BRIEN-BERNINI, FRANK, C.
Applicants: BRIEN BERNINI FRANK C O, MCGRATH RALPH D, OWENS CORNING FIBERGLASS CORP, MCGRATH, RALPH, D., O'BRIEN-BERNINI, FRANK, C., OWENS CORNING
Application year: 1999
Main classification: E04B1
IPC codes: E04B2, E04B9, E04C3