Patent ID: 12221792

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

FIG.10shows a single leg, resilient, sheet metal channel35in accordance with the prior art, used as a decoupling means between steel or wooden framed ceilings to separate the building structure from the drywall, effectively reducing sound transmission.

Therefore, in effect, this a soundproofing measure. This particular product is referred to as RC-1 resilient channel35offered by the TRADEMARK SOUNDPROOFING® company of Suffern, New York. The information forFIG.10can be accessed online at:—https://www.tmsoundproofing.com/RC1-Resilient-Channels-32-Pack.html#: ˜:text=RC1%200ne %20Leg %20Resilient %20Channels,8.6′ %20(102%22),
accessed online on Sep. 25, 2020.

The following information is provided by the above web-page. The RC-1 resilient channel35is a thin, flexible metal channel that is screwed to ceiling joists. Drywall is then screwed to the RC-1 resilient channel35, and the flexibility of the channel35creates a decoupled wall. The thickness is 25 Gauge (18 Mils). The width of the strip71for metal screws to fasten the RC-1 resilient channel35to the ceiling joists is 1.25 inches (˜32 mm). The width of the strip73for metal screws to fasten a drywall panel to the RC-1 resilient channel35is less than three-fourths (¾ths) of an inch (less than ˜19 mm). The overall width of the RC-1 resilient channel35is two inches (50.8 mm). The “single leg”77is the inclined wall sloping about 15° from vertical.

As an aside, the RC-1 resilient channel35is available in lengths of 8.5 feet (˜2.6 m).

More pertinent here, the RC-1 resilient channel35provides a drop in elevation from a plane containing the bottoms of the floor joists to the top surface of the drywall panel by 0.5 inches (12.7 mm).

FIG.1is an upward-looking perspective view of a framed ceiling80construction project in an intermediate stage of completion, showing a pair of single leg, resilient, sheet metal channels35in accordance with the prior art (see, eg.,FIG.10) cooperatively flanking a resilient channel complement100thereto in accordance with the invention (eg.,FIGS.2-9). In other words, the viewer is essentially standing on the floor and looking up.

InFIG.1, for example and without limitation, the floor joists112are shown as boards of nominal 2×6 dimensional lumber (or alternatively, wooden framing joists). Such wooden framing joists112typically come in lengths of eight feet to sixteen feet. In use, such framing joists112are typically arranged in parallel courses with respect to each other, which courses are typically sixteen inches apart between centers. From the perspective of the relatively lower floor, these wooden framing joists112might be reckoned as ‘ceiling’ joists112. Alternatively, from the perspective of the immediately succeeding floor, these wooden framing joists112might be reckoned as ‘floor’ joists112.

To turn to matters with respect to drywall panels124, the most commonly used panels124measure four feet wide but the lengths of choice are usually either eight feet long or twelve feet long. The preferred thickness of choice is usually one-half inch, but another widely available thickness is five-eighths of an inch. Other thicknesses are no doubt available, but usually, if a thickness of one-inch is desired, two half-inch panels124are layered together to build the combined thickness to one inch.

Thus a drywall ceiling panel124will have spaced long edges136four foot apart spacing spaced short edges200that might originally be eight feet or twelve feet apart. No doubt during construction, dimensions can be trimmed to fit the job.

To studyFIG.1further, it shows three strips of single leg, resilient, sheet metal channels35,100and35screwed to the bottoms114of the spaced framing joists112. The channel100in the center comprises the single leg resilient sheet metal channel complement100in accordance with the invention. The two channels35flanking the resilient channel complement100in accordance with the invention comprise two single leg resilient sheet metal channels35in accordance with the prior art.

Given the foregoing, a typical drywall ceiling panel124will be hung by fasteners116(see, eg.,FIGS.8and9) from consecutive and spaced single leg resilient sheet metal channels35that are (for example and without limitation) sixteen inches apart between centers.

If a construction project is of any size, the drywall portions of the project will be handled by a drywall contractor forming a crew of several individuals. One or more of these individuals is likely to be a specialist among the crew for the application of tape126(see, eg.,FIG.9) and the ‘floating’ of drywall compound128(again, seeFIG.9). In some parts of the country, this party might be referred to as the ‘taping and mudding’ pro. As an aside, this specialist is also likely to be the “compound” expert among the crew in selecting the appropriate compound composition for the specific coats and finishes for the project. But that subject is a huge subject unto itself and is not particularly crucial here.

It is an object of the invention that the single leg resilient sheet metal channel complement100in accordance with the invention essentially gives a seam220of drywall panels124in a ceiling80a shallow cathedral uprise230(seeFIG.8).

To turn toFIG.3A, it gives a non-limiting example of preferred dimensions for the single leg resilient sheet metal channel complement100in accordance with the invention. It comparably has a single leg103, albeit more or less vertical, and is likewise produced of something like and without limitation 25 Gauge (18 Mils) flexible sheet metal, in varying lengths as needed.

Given the foregoing, a preferred width of the strip105for a line of metal screws116to fasten the single-legged resilient sheet metal channel complement100in accordance with the invention to the ceiling joists112is preferably one inch (25.4 mm). It is believed that any extra width is needless.

The preferred width of the strip107for the line metal screws116to fasten two drywall panels in124a butt-to-butt200-to-200seam220to the single leg resilient sheet metal channel complement100in accordance with the invention is two inches (50.8 mm). That way, there can be about one inch (25.4 mm) for overlapping the top surface of one of the drywall panels124at the seam edge200thereof. The leftover other one inch (25.4 mm) width is provided for overlapping the top surface of the other of the drywall panels124at its abutting, seam220forming edge200.

In consequence, the strip107provides generous width for getting under the two drywall panels124at about inch-wide margins along their seam220forming edges200. The foregoing makes the overall width of the single leg resilient sheet metal channel complement100in accordance with the invention to be about three inches more or less (˜75 mm).

Much more pertinent here is, the relative drop240(seeFIG.8) in elevation of the single leg resilient sheet metal channel complement100in accordance with the invention as compared to the drop235(again, seeFIG.8) in elevation of the prior art (eg., RC-1) resilient channel35.

Again, the drop235in elevation of the prior art (RC-1) resilient channel35from a plane containing the bottoms114of the floor joists112to the top surface123of the drywall panel124(and as shown by reconcilingFIGS.8and10together) is given as 0.5 inches (12.7 mm).

In contrast, the drop240in elevation of the single leg resilient sheet metal channel complement100in accordance with the invention from a plane containing the bottoms114of the floor joists112to the top surfaces123of the two drywall panels124that are going to be joined in a permanent butt seam220(and as shown by reconcilingFIGS.3A and8together) is given as ⅜ths of an inch (˜9.5 mm).

That means that the bottom surfaces125of the drywall panels124will be ⅛ths of an inch (˜3.2 mm) higher under the single leg resilient sheet metal channel complement100in accordance with the invention than (as shown inFIG.8) under the flanking prior art (RC-1) resilient channels35.

FIGS.8and9show the advantage of that. The very seam220between the two seam220forming edges200of the two abutting drywall panels124forms the shallow cathedral uprise230.

A sheet rock worker who comes along and applies tape126to cover the seam220, and then applies (“floats”) drywall mud128to cover the tape126(ie., drywall finishing and/or joint compound), is provided with advantages in accordance with the invention. That is, the sheet rock worker has that shallow cathedral uprise230to advantageously work with, as more particularly explained below.

Without the shallow cathedral uprise230, the bottom surfaces125of the two drywall panels124would be level and planar with one another. The sheet rock worker would have to feather the drywall mud128a good foot (˜30 cm) on either side of the seam220or otherwise the drywall mud128would look like a keel or miniature rafter (eg., under-hanging beam).

It is an aspect of the invention that the shallow cathedral uprise230allows the sheet rock worker to feather the drywall mud128such that the broad dried coat of the drywall mud128is level on the undersurface129.

FIG.8is a side elevation view of a framed ceiling80construction project in accordance with the invention, partly in section, and taken in the direction of arrows VIII-VIII inFIG.2.FIG.9is an enlarged-scale side elevational view, partly in section, of the detail IX-IX inFIG.8.

With general reference toFIGS.8and9, they show the broad side of a framing joist112, which for example and without limitation might be a nominal 2×6 board of wooden dimensional number. The length of the framing joist112is indefinitely long in these views, with the ends being outside of the view on both sides.

FIG.8shows the three strips of single leg, resilient, sheet metal channel35,100and35in section. However, the channels35,100and35are so thin inFIG.8, it is impractical to include section shading.

The channel100in the center comprises the single leg resilient sheet metal channel complement100in accordance with the invention. The two channels35flanking the single leg resilient sheet metal channel complement100in accordance with the invention comprise two single leg resilient sheet metal channels35in accordance with the prior art.

Again,FIG.8shows a channel complement100in accordance with the invention flanked on the left and right by a pair of channels35in accordance with the prior art. AsFIG.1shows, all the channels35,100and35are aligned on parallel courses with each but which courses for the channels35,100and35are at right angles to the parallel courses of the bottoms114of the framing joists112.

Returning toFIG.8, preferably the flanking prior art channels35are spaced away from the central inventive channel complement100by the same distance.

Relative to channel35of the prior art, the respective drop235in elevation from a plane containing the bottoms114of the floor joists112to the top surface123of the drywall panel124is a set distance. This can be denominated the “channel35-induced drop in elevation”235. The example given above comprises 0.5 inches (12.7 mm).

Relative to channel complement100in accordance with the invention, the respective drop240in elevation from a plane containing the bottoms114of the floor joists112to the top surfaces123of drywall panel124is another set distance, but a relatively lesser set distance. This can be denominated the “complement100-induced drop in elevation”240. The example given above comprises given as ⅜ths of an inch (˜9.5 mm). Or that is, about 75% (seventy-five percent or three-fourths) of the channel35-induced drop in elevation235.

The result of all that is shown by general reference toFIGS.8and9. The prior art channels35give the drywall panels the channel35-induced drop in elevation235for the interior spans of the drywall panels112that are away from the edges200. Conversely, the channel complement100gives the drywall panels112at their adjacent edges200the complement100-induced drop in elevation240at the seam220between the adjacent drywall panels112.

Hence the channel35-induced drop in elevation240for the interior spans of the drywall panels112away from the edges200sets a “typical” plane for the height of the ceiling in the room. Conversely, the complement100-induced drop in elevation240for the seam220between the adjacent drywall panels112warps the “typical” plane for the height of ceiling at the seam220between the drywall panels112.

This “warp” in this description has been frequently been previously is referred in more descriptive terminology as the ‘shallow cathedral uprise’230. That is, the warp230is an uprise230from the elevation of the “typical” plane. The warp230has a linear aspect to it in that the warp230extends linearly (axially) along the seam220. And, the warp230is also shallow. In the preferred embodiment, the warp/uprise230is only an ⅛th of an inch (˜3.2 mm) deviation from the elevation of the typical plane, and that deviation is greatest in the crease of the uprise230.

FIG.9shows advantages obtained thereby. The shallow cathedral uprise230accommodates seam-covering tape126as well as a coating or coatings of drywall compound128which does(do) not need to be feathered out as far from the seam220as without the shallow cathedral uprise230. And when properly feathered out, the finish coating of the drywall compound230(if skillfully feathered out) should be planar with (or nearly so with) the typical plane of the ceiling80after completion.

The invention having been disclosed in connection with the foregoing variations and examples, additional variations will now be apparent to persons skilled in the art. The invention is not intended to be limited to the variations specifically mentioned, and accordingly reference should be made to the appended claims rather than the foregoing discussion of preferred examples, to assess the scope of the invention in which exclusive rights are claimed.