US20020157329A1

US20020157329A1 - Resilient construction member and retrofit system using same

Info

Publication number: US20020157329A1
Application number: US09/430,432
Authority: US
Inventors: Clarke Berdan
Original assignee: Individual
Current assignee: Owens Corning Fiberglas Technology Inc
Priority date: 1998-12-11
Filing date: 1999-10-29
Publication date: 2002-10-31
Also published as: CA2389158A1; AU777854B2; AU1913701A; EP1226321A1; CA2389158C; WO2001033007A1

Abstract

A construction beam includes a pair of lateral members and a resilient web extending therebetween, so as to present a cross-sectional profile corresponding to commonly used construction beam members (e.g., 2″×4″ or 2″×6″). The resilience of the web helps to attenuate sound transmission through the beam from one lateral member to the other. In particular, in a wall frame, the lateral members are mounted at opposite ends thereof to end plates consisting of other construction beams according to the present invention (i.e., a pair of lateral members with a resilient web extending therebetween). The resilient web according to the present invention is conveniently made from a unitary piece of material. When the wall frame is used in a building structure, the lateral members 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. The web is preferably (but not necessarily) provided with spacers formed thereon, so that the lateral members can be easily oriented relative to the web and to each other, so as to be self-jigging. The spacers may conveniently be formed by cutting and bending tabs in the material of the web in desired locations.

Description

This application is a continuation-in-part of U.S. Ser. No. 09/338,892 entitled “Self-Jigging Resilient Construction Member and Retrofit System Using Same” (filed on Jun. 23, 1999 and still pending), the entire application being incorporated herein by reference. U.S. Ser. No. 09/338,892 is in turn a continuation-in-part of U.S. Ser. No. 09/209,308 entitled “Resilient Wall Stud” (filed on Dec. 11, 1998 and still pending), that entire application being also incorporated herein by reference. [0001]
This application is also related to U.S. Ser. No. 09/260,272 entitled “Sound Attenuating Structural Systems and Sound Attenuating Board Member Used Therefor” (filed on Mar. 2, 1999 and still pending), which application is also a continuation-in-part of U.S. Ser. No. 09/209,308. The entire contents of U.S. Ser. No. 09/260,272 is also incorporated herein by reference. [0002]

TECHNICAL FIELD AND INDUSTRIAL APPLICABILITY OF THE INVENTION

The present invention relates to members used in construction, especially in applications where sound attenuation and sound isolation is important. 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. The present invention also relates to a system for retrofitting a pre-existing standard wall frame with an improved stud construction which improves sound attenuation characteristics across the wall.

BACKGROUND OF THE INVENTION

Standard wall frame systems including a plurality of interconnected individual studs have long been used to construct walls. Also, in general, it is conventionally known to resiliently mount a wall or ceiling in order to isolate sound or attenuate transmission therethrough.

U.S. Pat. No. 3,445,975 to Nelsson discloses a partition in which first and second lath panels are held against a metallic stud, channel, or fluring 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. Pat. 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. Pat. 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 individual 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.

Finally, a standard wall frame system must generally be completely torn down to put a conventional sound attenuating systems into place. It would be therefore desirable to be able to retrofit a standard wall frame system so as to increase its sound attenuation characteristics.

In addition to the devices for sound attenuation described hereinabove, a wood I-beam is commercially available (e.g., 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.

Commonly owned U.S. patent appln. Ser. No. 09/209,308 is directed to a resilient construction member comprising a pair of spaced apart lateral members and a resilient web extending between the lateral members. A frame system using such members is also disclosed. The resilience provided by the resilient web advantageously attenuates sound transmission across the construction beam member.

Commonly owned U.S. patent appln. Ser. No. 09/338,892 is directed to a construction beam member of the type generally disclosed in appln. Ser. No. 09/209,308, but in which one or more resilient webs are provided with one or more spacer structures. In this manner, the respective lateral members are easily oriented relative to the web, in a manner generally known in the construction art as “self-jigging.” This configuration is particularly suitable for retrofitting a preexisting frame structure (made from single studs) so as to create, after the fact, a frame comprising resilient construction members according to the present invention. The application discloses providing a single lateral member having one or more resilient webs thereon. The one or more resilient webs include spacer structures so as to facilitate orientation of the lateral member/web(s) relative to a preexisting stud.

SUMMARY OF THE INVENTION

The present invention is therefore most generally 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 which are comparable in size to conventional wood beams (e.g., 2″×4″ or 2″×6″). The beam comprises a pair of spaced lateral members having at least one resilient web extending therebetween. The web is preferably relatively stiff, but permits a slight flexure between the lateral members. The lateral members are preferably, but not necessarily, made from an easily workable material such as wood.

In addition, the web is preferably, but not necessarily, provided with one or more spacers so as to facilitate the arrangement of the respective lateral members relative to each other and relative to the web. In part, this facilitates the assembly of the lateral members relative to each other and relative to the lateral web so as to obtain a beam member according to the present invention.

In a particular embodiment of the present invention, a retrofit system comprising one lateral member having a resilient web attached thereto is provided. The resilient web is provided with one or more spacers so that the one lateral member having the resilient web attached thereto can be easily positioned relative to a respective beam in a standard wall frame construction, thereby imparting the sound attenuation benefits of a frame using resilient construction beams without needing to completely tear down the original structure. In this arrangement, respective beams in the standard wall frame act as the other lateral member of the beam according to the present invention.

In one embodiment of the present invention, in accordance with the foregoing, the resilient web is made from a unitary piece of material which is formed so as to have an x-shaped cross-section. The respective ends of the “x” are attached to the respective lateral members in a known manner. Furthermore, the resilient web formed in this manner may include spacers, as discussed above, to facilitate orientation of the respective lateral members relative to the resilient web. Moreover, the x-shaped resilient web may be used in combination with one lateral member, such that the other side of the resilient web may be used to retrofit a beam in a standard wall frame construction, as discussed above.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will be described in detail hereinbelow, with reference to the drawings appended hereto, in which: [0020]
FIG. 1 is a partial perspective view of an end of a construction beam according to the present invention; [0021]
FIG. 2 is an end view of a beam according to the present invention; [0022]
FIG. 3 is a plan view of a beam according to a second embodiment of the present invention; [0023]
FIG. 4 is a perspective view of an example of a resilient web for linking lateral members in a beam according to the present invention; [0024]
FIG. 5 is a partial perspective view of a framework for mounting wallboard or the like, utilizing beams according to the present invention; [0025]
FIG. 6 is a partial perspective view of a beam according to a third embodiment of the present invention; [0026]
FIG. 7 is a plan view of a beam according to the embodiment of the present invention shown in FIG. 6; [0027]
FIG. 8 is a plan view of a variant of the beam shown in FIG. 7; [0028]
FIG. 9 is a perspective view of a retrofit assembly including a lateral member and a web, according to a fourth embodiment of the present invention; [0029]
FIG. 10 is a cross-sectional view of a construction member according to a fifth embodiment of the present invention shown in FIG. 9; [0030]
FIG. 11 is a plan view of a resilient web according to a sixth embodiment of the present invention; [0031]
FIG. 12 is a front perspective view of the resilient web illustrated in FIG. 11; [0032]
FIG. 13 is a front elevational view of a resilient construction member according to the sixth embodiment of the present invention; and [0033]
FIG. 14 is an end view of a resilient construction member according to the sixth embodiment of the present invention. [0034]

DETAILED DESCRIPTION AND PREFERRED EMBODIMENTS OF THE PRESENT INVENTION

FIGS. 1 and 2 illustrate a portion of a [0035] beam 100 according to the present invention. In general, beam 100 comprises lateral members 102 and 104 with a web 106 spanning therebetween.
[0036] Lateral members 102, 104 are generally (but not always, as discussed below) rectangular or squared in cross-sectional profile and preferably have at least the same thickness y (see FIG. 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, [0037] beam 100 can present a cross section having a major dimension x and minor dimension y corresponding to any standard beam size (e.g., 2″×4″, 2″×6″, and so on, without limitation).
According to the present invention, [0038] 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 (e.g., 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.
[0039] 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, [0040] web 106 is made from galvanized 22 gauge steel. As seen in FIG. 4, web 106 includes edge portions 106 a and an intermediate portion 106 b. Edge portions 106 a are embedded in lateral members 102, 104, and intermediate portion 106 b 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). The use of galvanized steel as described here may offer additional ancillary benefits, such as improved fire safety protection.
Edge portions [0041] 106 a 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 106 a. Once edge portions 106 a 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 106 a are wedged into place and retained in the grooves.
[0042] 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 FIG. 3).
Whether one or a plurality of [0043] webs 106 are provided, it is specifically contemplated that beams 100 are provided in standardized lengths (e.g., 8′) as seen in FIG. 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, FIG. 5 is a partial perspective view of a frame work (as might be used for walls in a building). [0044]
As seen in FIG. 5, beams [0045] 100 a, 100 b are mounted as studs on a laterally extending beam (i.e., a head plate or toe plate) 100 c. (Another laterally extending beam (not shown) is provided at the other end of beams 100 a, 100 b.) The structure of each of beams 100 a-100 c 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 102 a and 102 b and 104 a and 104 b are mounted with respect to lateral members 102 c and 104 c, respectively, with nails, screws or any other conventional fasteners (not shown here). Accordingly, it can be appreciated that one side of the frame (i.e., lateral members 102 a-102 c) is resiliently separated by way of respective webs 106′, 106″, and 106′″ from the other side of the frame (i.e., lateral members 104 a-104 c). 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 (e.g., lateral member [0046] 104 c and/or lateral members 104 a, 104 b) is fixed to the surrounding building structure, and the other side of the frame assembly has wall board or the like mounted thereon (i.e., on lateral members 102 a, 102 b), without attachment to the surrounding structure. The wall is therefore mounted on the “free” or “floating” side of the studs.
A particularly beneficial wall board structure is disclosed in commonly owned and co-pending application Ser. No. 09/260,272, and comprises, generally, first and second dry wall layers with a visco-elastic material layer interposed therebetween. In particular, a visco-elastic asphalt material is useful with such a wall board structure. [0047]
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 [0048] lateral beam 100 c and the surrounding structure (i.e., 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 (not illustrated here), including at comers of rooms. Therefore the wall surface is visually continuous, but physically decoupled, in order to take advantage of the resultant sound attenuation effects. [0049]
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. [0050]
FIGS. 6 and 7 are a partial perspective view and a partial plan view, respectively, of [0051] beam 200, in accordance with another embodiment of the present invention.
The design concept [0052] 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 205, as shown in FIGS. 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 [0053] webs 206 may be provided along the length of beam 200 (see, for example, FIG. 7).
[0054] 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 [0055] beam 100 and beam 200, respectively. 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 FIG. 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 [0056] 200) (see FIG. 8). In FIG. 8, beam 300 comprises lateral beams 302 and 304, and includes a plurality of first webs 306 a which are spaced from and alternate with a plurality of second webs 306 b. Accordingly, respective intermediate portions of webs 306 a and 306 b 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 (e.g., 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. [0057]
Such “tuning” can be accomplished by varying the thickness of [0058] 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 FIG. 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 FIGS. 3, 7, and 8.
It can therefore be appreciated that adjoining rooms may be constructed (e.g., 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 FIG. 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. [0059]
Assembly of lateral members and resilient webs according to the present invention is facilitated by providing at least one spacer on the resilient web or webs to orient the lateral members relative to the resilient web. [0060]
FIG. 10 is a schematic cross-sectional view of a [0061] beam 400, somewhat similar to beams 200 and 300 in FIGS. 6-8. Here again, beam 400 comprises lateral members 402 and 404, and a resilient web 406 extending therebetween.
[0062] Resilient web 406 is attached to opposite facing sides of lateral members 402 and 404, respectively, by, for example, staples 408 (although any conventional attachment method can be used, including, without limitation, screws, nails, bolts, and the like).
Resilient web includes a first portion [0063] 406 a, a second portion 406 b bent at an angle to first portion 406 a, and a third portion 406 c bent at an angle to second portion 406 b and generally parallel with first portion 406 a. Generally, lateral members 402 and 404 are received in the bends defined by the first and second portions 406 a and 406 b, and by the second and third portions 406 b and 406 c, as shown in FIG. 10.
It is a particular feature of this embodiment to provide a spacer [0064] 410 (412) on at least one of first and third portions 406 a and 406 c to space a respective at least one of the lateral members 402 and 404 away from second portion 406 b of the resilient web 406. In general, the provision of spacers 410 (412) allows easy assembly of the lateral members and the resilient web (known in the art as “self-jigging”). In particular, the provision of spacers 410, 412 prevents the respective lateral members 402, 404 from being placed in abutting relation to second portion 406 b. If such an arrangement were to be had, then the abutment of the resilient members against the second portion 406 b would undesirably retard the resilient sound-damping characteristics of the resilient web 406.
It is noted that the slight spacing shown in FIG. 10 between [0065] lateral members 402 and 404 and the resilient web 406 is for clarity of illustration only and is not necessarily illustrative of the present invention.
The arrangement of the present invention illustrated in FIG. 10 can be extended desirably to an apparatus and method for retrofitting standard beam members, especially beam members already assembled into a standard frame arrangement. [0066]
FIG. 9 illustrates a retrofitting [0067] assembly 500 comprising a lateral beam 502, to which at least one resilient web 506 is attached by staples 508 or the like. Each resilient web 506 as shown includes spacers 510 and 512. However, the provision of spacers 512 is most important here. It is emphasized that assembly 500 in and of itself is not a construction member per se, but is used in conjunction with standard beams in order to provide a resilient beam arrangement.
As before, [0068] resilient web 506 may be made from any suitably resilient material, including (without limitation) metal, rubber, asphalt, plastic, or other resilient polymeric material. In one example, spacers 510, 512 are protruding tabs formed integrally with the resilient web 506. In a specific example, spacers 510, 512 may be punch-formed into the material of the resilient web 506 (especially, but not necessarily only, where the resilient web 506 is made from metal). The punch-formed portions can simply be turned away from the web material as needed to form the required spacers.
In the arrangement illustrated in FIG. 9, it is especially important to provide [0069] spacers 512 as shown. The assembly 500 is arranged relative to a single standard beam such as a 2″×4″ (not shown here) and fastened thereto (again, by staples, screws, nails, bolts, or any known and suitable fastener). The arrangement of the assembly 500 relative to a standard beam is made simple by the provision of spacers 512, especially where assembly 500 is coupled to a standard beam forming part of a conventional framework.
In addition, the [0070] resilient webs 506 may be provided in an alternating arrangement, so that opposite sides of lateral member 502 are attached to respective resilient webs 506, as seen in FIG. 9 (this is similar to the arrangement illustrated in FIG. 8 and discussed above). With this arrangement, the assembly 500 may be even more easily arranged relative to a standard beam by orienting the assembly 500 so that respective free ends of the resilient webs 506 are arranged on opposite sides of the standard beam. Although the alternating arrangement of resilient webs 506 seen in FIG. 9 is beneficial (for reasons similar to those discussed above relative to FIG. 8), it is not necessary according to the present invention. The present invention is certainly operable with the resilient webs 506 all arranged in like manner along lateral member 502.
As with the other embodiments discussed above, [0071] lateral member 502 may be rectangular or squared in cross-section, and may preferably be made from continuous lumber or a composite wood material, as well as plastic reinforced with glass fibers.
In one example of the present invention, the [0072] spacers 410, 412, 510, 512 may be arranged to space the respective lateral members about 0.25 inches from the portion of the resilient web spanning the space between the lateral members. However, the present invention is not restricted to a specific spacing, except for that sufficient to prevent the respective lateral members from fully abutting the resilient web, as discussed above.
One of ordinary skill will appreciate that the [0073] resilient web 506 may be shaped so as to be attached to lateral members of different profiles. In one example, a lateral member 502 which is rectangular or squared in cross-section attached to the resilient web 506 may be used so as to be attached to a conventional rigid I-beam (discussed above relative to the related art) or vice versa.
It will be appreciated that the [0074] assembly 500 as seen in FIG. 9 can been seen as somewhat analogous to a conventional resilient channel. However, at least because of the self-jigging aspect of the assembly 500 (due to the provision of spacers), the assembly 500 is much easier to work with compared with resilient channel structures.
FIG. 11 is a plan view of a resilient web [0075] 600 according to sixth embodiment of the present invention. Resilient web 600 is characteristically made from a single piece of material formed so as to generally have a x-shape in cross-section. In general, resilient web includes first and second main portions 602, 604 which are angled relative to one another (see, for example, FIG. 12). Each main portion 602, 604 has first and second end portions (602 a, 602 b, 604 a, 604 b) adapted to be attached to lateral members 608 (see, for example, FIGS. 13 and 14) so as to form a construction member according to the present invention. For example, the first and second end portions of each main portion may be bent relative to their respective main portions at fold lines 606, whereby the lateral members 608 are arranged between generally parallel but unaligned first portions 602 a, 604 a and second portions 602 b, 604 b (see, again, for example, FIGS. 13 and 14).
Resilient web [0076] 600 may, for example, be made from a flat piece of metal (for example, steel). Longitudinal cuts 610 a and 610 b are formed generally down the midwidth of the piece of metal, all the way to the respective longitudinal ends of the piece of metal. Longitudinal cuts 610 a and 610 b may or may not be aligned with each other. Furthermore, longitudinal cuts 610 a and 610 b do not meet (lest the piece of metal be completely severed), but end at a pivot point or line 610 c. In forming the resilient web, first and second main portions 602 and 604 are rotated relative to each other about a pivot axis lying in the plane of the originally flat piece of metal and extending through the pivot point 610 c. Although steel was specified above as a material of manufacture, any suitable metallic material may be used instead. Indeed, any (metallic or non-metallic) material that is similar in bending stiffness to steel may be used, as long as its physical characteristics are amenable as a whole to the invention disclosed herein (especially with regard to resilient flexibility). In addition, the first and second end portions of each main portion 602, 604 may be bent as needed so as to be attachable to lateral members 608. As seen, by way of example in FIG. 14, the respective end portions are attached to lateral members 608 conventional fasteners such as nails 612, but alternatively including, without limitation, screws, rivets, staples, liquid or solid adhesive, or any combination of one or more conventional fasteners.
Instead of cutting and bendingly forming a metal plate, as discussed above, resilient web [0077] 600 may be molded from any suitable thermoplastic material, as long as that material possesses resilient properties that make it amenable as a whole to the invention disclosed herein (especially with regard to resilient flexibility).
Like the lateral members disclosed elsewhere herein, [0078] lateral members 608 are preferably made from any easily workable material, especially, but not only, wood and various formed wood products. Plastic material reinforced with, for example, glass fiber, is also suitable.
The resilient web of the sixth embodiment, as seen in FIGS. [0079] 11-14, is conveniently made using a conventional method of manufacture (e.g., using conventional metal stamping or conventional molding). From an acoustical perspective, a construction member using the resilient web of the sixth embodiment allows linear relative motion between the lateral members, but resists rotational or lateral relative motion.
Although not specifically illustrated herein, resilient web [0080] 600 may be provided with one or more spacers as illustrated in, for example, FIGS. 9 and 10, from which comparable benefits are gained. Also, although not specifically illustrated herein, the wall board structure disclosed in commonly owned U.S. patent appln. Ser. No. 09/260,272 is also desirable for use in connection with a construction member using the resilient web of this sixth embodiment.
As disclosed elsewhere herein, it is beneficial to provide at least one opening in resilient web [0081] 600 so as to provide a Helmholtz resonator effect. 2 It will be appreciated that resilient web 600 may be used with only one lateral member 608, in a manner similar to the arrangement illustrated in FIG. 9. The combination of resilient web 600 and one lateral member 608 can therefore be mounted on a stud in a preexisting wall frame so as to provide retrofit sound attenuation benefits. As with the arrangement in FIG. 9, one or more spacers (similar to spacers 512) may be provided to facilitate arrangement of the web/lateral member combination relative to a stud in the preexisting wall frame.
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. [0082]
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 (i.e., the lateral member not fixed to the building structure). [0083]
The use of substantially identical lateral members is contemplated according to the present invention. However, use of dissimilar lateral members is also expressly within the scope of the present invention for all embodiments. For example, one of the [0084] lateral members 102, 104 shown in FIG. 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. Similarly, webs 506 and 600 (as illustrated in FIGS. 9 and 10 and FIGS. 11-14, respectively) are arranged to have end portions on opposite sides of one of the flange portions of the wood I-beam.
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. [0085]
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. It is specifically noted that several embodiments are directed to particular features of the present invention. The manner in which different specific aspects of the present invention can be used in conjunction is discussed to some extent hereinabove. However, the mere fact that one particular feature disclosed herein is not expressly disclosed as being used in conjunction with another particularly disclosed feature is, alone, not meant to be limiting. [0086]

Claims

What is claimed is:

1. A beam member comprising:

a plurality of spaced apart lateral members; and

a resilient web extending between a respective pair of said lateral members, wherein said resilient web is a unitary piece comprising crossing first and second main portions, said first and second main portions each including first and second end portions provided at opposite ends thereof, wherein said first end portions are attached to a first of said pair of lateral members and said second end portions are attached to a second of said pair of lateral members.

2. The beam member according to claim 1, wherein said first and second main portions of said resilient web are each generally flat material portions rotated about an axis lying in respective planes of both said first and second main portions.

3. The beam member according to claim 1, wherein said first and second end portions of said first and second main portions, respectively, are bent so as to be generally parallel with each other.

4. The beam member according to claim 3, wherein said first end portions of said first and second main portions are bent relative to said first and second main portions, respectively, so as to oppose opposite sides of said first of said pair of lateral members.

5. The beam member according to claim 3, wherein said second end portions of said first and second main portions are bent relative to said first and second main portions, respectively, so as to oppose opposite sides of said second of said pair of lateral members.

6. The beam member according to claim 4, wherein said second end portions of said first and second main portions are bent relative to said first and second main portions, respectively, so as to oppose opposite sides of said second of said pair of lateral members.

7. The beam member according to claim 1, further comprising at least one spacer arranged on said resilient web for orienting at least one of said pair of lateral members relative to said resilient web.

8. The beam member according to claim 1, wherein at least one of said pair of lateral members is squared in cross-section.

9. The beam member according to claim 7, wherein said at least one spacer is arranged on at least one of said first and second end portions of at least one said first and second main portions.

10. The beam member according to claim 9, wherein said at least one spacer is arranged on each of said first and second end portions of at least one of said first and second main portions.

11. The beam member according to claim 1, wherein said first end portions are attached to said first of said pair of lateral members by one or more of nails, screws, staples, and adhesive.

12. The beam member according to claim 1, wherein said second end portions are attached to said second of said pair of lateral members by one or more of nails, screws, staples, and adhesive.

13. The beam member according to claim 1, wherein said resilient web is made from metal.

14. The beam member according to claim 13, wherein said resilient web is made from steel plate.

15. The beam member according to claim 13, wherein said resilient web is made from 26 gauge stock or thinner.

16. The beam member according to claim 14, wherein said resilient web is made from 26 gauge stock or thinner.

17. The beam member according to claim 1, wherein at least one said lateral member is made from any one of continuous wood, wood particle board, finger jointed wood segments, and plastic material reinforced with glass fiber.

18. The beam member according to claim 1, wherein said resilient web is a molded unitary piece.

19. The beam member according to claim 1, comprising a plurality of spaced apart said resilient webs extending between said pair of lateral members.

20. The beam member according to claim 1, wherein said resilient web includes at least one opening therein sized in accordance with Helmholtz resonator principles so as to correspond to a predetermined sound frequency.

21. A wall frame in a building construction comprising:

a first end plate comprising a first pair of lateral members and a first resilient web extending therebetween; and

a stud comprising a second pair of lateral members and a second resilient web extending therebetween;

wherein at least one of said first and second resilient webs is a unitary piece comprising crossing first and second main portions, said first and second main portions each including first and second end portions provided at opposite ends thereof, wherein said first and second end portions are attached to respective ones of said first and/or second pair of lateral members;

wherein said stud is orthogonally mounted on said plate.

22. The frame according to claim 21, wherein said first resilient web includes at least one first spacer arranged thereon for orienting at least one of said first pair of lateral members relative to said first resilient web; and wherein said second resilient web includes at least one second spacer arranged thereon for orienting at least one of said second pair of lateral members relative to said second resilient web.

23. The frame according to claim 21, wherein both lateral members of said second pair of lateral members are fixed to respective lateral members of said first pair of lateral members.

24. The frame according to claim 21, wherein said stud comprises a plurality of spaced apart said second resilient webs extending between said second pair of lateral members.

25. The frame according to claim 21, further comprising a second end plate comprising a third pair of lateral members and a third resilient web extending therebetween, an opposite end of said stud from said first end plate being mounted on said second end plate, wherein said third resilient web includes at least one third spacer arranged thereon for orienting at least one of said third pair of lateral members relative to said third resilient web.

26. The frame according to claim 25, wherein said third resilient web is a unitary piece comprising crossing first and second main portions, said first and second main portions each including first and second end portions provided at opposite ends thereof, wherein said first and second end portions are attached to respective ones of said third pair of lateral members.

27. The frame according to claim 21, wherein said first and second resilient webs are made from one of a molded resilient polymeric material and a metallic material.

28. The frame according to claim 21, wherein said second resilient web 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 frame according to claim 25, wherein said third resilient web is made from one of a resilient polymeric material and a metallic material.

30. In a building structure, a frame for mounting a wall comprising:

a first end plate comprising a first pair of lateral members and a first resilient web extending therebetween;

a second end plate generally parallel to said first end plate and comprising a second pair of lateral members and a second resilient web extending therebetween; and

a stud comprising a third pair of lateral members and a third resilient web extending therebetween;

wherein at least one of said first, second, and third resilient webs is a unitary piece comprising crossing first and second main portions, said first and second main portions each including first and second end portions provided at opposite ends thereof, wherein said first and second end portions are attached to respective said lateral members of a corresponding at least one of said first, second, and third pairs of lateral members.

31. The frame according to claim 30, wherein at least one of said first, second, and third resilient webs includes at least one of, respectively:

at least one first spacer arranged thereon for orienting at least one of said first pair of lateral members relative to said first resilient web;

at least one second spacer arranged thereon for orienting at least one of said second pair of lateral members relative to said second resilient web; and

at least one third spacer arranged thereof for orienting at least one of said third pair of lateral members relative to said third resilient web.

32. A beam member comprising:

an I-beam comprising a pair of flange portions and a rigid web extending therebetween;

a secondary member; and

a resilient web extending between said I-beam and said secondary member, wherein said resilient web is a unitary piece comprising crossing first and second main portions, said first and second main portions each including first and second end portions provided at opposite ends thereof, wherein said first end portions of said first and second main portions are attached to one said flange portion of said I-beam, and said second end portions of said first and second main portions being attached to said secondary member.

33. The beam member according to claim 32, wherein said resilient web includes at least one spacer arranged thereon for orienting at least one of said I-beam and said secondary beam relative to said resilient web.

34. The beam member according to claim 32, wherein said rigid web and said resilient web have generally parallel directions of extension.

35. A frame member for hanging a ceiling in a building structure, comprising:

a beam comprising a pair of lateral members and a resilient web extending therebetween,

wherein one of said lateral members is fixed to the building structure, and the other of said lateral members is left resiliently free-floating, the other of said lateral members being adapted to have a ceiling member fixed thereto,

wherein said resilient web is a unitary piece comprising crossing first and second main portions, said first and second main portions each including first and second end portions provided at opposite ends thereof, wherein said first end portions of said first and second main portions are attached to one said lateral member, and said second end portions of said first and second main portions being attached to the other said lateral member.

36. The frame member according to claim 35, comprising at least one spacer arranged on said resilient web for orienting at least one of said lateral members relative to said resilient web.

37. The frame member according to claim 35, wherein said lateral member fixed to said building structure is an I-beam comprising a pair of flange portions and a rigid web extending therebetween.

38. The frame member according to claim 37, wherein one of said flange portions is fixed to the building structure and the other of said flange portions is attached to said resilient web.

39. The frame member according to claim 38, wherein said I-beam is made from wood.

40. A retrofittable member for converting a standard beam into a sound-attenuating resilient beam, comprising:

a lateral member; and

a resilient web attached to and extending from said lateral member, wherein said resilient web is a unitary piece comprising crossing first and second main portions, said first and second main portions each including first and second end portions provided at opposite ends thereof, wherein said first end portions of said first and second main portions are attached to said lateral member, and said second end portions of said first and second main portions being adapted for attachment to a standard beam to obtain the sound-attenuating resilient beam.

41. The member according to claim 41, wherein said resilient web includes at least one spacer arranged thereon for orienting said lateral member with said resilient web attached thereto relative to the standard beam.

42. The member according to claim 41, wherein said spacer is a tab formed in said resilient web.

43. The member according to claim 42, wherein said resilient web is made from a metallic material and said tab is punch-formed in said metallic material and bent perpendicularly away therefrom.

44. The member according to claim 40, comprising a plurality of spaced apart said resilient webs.

45. The member according to claim 40, wherein said second end portions include said at least one spacer formed thereon for orienting said lateral member and said resilient web relative to the standard beam, whereby said second end portions are attachable to the standard beam.

46. A resilient web for connecting a pair of lateral members, wherein said resilient web is a unitary piece comprising crossing first and second main portions, said first and second main portions each including first and second end portions provided at opposite ends thereof, wherein said first end portions are attached to a first of said pair of lateral members and said second end portions are attached to a second of said pair of lateral members.

47. The resilient web according to claim 46, wherein said first and second main portions of said resilient web are each generally flat material portions rotated about an axis lying in respective planes of both said first and second main portions.

48. The resilient web according to claim 46, wherein said first and second end portions of said first and second main portions, respectively, are bent so as to be generally parallel with each other.

49. The resilient web according to claim 48, wherein said first end portions of said first and second main portions are bent relative to said first and second main portions, respectively, so as to oppose opposite sides of said first of said pair of lateral members.

50. The resilient web according to claim 48, wherein said second end portions of said first and second main portions are bent relative to said first and second main portions, respectively, so as to oppose opposite sides of said second of said pair of lateral members.

51. The resilient web according to claim 49, wherein said second end portions of said first and second main portions are bent relative to said first and second main portions, respectively, so as to oppose opposite sides of said second of said pair of lateral members.

52. The resilient web according to claim 46, further comprising at least one spacer arranged on said resilient web for orienting at least one of said pair of lateral members relative to said resilient web.

53. The resilient web according to claim 46, wherein at least one of said end portions is fabricated to receive a lateral member having a square cross-section.