US3421281A - Resilient channel member - Google Patents

Description

Jan. A HARR|S RESILIENT CHANNEL MEMBER INVENTOR- DAVID HARRIS flaw/rig AT TORNEYS United States Patent i 3,421,281 RESILIENT CHANNEL MEMBER David A. Harris, Castro Valley, Califi, assignor to Fibreboard Corporation, a corporation of Delaware Filed Oct. 4, 1965, Ser. No. 492,692 US. Cl. 52735 Int. Cl. E04c 3/02; E04f 19/02 7 Claims ABSTRACT OF THE DISCLOSURE The present invention relates generally to a member for improving wall and ceiling construction, and more particularly to an improved resilient furring channel for use in the construction of partition and floor-ceiling structures with improved strength and sound isolation characteristics.

Variously designed resilient channels or hangers have been developed in recent years for use in partition construction to improve such construction and particularly the sound reduction characteristics thereof. The various channel designs can be more clearly distinguished by classifying them into three general configuration herein defined as: a cantilever or leaf, an expanded-metal, and a combination cantilever and slit configuration.

The cantilever channel is unsymmetrical in crosssection and is thus secured to its supporting structure along only One lateral edge thereof, there-by utilizing a cantilever spring principle to achieve the desired resilience. Likewise, the cantilever and slit channel configuration is unsymmetrical in cross-section and is secured along only one lateral edge thereof, but achieves the desired resilience not only by means of the cantilever spring principle, but also from a slitted configuration which enhances the channel flexibility. The expanded-metal channel configuration is symmetrical in cross-section and is secured along both lateral edges thereof to its respective supporting structure, and accordingly utilizes the more flexible, expanded metal portions of its structure to achieve the desired resilience.

The present invention provides an improved resilient furring channel with relatively improved sound reduction characteristics, in the form of an improved configuration whereby relatively greater ceiling or wall weight, generally in the form of some type of wallboard, may be safely supported. lMore specifically the resilient channel comprises an elongated metal strip generally hat-shaped in cross section. A central crown portion extends linearly along the length of the strip, While a series of resilient bent leg portions supports the crown above and spaced from lateral edge portions extending the length of the strip. Metal removed from between the resilient leg portions is bent laterally and outwardly in a plane next to Patented Jan. 14, 1969 and parallel with the edge portions to form nailing tabs along both sides of the resilient channel.

Accordingly, it is an object of the present invention to provide an improved configuration for a resilient furring channel.

It is another object of the invention to provide a furring channel of improved sound isolation and weight supporting characteristics.

It is still another object of the invention to provide a resilient furring channel of greater durability and versatility which lends itself to inexpensive mass production methods since it can be formed of a single length of material with no remnant waste.

It is a further object of the invention to provide a resilient furring channel of a configuration which lends itself to simplified installation due to the fact it does not bow or twist during insertion of self-tapping screws for supporting the wallboard.

It is yet another object of the invention to provide a symmetrical resilient furring channel wherein the desired resilience and strength is provided with relatively more eflicient use of the construction material than in prior art symmetrical channels.

It is still another object of the invention to provide a resilient furring channel of improved construction wherein removal of portions of material thereof simultaneously provides the desired channel resilience as well as a succession of tabs for securing the channel to its supporting structure.

'It is a further object of the invention to provide an improved resilient furring channel utilizing punch-out tabs formed of material thereof which would otherwise be wasted, wherein the tabs extend outwardly from the body of the channel to provide a large nailing area removed from the body to preclude damage thereto by a poorly applied hammer blow.

It is still a further object of the invention to provide an improved resilient furring channel wherein the required resilience is provided by a succession of simple, partially folded strips, bent to form a dogleg having an inside angle of generally greater than Other objects and advantages will be apparent from the following description and claims taken in conjunction with the drawing, in which:

FIG. 1 is a perspective view of a portion of a resilient furring channel in accordance with the present invention.

FIG. 2 is an elevational view of the furring channel of FIG. 1 with a length of wallboard installed.

FIG. 3 is an end view taken along the lines 3-3 of FIG. 2.

Referring to the drawing, there is shown an improved configuration for a resilient furring channel 10, formed of a single piece of material, such as for example, an elongated, fiat strip of coated (galvanized) sheet steel approximately 0.022 inch thick and about three inches wide.

Referring generally to the cross section, the channel length is formed of a crown portion 12, lateral edge portions 14 and integral, interconnecting resilient leg portions 16 extending therebetween. The crown portion 12 comprises that portion of the channel 10 to which wallboard 13 is secured with suitable fastening means, the lateral edge portions 14 provide a base for securing the channel 10 at either side thereof to the face of studs, the bottom surfaces of joists or like structural wall or partition supports, herein indicated by a numeral 15. The

interconnecting resilient leg portions 16 provide the spring action between the crown and edge portions 12, 14 respectively thereby providing the desired sound damping effect therebetween. Channel securing tabs 18 are formed along the length of the channel at predetermined, spaced intervals by punching, or otherwise cutting out, three sides of a preferably rectangular portion of material adjacent the lateral edge portions 14. The rectangular portions are folded outwardly in a 180 arc (prior to forming the channel) to lie flat against the lateral edge portions 14, the lateral width of the tabs 18 being great enough to allow them to protrude substantially beyond the outer edge of portions 14. A series of spaced holes 20 are formed along the tabs 18 slightly beyond the edge portions 14, to allow insertion of nails 22, or like fasteners, through the channel tabs to secure same to the studs or joist supports 15. The holes 20 are spaced to provide conveniently located holes for attachment of the channels 10 to the supports at any point therealong.

Removal of the rectangular portions to form tabs 18 simultaneously provides, in one forming or punching operation, a succession of openings 23 along the channel 10 length with an alternate succession of resilient leg strips 24. After forming the channel as shown in the drawing, the leg strips 24 are bent to define an agle or dogleg to provide the major amount of spring action or resilience of the channel 10.

The width, W, of the leg strips 24 and thus the resonant frequency thereof, can be predetermined and varied during fabrication of the channel 10 according to the intended use, thereby allowing a choice in the desired amount of resilience. The most practical configuration has been found to utilize resilient leg strips 24 of /2 inch width W and a tab width M of 1 /2 inches. Such dimensions have been shown to provide a compromise between channel strength and resilience commensurate to an optimum reduction of sound transmission while maintaining the installed wallboard material with sufiicient rigidity to make it feel aesthetically pleasing to hand-applied pressure.

The crown portion 12 which receives the wallboard fastening means, preferably self-drilling, self-tapping, power driven sheet metal screws 26, has slightly raised lips 28 formed along either lateral edge thereof to provide space between the facing side of the wallboard 13 and the crown 12 surface to provide for optimum ease of screw insertion, viz, to prevent screw bit flash. Additionally, the outer recessed surface of the crown portion 12 is knurled or otherwise scored, to provide a roughened surface 30 which prevents slippage of the self-tapping screws 26 during insertion thereof.

It is to be noted that the depth of the channel 10 extending perpendicularly from the crown portion 12 to a plane passing through the lateral edge portions 14 should be great enough to allow the self-tapping screws 26 to protrude through the crown portion 12 but without the tips thereof touching the supports 15 since this would prevent the desired resilient action. Thus a plane passing through the surface 30 of crown portion 12 lies substantially parallel to, but spaced apart from, the plane lying along the lateral edge portions 14.

FIGS. 2 and 3 exemplify one manner of securing the channel 10 to the stud or joist supports 15, and the wallboard 13 to the channel 10. The channel 10 is equally useful for ceiling construction, particularly due to the symmetrical cross section configuration, whereby both edges of the channel can be secured to the ceiling joist supports 15 to provide greater strength while still providing the required resilience for improved sound isolation. The crown 12 is of sufficient width to allow the channels to be installed parallel to the wallboards, wherein adjacent, abutting edges of the wallboards 13 are secured to the channels 10 by means of two rows of screws 26 which are driven therethrough into the crown portion 12. Generally however, the wallboards are installed in perpendicular relation across the channels, as shown in the figures.

The unique channel configuration lends itself to ready and inexpensive fabrication by mass production methods. An elongated flat strip of construction material is preferably first punched to simultaneously form the extending tabs 18 and the resilient leg strips 24, and thereafter the material is folded and pressed to form the hat-shaped cross section comprising the crown portion 12, the resilient leg portions 16 and the lateral edge portions 14. The resilience of the channels 10 can thus readily be varied for a particular batch of channels by simply relocating the punch apparatus which forms the tabs 18 to regulate the width, W, of the remaining leg strips 24 as well as the width, M, of the tabs 18. Additionally, the various dimensions of the resilient leg portion 16 and the various angles at which the channel 10 is formed, particularly the dogleg angle of the resilient strips 24, and generally chosen commensurate to the resilience and strength characteristics desired for the type of wall or ceiling construction in which the channels are to be used. Increasing the width W of the leg strips 24 increases their rigidity and thus the channel resilience.

Although the present invention has been described with respect to a single embodiment, it will be apparent that numerous variations and modifications may be made within the spirit and scope of the invention.

What is claimed is:

1. An improved resilient furring channel for resiliently securing wallboard to a supporting structure comprising; an elongated strip of sheet material formed in a generally hat-shaped symmetrical cross section; including a centrally extending crown portion, lateral edge portions disposed at either side of the crown portion, and resilient leg portions having at least one bend intermediate the ends thereof integrally formed with and interconnecting said crown portion and said lateral edge portions, said crown and edge portions disposed along substantially parallel planes spaced a selected distance apart by said interconnecting resilient leg portions, said resilient leg portions including a spaced succession of resilient leg strips of the sheet material extending transverse of the length of the sheet material strip, and tab means for securing the channel to the supporting structure formed of material from the resilient leg portion.

2. The resilient furring channel of claim 1 wherein said tab means are formed of material partially removed from between said succession of resilient leg strips folded outwardly to extend generally along the plane of said lateral edge portions beyond the outermost edges thereof.

3. The resilient furring channel of claim 2 wherein said crown portion further comprises a flat fastener-receiving portion having raised edges formed along either side thereof to space the wallboard from the surface of said flat fastener-receiving portion, said surface having a scored finish thereon to provide ready insertion therethrough of the wallboard fasteners.

4. The resilient furring channel of claim 2 wherein said resilient leg strips have a width substantially less than the width of said material partially removed and folded to form said tab means.

5. The resilient furring channel of claim 4 wherein the width of said resilient leg strips of the order of /2 inch, and the width of said partially removed material is of the order of 1 /2 inches.

6. The resilient furring channel of claim 4 wherein said succession of resilient leg strips comprise fiat strips of the sheet material formed with at least one bend, said strips being disposed with the bend angle oriented in outwardly extending relation to the volume bounded by said hat-shaped channel.

7. The resilient furring channel of claim 4 wherein the material partially removed and folded outwardly from the resilient leg portions forms said tab means for securing the channel to the supporting structure, the remaining material therebetween simultaneously forming said succession of resilient leg strips.

References Cited UNITED STATES PATENTS 6 4/1965 Brown et a1 52488 11/ 1965 Downing 52-735 BOBBY R. GAY, Primary Examiner.

5 A. M. CALVERT, Assistant Examiner.

US. Cl. X.R.

Images