Interior wall and partition construction

• US 7,032,356 B2
• Filed: 11/14/2003
• Issued: 04/25/2006
• Est. Priority Date: 08/19/2003
• Status: Expired due to Fees

• Current Assignee: Strawmen L.P.
• Original Assignee: Strawmen L.P.
• Inventors: Layfield, Derek J.
• Primary Examiner(s): Safavi, Michael
• Assistant Examiner(s): SPAHN, GAY
• Application Number:
  US10/714,830
• Publication Number:
  US 20050055935A1
• Time in Patent Office: 893 Days
• Field of Search: 524/043, 524/073, 524/071, 527/941, 524/811, 524/831
• US Class Current: 52/407.1
• CPC Class Codes: E04B 2/7411 Details for fire protection
• CPC Class Codes: E04B 2001/745 Vegetal products, e.g. plant stems, barks

Abstract

An improved interior wall construction that provides both sound attenuating and fire resistant properties. The improved wall construction eliminates the need for conventional vertical studs by including at least one rigid interior structural panel comprised of compressed straw. A compressed straw panel is situated in a substantially layered configuration with conventional non-woven insulation, at least one air space and a gypsum board sheet on each face. Connection between the compressed straw panel and at least one gypsum board sheet is comprised semi-flexible substantially Z-shaped resilient channel members. The Z-shaped channel members and compressed straw panel each being capable of partially attenuating sound energy passed therethrough.

Claims

1. An improved wall construction, comprising:

a compressed straw panel, said panel being comprised of compressed straw or other cellulosic fibers and having a substantially rectangular shape and having first and second sides;

a plurality of resilient rail members, said rail members each having a substantially elongated shape and first and second edges, said first and second edges being suitable for flat contact with a planar surface;

first fastener means attaching said first edge of said rail members to said first side of said straw panel;

a first gypsum board sheet, said first gypsum board sheet having a substantially rectangular shape, inside and outside faces, and being oriented adjacent and planar to said first side of said straw panel so to create a uniform first air space therebetween;

first penetrating fastener means attaching said first gypsum board sheet to said second edge of said rail members;

a plurality of resilient z-channel members, said z-channel members each having a substantially elongated shape and a substantially “

Z”

shaped cross section and having first and second flanges, said first flange being contained in a first plane which is parallel to a second plane containing said second flange;

second fastener means attaching said first flange of said z-channel members to said second side of said straw panel;

a second gypsum board sheet, said second gypsum board sheet having a substantially rectangular shape, inside and outside faces, and being oriented adjacent and planar to said second side of said straw panel and spaced so as to create a uniform second air space therebetween;

second penetrating fastener means attaching said second gypsum board sheet to said second flange of said z-channel members; and

insulating material, said insulating material positioned between said second side of said straw panel and said inside face of said second gypsum board sheet, said insulating material further sized to substantially and uniformly cover said second side of said straw panel and partially fill said second air space.

2. The improved wall construction of claim 1, wherein said z-channel members each comprise:

a web member, said web member being substantially flat and having first and second edges;

said first flange of each of said z-channel members being substantially flat and having inside and outside edges, said inside edge being rigidly connected to said first edge of said web member, said first flange being oriented with respect to said web member as to provide an angle therebetween greater than 95°

;

said second flange of each of said z-channel members being substantially flat and having inside and outside edges, said inside edge being rigidly connected to said second edge of said web, said second flange member oriented with respect to said web member so as to provide an angle therebetween greater than 95°

.

3. The improved wall construction of claim 2, wherein said z-channel members are made of a material having a melting temperature above 2400°

F. and a Young'"'"'s modulus below 30×

10⁶ lbs./in².

4. The improved wall construction of claim 3, wherein said z-channel members are made of material selected from the group consisting of steel, iron containing alloys, aluminum containing alloys, copper containing alloys, thermoplastic polymers, and thermosetting polymers.

5. The improved wall construction of claim 1, wherein said first air space between said first side of said compressed straw panel and said inside face of said first gypsum board sheet is at least ½

″

wide.

6. The improved wall construction of claim 1, wherein said second air space between said second side of said compressed straw panel and said inside face of said second gypsum board sheet is at least 1½

″

wide.

7. The improved wall construction of claim 1, wherein said insulating material fills not more than 75% of the volume of said second air space.

8. The improved wall construction of claim 1, wherein said insulating material has a substantially rectangular shape, is adhered to and substantially lines said second side of said compressed straw panel and has a thickness not more than 75% of the distance of a line normal to said second side of said compressed straw panel and said inside face of said second gypsum board sheet.

9. The improved wall construction of claim 1, wherein said insulating material fills 100% of the volume of said second air space.

10. The improved wall construction of claim 1, wherein said insulating material has a substantially rectangular shape, is adhered to and substantially lines said second side of said compressed straw panel and has a thickness equal to the distance of a line normal to said second side of said compressed straw panel and said inside face of said second gypsum board sheet.

11. The improved wall construction of claim 1, wherein said first and second fastener means are selected from the group consisting of nails, brads, tacks, staples, screws, lag screws, rivets, bolts, lag bolts, machine bolts, carriage bolts, stove bolts, toggle bolts, anchor bolts, adhesives, and any combination thereof.

12. The improved wall construction of claim 1, wherein said first and second penetrating fastener means are selected from the group consisting of nails, brads, tacks, staples, screws, lag screws, rivets, bolts, lag bolts, machine bolts, carriage bolts, stove bolts, toggle bolts, anchor bolts, adhesives, and any combination thereof.