Support profile, wall comprising a support profile and method for constructing a wall using a support profile

Abstract

Elongated support profile for use in the construction of a wall, comprising an elongated member comprising a profile side section extending parallel to a longitudinal axis of the elongated member, an elongated strip of acoustically insulating material arranged on the profile side section and a cover profile arranged on the acoustically insulating material, wherein the elongated cover profile and the profile side section extent at a mutual distance and sandwich the elongated strip of acoustically insulating material.

Description

[0001] Support profile, wall comprising a support profile and method for constructing a wall using a support profile

[0002] The present invention relates to a support profile, a wall comprising a support profile and a method for constructing a wall using a support profile.

[0003] In the construction of building walls, in particular interior walls, a wall structure using a plurality of vertical beams (also called “studs”), with wall panelling, such as gypsum board and / or drywall, attached on either side of the row of vertical beams. Usually, insulation is packed between the sides of drywall on the inside of the wall. Wood beams can be used, but also elongated support profiles, which can be made of a metal such as steel. In some applications, especially in walls dividing units, such as residential units or hotel rooms, it is desirable to have a high degree of sound insulation. A problem with the walls as described above is that sound is rather easily transmitted through the construction, requiring for example a double wall to be used, which increases cost and requires more space.

[0004] It is a goal of the present invention, next to other goals, to provide an improved support profile, wherein preferably the above mentioned problem is at least partly alleviated.

[0005] This goal, next to other goals, is met by an elongated support profile according to appended claim 1. More specifically, this goal, next to other goals, is met by an elongated support profile for use in the construction of a wall, comprising an elongated member comprising a profile side section extending parallel to a longitudinal axis of the elongated member, an elongated strip of acoustically insulating material arranged on the profile side section and a cover profile arranged on the acoustically insulating material, wherein the cover profile and the profile side section extend at a mutual distance and sandwich the elongated strip of acoustically insulating material. The cover profile is thus not preferably in direct contact with the elongated member, preventing the direct transmission of vibrations (and thus sound) from the cover profile to the elongated member. The acoustically insulating material reduces the transmission of vibrations from the cover profile to the elongated member.

[0006] In a preferred embodiment, the cover profile extends along substantially the entire length of the elongated member. This allows for flexibility during construction, as the support profile can be shortened by cutting it anywhere, and it allows for screws and the like to be inserted at any location along the length of the support profile. The cover profile extending along substantially the entire length of the elongated member is however not strictly necessary, and support profiles with multiple shorter sections of cover profile applied to the insulating material are also envisioned. Preferably, the cover profile is arranged to connect to a plate member, such as, but not limited to, a gypsum board, drywall plate and / or wood plate, allowing the construction of a wall using one or more profiles and plate members, while the plate member is acoustically uncoupled from the elongated member. The elongated support profile thus inherently provides for acoustic uncoupling of the plate member and the elongated member. Due to the resulting high degree of acoustic dampening provided by the support profile, a single wall constructed out of a single row of support profiles with wall panelling on either side provides a high degree of sound insulation.

[0007] Preferably, the acoustically insulating material comprises any acoustically insulating material known in the art, but more preferably comprises a material selected from a group containing cork, cellulose, melamine, glass wool, wood wool, stone wool, mineral wool, rubber, textile, polyethylene terephthalate (PET), polyurethane (PU), polypropylene (PP), polyvinyl chloride (PVC), felt, natural fibres such as bio-based fibres, such as hemp fibres, flax fibres and in particular coconut fibres. Preferably, the insulating material possesses sufficient structural integrity to securely connect the cover profile to the elongated member.

[0008] Preferably, the acoustically insulating material comprises wool felt, acrylic felt, rayon felt, viscose felt, or coconut fibre felt or coir felt. Felts, and felt-like materials provide a desirable combination of structural integrity and acoustic dampening, making them desirable materials for this application.

[0009] Preferably, the acoustically insulating material comprises coconut fibres, in particular felt comprising coconut fibres, more in particular felt made substantially entirely out of coconut fibres (coconut felt). Coconut felt is sufficiently acoustically dampening, and additionally is a natural product which thus reduces plastic waste and such when disposed.

[0010] Preferably, the strip of acoustically insulating material is connected, preferably rigidly connected, to the profile side section. More preferably, the strip of acoustically insulating material is stapled to the profile side section. Preferably, the cover profile is connected, preferably rigidly connected, to the profile side section. More preferably, the cover profile is stapled to the strip of acoustically insulating material. This provides a secure bond without introducing a potential direct connection between the elongated member and the cover profile. Additionally or alternatively, the strip of acoustically insulating material is glued to the profile side section. Additionally or alternatively, the cover profile is glued to the strip of acoustically insulating material. This also provides a secure bond without introducing a potential direct connection between the elongated member and the cover profile.

[0011] Preferably, the elongated member comprises a first profile side section at a first side and a second profile side section at a second side extending substantially parallel to each other, preferably at a nonzero offset in a direction perpendicular to the first and second profile side section, wherein the elongated member further comprises a connection section arranged to connect the first profile side section and the second profile side section, wherein both the first and the second profile side section comprise a strip of acoustically insulating material and a cover profile. Thus, a two-sided profile is obtained, wherein wall plates, such as drywall plates, can be connected to either side. Both sides are then acoustically insulated from the elongated member as well as the other side.

[0012] Preferably, the cover profile comprises a substantially planar longitudinal base section and at least one folded edge section extending in a direction with a component perpendicular the substantially planar base section. Preferably, the base section is connected to the strip of acoustically insulating material. The folded edge section then preferably at least partially envelops the strip of acoustically insulating material, protecting it. In addition, the folded edge provides rigidity to the cover profile, and thus to the entire profile. Preferably, the folded edge extends along substantially the entire length of the cover profile.

[0013] Preferably, the elongated member comprises a C-profile, H-profile, Z-profile, tubular profile or box profile. These profile types are known in the art, and are convenient to use in the construction of walls. More preferably, the elongated member comprises a C-profile. This allows for optimal handling during construction, as well as structural rigidity and low cost.

[0014] Preferably, the cover profile comprises a substantially planar elongated base section, wherein the cover profile further comprises an offset section extending substantially parallel to the base section along the longitudinal axis at a nonzero distance in an offset direction extending perpendicular to the base section. In other words, the cover profile comprises a base section which is substantially planar and attached to the strip of insulating material, as well as at least one offset section which is located outside of the plane of the base section. This offset section thus extends outwards, away from the elongated member. A wall plate connected to the profile thus contacts the offset section rather than the entire cover profile. This allows for easier assembly of a wall and a more secure connection. Preferably, the cover profile comprises two offset sections arranged at either longitudinal edge of the base section. The cross section of the cover profile is thus preferably substantially symmetrical. This facilitates a secure connection between a wall plate and the cover profile, and thus the elongated member.

[0015] Preferably, the cover profile comprises at least two folded edge sections connected to either offset section, wherein the at least two folded edge sections extend in a direction with a component opposite the offset direction. The folded edges thus at least partially envelop the strip of insulating material, protecting it. In addition, the folded edges provide stiffness to the cover profile.

[0016] Preferably, the cover profile extends at least partially around the strip of acoustically insulating material. This protects the insulating material.

[0017] Preferably, the elongated member is substantially made of a metal. Preferably, the cover profile is substantially made of a metal. Preferably, steel is used for the elongated member and / or the cover profile.

[0018] Another aspect relates to a wall comprising a support profile as described above, further comprising at least a first plate member connected to the cover profile. The plate member may comprise a drywall plate or the like as commonly used in the art in interior wall construction. A wall that has improved acoustic dampening properties may then be constructed from one or more support profiles and plate members directly connected to the cover profile of said support profile. In wall constructed in manners known in the art, the plate members are connected directly to the support profile, which does not comprise acoustically insulating material. Thus, the plate members provide support to the support profile, and vice versa, increasing the overall stiffness of the wall. A drawback of the wall comprising a support profile as described above is that, since the plate member is not directly connected to the elongated member (which provides the majority of the stiffness of the support profile), thereby not providing direct support to the elongated member. A wall comprising the support profile as described above is thus less stiff.

[0019] Preferably, the wall further comprises a second plate member arranged on a surface of the first plate member that faces away from the profile, wherein the second plate member is at least connected to the first plate member. Thus, two layers of plates, such as drywall, are applied to the profile, increasing structural stability of the wall, as well as increasing the acoustic dampening of the wall and the fire resistance of the wall. Preferably, the first plate member is connected to the cover profile by means of a first screw, wherein the first screw is shorter than a distance between a surface of the first plate member facing away from the profile and the profile side section closest to the first plate member. In other words, the first screw is preferably shorter than the total thickness of the first plate member, the cover profile and the strip of insulating material. The first screw thus does not directly contact the elongated member, preventing a direct connection between the plate member and the elongated member, and thus preventing the direct transmission of vibrations from the plate member, through the screw to the elongated member. To achieve this, it is not essential that the first screw is shorter than the total thickness of the first plate member, the cover profile and the insulating material. As long as the first screw does not extend into the elongated member, the acoustic decoupling properties described above can be achieved. Other methods of connecting the plate member to the cover profile are also envisioned, such as glueing or using (double sided) tape.

[0020] Preferably, the second plate member is connected to the cover profile by means of a second screw, wherein the second screw is shorter than a distance between a surface of the second plate member facing away from the profile and the profile side section closest to the first plate member. In other words, the second screw is shorter than the total thickness of the first plate member, the second plate member, the cover profile and the strip of insulating material. The second screw thus also does not directly contact the elongated member, providing the above mentioned effects and benefits. To achieve this, it is not essential that the second screw is shorter than the total thickness of the first plate member, the second plate member, the cover profile and the insulating material. As long as the second screw does not extend into the elongated member, the acoustic decoupling properties described above can be achieved. The skilled person will appreciate that the second plate member is thus preferably also connected to the first plate member by means of the second screw. Other methods of connecting the second plate member to the first plate member, not requiring a screw, are also envisioned, such as glueing and using (double sided) tape.

[0021] In a preferred embodiment, a thickness of the plate members is between 10 - 15 more preferably between 12,0 - 13,0 mm and more preferably the plate members have a thickness of approximately 12,5 mm. The length of the first screw is preferably between 20 - 26 mm, more preferably between 22,0 - 24,0 mm and more preferably the length is approximately 23 mm. Generally, the length of the second screw is larger than the length of the first screw. The length of the second screw is preferably between 30 - 36 mm, more preferably between 32,0 - 34,0 mm and more preferably the length is approximately 33 mm. Preferably, the wall comprises at least a first plate member connected to a cover profile at a first side of the elongated member, and at least another first plate member connected to a cover profile at a second side of the elongated member. Thus, a wall with plate members on both sides is obtained, which may thus comprise a structurally complete (interior) wall. It will be appreciated that second plate members may be additionally installed on top of the first plate members in a way as described above.

[0022] Another aspect relates to a method for constructing a wall as described above, comprising the steps of: providing a support profile as described above, providing a first plate member, and connecting the first plate member to a cover profile of the profile. The resulting wall provides benefits as described above.

[0023] Preferably, the method additionally comprises the steps of: providing a second plate member, arranging the second plate member on the surface of the first plate member facing away from the profile, and connecting the second plate member to the first plate member. The resulting wall provides benefits as described above.

[0024] Preferably, the method additionally comprises the steps of: providing a first screw, wherein the first screw is shorter than a distance between a surface of the first plate member facing away from the profile and the profile side section closest to the first plate member, and attaching the first plate member to the cover profile using the first screw. The resulting wall provides the benefits as described above.

[0025] Preferably, the method additionally comprises the steps of: providing a second screw, wherein the second screw is shorter than a distance between a surface of the second plate member facing away from the profile and the profile side section closest to the first plate member, and attaching the second plate member to the cover profile using the second screw. The resulting wall provides the benefits as described above.

[0026] Another aspect relates to a kit of parts for a wall as described above, comprising at least a a support profile as described above, and a first plate member. Preferably, the kit of parts additionally comprises a second plate member.

[0027] Preferably, the kit of parts additionally comprises: a first screw, wherein the first screw is shorter than the total thickness of the first plate member, the cover profile and the strip of insulating material. Preferably, the kit of parts additionally comprises: a second screw, wherein the second screw is shorter than the total thickness of the first plate member, the second plate member, the cover profile and the strip of insulating material.

[0028] The present invention is further illustrated by the following Figures, which show a preferred embodiment of the device according to the invention, and are not intended to limit the scope of the invention in any way, wherein: figure 1 shows a cross section of a profile; figure 2 shows a cross section of a wall; figure 3 shows a perspective view of the profile; and figure 4 shows a perspective view of the wall.

[0029] Figure 1 shows a cross section of a support profile 1 , along a plane perpendicular to the longitudinal direction of the profile 1. A profile 1 comprises an elongated member 2, in other words a base profile 2, in the shown embodiment comprising a C-profile 2. The elongated member 2 comprises two profile side sections 3a and 3b, interconnected by a connection section 4. the profile side sections 3a, b comprise folded edge sections 6a, b, which add bending and torsional stiffness to the elongated member 2. The profile side sections 3a, b are offset with a distance d2. On both profile side sections 3 a, b a strip of acoustically insulating material 4a, b is arranged. On top of the strips of acoustically insulating material 4a, b, cover profiles 5a, 5b are arranged. Preferably, the strips of acoustically insulating material 4a, b are stapled to the profile side sections 3a, b. Preferably, the cover profiles 5a, b are in turn also stapled to the strips of acoustically insulating material 4a, b. Thus, each strip 4a, b is sandwiched between a profile side section 3a, b and a cover profile 5a, b. The cover profile 5a, b and the profile side section 3a, 3b do not directly touch, ensuring acoustic uncoupling between the cover profile 5a, b and the profile side section 3a, b. The cover profile 5a, b comprises a substantially planar base section 51, and two offset sections 52a, b offset from the base section 51 with an offset distance dl. In addition, the cover profile 5a, b comprises folded edge sections 53a, b which partially enclose the strip of acoustically insulating material 4a, b. Preferably, the folded edge sections 53a, b thus extend at least partially around the insulating material 4a, b. In addition, the folded edge sections 53a, b preferably do not touch the insulating material 4a, b, instead extending at a slight distance form the insulating material 4a, b. While figure 1 shows a profile with a strip of acoustically insulating material 4a, b and a cover profile 5a, b on both profile side sections 3a, b, embodiments are also envisioned wherein a strip of acoustically insulating material 4a, b and cover profile 5a, b are only placed on a single profile side section 3a, b. Figure 2 shows a cross section of a wall 10 comprising a profile 1, along a plane perpendicular to the longitudinal direction of the profile 1 and wall 10. A first plate member 61a, b is arranged on a cover profile 5a, b. In the shown embodiment, the first plate member 61a, b is connected to the cover profile 5a, b using first screws 71. These first screws 71 are shorter than the distance d3 between the closest profile side section 3a, b and the surface 63a of the first plate member 61a, b that faces away from the profile 1. A second plate member 62a, b is arranged on top of the first plate member 61a, b. In the shown embodiment, the second plate member 62a, b is connected to the cover profile 5a, b using second screws 72. These second screws 72 are shorter than the distance d43 between the closest profile side section 3a, b and the outer surface 64a, b of the second plate member that faces away from the profile 1. The space inside the wall, between the first plate members 61a and 61b, which contains the profile 1 may further be filled with insulation material 8. The edges of the plate members 61a, b and 62a, b may be chamfered / tapered. Thus, filler material 65 is applied to these sections to ensure a flat surface.

[0030] Figure 3 shows a perspective view of the profile 1 , comprising a strip of acoustically insulating material 4a, b on either side of the elongated member 2, as well as cover profiles 5a, b applied on both sides of the insulating material 4a, b. The profile 1 extends along a longitudinal axis A. Figure 4 shows a perspective view of the wall 10, comprising a row of profiles 1. A layer of first plate members 61a, b and second plate members 62a, b is arranged on either side of the row of profiles 1. In a preferred use case, the wall 10 extends between for example a floor (not shown) and a ceiling (not shown) which may also be referred to as the floor above the aforementioned floor.

[0031] The present invention is not limited to the embodiment shown, but extends also to other embodiments falling within the scope of the appended claims.

Claims

Claims1. Elongated support profile for use in the construction of a wall, comprising an elongated member comprising a profile side section extending parallel to a longitudinal axis of the elongated member, an elongated strip of acoustically insulating material arranged on the profile side section and a cover profile arranged on the acoustically insulating material, wherein the elongated cover profile and the profile side section extent at a mutual distance and sandwich the elongated strip of acoustically insulating material.

2. Support profile according to any of the preceding claims, wherein the acoustically insulating material comprises a material selected from a group containing cork, cellulose, melamine, glass wool, wood wool, mineral wool, rubber, textile, polyethylene terephthalate (PET), polyurethane (PU), polypropylene (PP), polyvinyl chloride (PVC), felt, natural fibres, in particular coconut fibres.

3. Support profile according to any of the preceding claims, wherein the acoustically insulating material comprises wool felt, acrylic felt, rayon felt, viscose felt, or coconut fibre felt.

4. Support profile according to any of the preceding claims, wherein the acoustically insulating material comprises coconut fibres.

5. Support profile according to any of the preceding claims, wherein the strip of acoustically insulating material is rigidly connected to the profile side section.

6. Support profile according to any of the preceding claims, wherein the strip of acoustically insulating material is stapled to the profile side section.

7. Support profile according to any of the preceding claims, wherein the cover profile is rigidly connected to the strip of acoustically insulating material.

8. Support profile according to any of the preceding claims, wherein the cover profile is stapled to the profile side section.

9. Support profile according to any of the preceding claims, wherein the elongated member comprises a first profile side section at a first side and a second profile side section at asecond side extending substantially parallel to each other at a nonzero offset in a direction perpendicular to the first and second profile side section, wherein the elongated member further comprises a connection section arranged to connect the first profile side section and the second profile side section, wherein both the first and the second profile side section comprise a strip of acoustically insulating material and a cover profile.

10. Support profile according to any of the preceding claims, wherein the cover profile comprises a substantially planar longitudinal base section and at least one folded edge section extending in a direction with a component perpendicular the substantially planar base section.

11. Support profile according to any of the preceding claims, wherein the elongated member comprises a C-profile, H-profile, Z-profile, tubular profile or box profile.

12. Support profile according to any of the preceding claims, wherein the elongated member comprises a C-profile.

13. Support profile according to any of the preceding claims, wherein the cover profile comprises a substantially planar elongated base section, wherein the cover profile further comprises an offset section extending substantially parallel to the base section along the longitudinal axis at a nonzero distance in an offset direction extending perpendicular to the base section.

14. Support profile according to claim 13, wherein the cover profile comprises two offset sections arranged at either longitudinal edge of the base section.

15. Support profile according to claim 10 and 14, wherein the cover profile comprises at least two folded edge sections connected to either offset section, wherein the at least two folded edge sections extend in a direction with a component opposite the offset direction.

16. Support profile according to any of the preceding claims 10 - 15, wherein the cover profile extends at least partially around the strip of acoustically insulating material.

17. Support profile according to any of the preceding claims, wherein the elongated member is substantially made of a metal.

18. Support profile according to any of the preceding claims, wherein the cover profile is substantially made of a metal.

19. Wall comprising a support profile according to any of the preceding claims, further comprising at least a first plate member connected to the cover profile.

20. Wall according to claim 19, further comprising a second plate member arranged on a surface of the first plate member that faces away from the profile, wherein the second plate member is at least connected to the first plate member.

21. Wall according to any of the preceding claims 19 - 20, wherein the first plate member is connected to the cover profile by means of a first screw, wherein the first screw is shorter than a distance between a surface of the first plate member facing away from the profile and the profile side section closest to the first plate member.

22. Wall according to any of the preceding claims 20 - 21, wherein the second plate member is connected to the cover profile by means of a second screw, wherein the second screw is shorter than a distance between a surface of the second plate member facing away from the profile and the profile side section closest to the first plate member.

23. Wall according to any of the preceding claims 19 - 22, comprising a profile according to any of the preceding claims 9 - 18, comprising at least a first plate member connected to a cover profile at a first side of the elongated member, and at least another first plate member connected to a cover profile at a second side of the elongated member.

24. Method for constructing a wall according to any of the preceding claims 19 - 23, comprising the steps of: providing a support profile; providing a first plate member; connecting the first plate member to a cover profile of the profile.

25. Method according to claim 24, additionally comprising the steps of: providing a second plate member; arranging the second plate member on the surface of the first plate member facing away from the profile; connecting the second plate member to the first plate member.

26. Method according to any of the preceding claims 24 - 25, additionally comprising the steps of: providing a first screw, wherein the first screw is shorter than a distance between a surface of the first plate member facing away from the profile and the profile side section closest to the first plate member; attaching the first plate member to the cover profile using the first screw.

27. Method according to any of the preceding claims 24 - 26, additionally comprising the steps of: providing a second screw, wherein the second screw is shorter than a distance between a surface of the second plate member facing away from the profile and the profile side section closest to the first plate member; attaching the second plate member according to claim 25 to the cover profile using the second screw.

28. Kit of parts for a wall according to any of the preceding claims 19 - 23, the first plate member having a thickness, the kit of parts comprising at least: a profile according to any of the preceding claims 1 - 18; a first screw, wherein the first screw is shorter than the total thickness of the first plate member, the cover profile and the strip of insulating material.

29. Kit of parts according to claim 28, for a wall according to any of the preceding claims 20 -23, the second plate member having a thickness, the kit of parts additionally comprising: a second screw, wherein the second screw is shorter than the total thickness of the first plate member, the second plate member, the cover profile and the strip of insulating material.

30. Kit of parts according to any of the preceding claims 28 - 29, additionally comprising: a first plate member.

31. Kit of parts according to any of the preceding claims 28 - 30, additionally comprising: a second plate member

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