Composite Stud Frame Connector for Movement and Sound Isolation
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Solution Overview
Problem
Conventional stud frame constructions in building walls fail to accommodate horizontal movement, leading to sound transference and structural deformation during fire due to lack of provisions for horizontal forces and thermal expansion, necessitating improved connectors for stud members.
Innovation Solution
A connector comprising a polymeric block element with locking wings and a metallic plate element is used to connect stud members, minimizing metal-on-metal contact and ensuring structural integrity, particularly in high temperatures, while allowing for movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional steel stud connections are used to provide rigid structural support, then strength and stability are improved, but sound transference increases and adaptability to movement decreases
Solution Approach 1:
The patent introduces a polymeric connector as an intermediary element between steel stud members. This connector has a rigid metallic plate for structural strength and polymeric blocks that act as sound-dampening intermediaries at connection points, thereby reducing sound transference while maintaining structural support capability
Solution Approach 2:
The connector combines dissimilar materials - a rigid metallic plate (for strength and stability) with polymeric blocks (for sound dampening and movement accommodation). This composite structure resolves the contradiction by allowing each material to contribute its beneficial properties: the metal provides structural integrity while the polymer reduces sound transference
2Stability of the object's composition
If fixed rigid connections are used between stud members and tracks, then structural stability is improved, but adaptability to thermal expansion and movement decreases
Solution Approach 1:
The connector transitions from a purely rigid connection to a dynamic system where the polymeric blocks can deform and the connection allows controlled movement. The rigid plate maintains stability while the polymeric elements provide adaptability to thermal expansion and structural movement through their ability to deform elastically
Solution Approach 2:
The connector changes the physical parameters of the connection by introducing polymeric material with different thermal expansion properties and mechanical characteristics compared to steel. This allows the connection to accommodate thermal expansion and movement while maintaining structural stability under normal loading conditions
3Ease of manufacture
If traditional metal connectors are used for connecting stud members, then ease of manufacture is improved, but fire resistance decreases due to thermal conduction
Solution Approach 1:
The polymeric blocks serve as thermal intermediaries between the metallic plate and the steel stud members. During fire, these polymeric blocks act as thermal barriers that slow heat transfer to the steel framework, providing additional fire resistance while the metallic plate maintains the structural connection
Solution Approach 2:
The combination of metal and polymeric materials in the connector creates a composite structure with improved fire resistance. The polymeric material has lower thermal conductivity than metal, creating a thermal barrier that protects the steel structure during fire while the metallic plate ensures the connector remains manufacturable and structurally sound
4Manufacturing precision
If accurate cutting of vertical studs is required to fit between head and base tracks, then manufacturing precision is improved, but productivity decreases
Solution Approach 1:
The connector changes the dimensional parameters of the assembly by incorporating the polymeric blocks with specific dimensions that accommodate stud length variations. This allows studs to be cut to standard lengths without requiring precise individual measurement and cutting to fit specific gaps between head and base tracks
Solution Approach 2:
The connector segments the connection function into distinct components: the metallic plate for structural connection and the polymeric blocks for dimensional accommodation. This segmentation allows the stud length to be determined by standard dimensions rather than by the variable gap between tracks, improving installation productivity
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The connector reduces sound transference and maintains structural integrity by allowing for movement of stud members relative to tracks, enhancing fire resistance and ease of installation.
Implementation Method 1
The connector reduces sound transference by minimizing metal-on-metal contact between the stud members and the tracks
Implementation Method 2
Increased temperatures due to the fire lead to significant thermal expansion of the vertical steel studs within the wall
Data Source
AI summary
A connector for connecting two stud members in a stud wall comprises a block element made from a polymeric material, the block element comprising a main body portion configured for insertion into an end of a first stud member, the main body portion comprising four substantially orthogonal side walls, an engagement slot being provided in a first one of the side walls and the engagement slot extending in a direction towards an opposite second one of the side walls; an attachment portion extending from the main body portion, the attachment portion including a pair of locking wings configured to engage with a second stud member such that, in use, a part of the second stud member is disposed in gaps between the locking wings and the main body portion; and a plate slot extending through a part of the attachment portion and through a part of the main body portion. The connector further comprising a plate element made from a metallic material, the plate element comprising first and second side edges and a notch in each of the first and second side edges, the plate element being disposed in the plate slot of the block element such that the notches of the plate element are aligned with the gaps in the block element.