Gypsum stud wall system with high knock factor

Abstract

An interior wall is provided, including a frame including at least one footer, at least one header, at least one vertical frame member connecting at least one of the at least one footer to at least one of the at least one header, the frame having a first side and a second side, and defining an interior frame space. A first wallboard panel is fastened to the first side of the frame. At least one gypsum wallboard stud is secured in the interior frame space, being fastened to the first wallboard panel and being dimensioned to extend from the first side to the second side. A second wallboard panel is fastened to the second side of the frame and to the at least one gypsum wallboard stud for creating a continuous acoustic connection between the first wallboard panel and the second wallboard panel.

1 . An interior wall, comprising:
 a frame including at least one footer, at least one header, at least one vertical frame member connecting at least one of said at least one footer to at least one of said at least one header, said frame having a first side and a second side, and defining an interior frame space;   a first wallboard panel fastened to said first side of said frame;   at least one wallboard stud secured in said frame space, being fastened to said first wallboard panel and being dimensioned to extend from said first side to said second side;   a second wallboard panel being fastened to said frame and to said at least one wallboard stud for creating a continuous acoustic connection between said first wallboard panel and said second wallboard panel.   
     
     
         2 . The interior wall of  claim 1 , wherein said frame is made of metal channel and said wallboard studs are configured to have a thickness dimensioned to fill a cavity defined by walls of said metal channel. 
     
     
         3 . The interior wall of  claim 1 , further including an acoustic mat installed between said frame and a substrate. 
     
     
         4 . The interior wall of  claim 3 , wherein said acoustic mat is disposed between said footer and the substrate. 
     
     
         5 . The interior wall of  claim 1 , wherein said wallboard studs have an on center spacing of one of 12 and 24 inches, and said wall having a knock factor ratio of 0.8. 
     
     
         6 . A method for constructing an interior wall as defined in  claim 1  comprising:
 measuring a knock factor of the assembled wall; and 
 adjusting at least one of the number and lateral spacing of said at least one wallboard stud in said interior frame space to achieve a knock factor ratio of 0.8. 
 
     
     
         7 . A gypsum stud for use in the wall of  claim 1 , comprising:
 a gypsum wallboard panel having first and second facing sheets sandwiching a core therebetween;   a series of cuts formed on at least one of said first and second facing sheets and extending into a core located between said sheets, retaining intact an opposing one of said first and second facing sheets to form a hinge point;   said panel being rolled from a first side to a second side into a rolled condition so that a rolled up stud is formed.   
     
     
         8 . The gypsum stud of  claim 7  further including a layer of adhesive applied to at least one of said first and second facing sheets so that said panel is held in said rolled condition. 
     
     
         9 . The gypsum stud of  claim 7  wherein said cuts are 90° cut and said cuts extend up to the opposite facing sheet from where they begin. 
     
     
         10 . The gypsum stud of  claim 7 , wherein said cuts are made in the following sequence: 1″ (2.5 cm), 1″ (2.5 cm), 1.5″ (3.8 cm), 1.5″ (3.8 cm), 2.0″ (5.0 cm), 2.0″ (5.0 cm), 2½″ (6.35 cm), 2½″ (6.35 cm), and 2½″ (6.35 cm) and the rolling begins at the 1″ end so that the resulting stud has a width of 2½″. 
     
     
         11 . The gypsum stud of  claim 7 , wherein said cuts are made in multiple groups of the following sequence: 3.8 (1.5 in.), 6.9 (2.7 in.), 3.8 (1.5 in.), 6.9 (2.7 in.), 6.4 (2.5 in.), 6.4 (2.5 in.), 6.4 (2.5 in.). 
     
     
         12 . The gypsum stud of  claim 1 , wherein said gypsum wallboard panel is a full-size, standard panel, and said cuts are made into said first and second facing sheets to form multiple wallboard studs. 
     
     
         13 . The gypsum stud of  claim 12 , wherein said cuts are made in multiple groups of the following sequence: 3.8 (1.5 in.), 6.9 (2.7 in.), 3.8 (1.5 in.), 6.9 (2.7 in.), 6.4 (2.5 in.), 6.4 (2.5 in.), 6.4 (2.5 in.). 
     
     
         14 . The gypsum stud of  claim 12 , wherein three said gypsum studs, including three tubular outer portions and three insert portions are created from said panel. 
     
     
         15 . The gypsum stud of  claim 7 , wherein said stud is made of two portions, an outer portion defining a central opening, and an insert portion dimensioned to fit within said central opening.