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US20150075901A1 - Interlocking soundproofing block system and method - Google Patents

Interlocking soundproofing block system and method Download PDF

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Publication number
US20150075901A1
US20150075901A1 US14/344,592 US201214344592A US2015075901A1 US 20150075901 A1 US20150075901 A1 US 20150075901A1 US 201214344592 A US201214344592 A US 201214344592A US 2015075901 A1 US2015075901 A1 US 2015075901A1
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distal
proximal
panel
block
edge
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Frank Beresowski
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Individual
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    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
    • E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
    • E04B1/82—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to sound only
    • E04B1/84—Sound-absorbing elements
    • E04B1/86—Sound-absorbing elements slab-shaped
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B9/00—Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation
    • E04B9/04—Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation comprising slabs, panels, sheets or the like
    • E04B9/0435—Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation comprising slabs, panels, sheets or the like having connection means at the edges
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B9/00—Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation
    • E04B9/04—Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation comprising slabs, panels, sheets or the like
    • E04B9/045—Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation comprising slabs, panels, sheets or the like being laminated
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
    • E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
    • E04B2001/742—Use of special materials; Materials having special structures or shape
    • E04B2001/747—Corrugated materials
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
    • E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
    • E04B1/82—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to sound only
    • E04B1/84—Sound-absorbing elements
    • E04B2001/8457—Solid slabs or blocks
    • E04B2001/8461—Solid slabs or blocks layered
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49826—Assembling or joining

Definitions

  • the present invention relates to the field of soundproofing panels for use in construction of buildings.
  • Soundproofing problems 1) acoustic treatments—to improve sound travel within a room (for example, an anechoic chamber) and 2) soundproofing, such as quieting, noise mitigation, and noise control can be used to limit unwanted noise. Soundproofing can suppress unwanted indirect sound waves such as reflections that cause echoes and resonances that cause reverberation. Soundproofing can reduce the transmission of unwanted direct sound waves from the source to an involuntary listener through the use of distance and intervening objects in the sound path.
  • the present invention relates to “soundproofing” as opposed to the enhancement of acoustics within a room.
  • soundproofing is any means of reducing the sound pressure with respect to a specified sound source and receptor.
  • soundproofing is any means of reducing the sound pressure with respect to a specified sound source and receptor.
  • Bass or low frequency sound
  • Bass is the worst sound of all because it assaults from long distance. It penetrates normal building walls and ceilings. While low frequencies are the largest and generally the most powerful sound waves, they are impossible to escape. Paradoxically, the low frequency “bass” is what is being sought more and more in home theaters, bands, and music systems. So effective sound abatement and soundproofing techniques will continue to be of utmost importance.
  • the “volume” level of sound is measured in Decibels (dB).
  • the frequency of sound (bass, midrange, treble, low notes, high notes, etc) is measured in Hertz (Hz).
  • the sounds that are most problematic are the low frequencies below 125 Hz.
  • STC Sound Transmission Coefficient
  • noise reduction or abatement means, it is of course much easier to head off the problem during construction than try to correct it afterward. That said, today's construction techniques do nothing to prioritize sound abatement.
  • the best acoustic isolation methods i.e.: rooms within rooms
  • fiberglass, foam insulation, sound board, or extra layers of drywall do very little to stop noise transmission.
  • Even a poured concrete or concrete block wall is not a very good sound barrier. Sound is very difficult to stop and solid rigid materials actually tend to transmit sound very well.
  • a material can absorb sound.
  • the choice of sound absorbing material will be determined by the frequency distribution of noise to be absorbed and the acoustic absorption profile required.
  • Porous absorbers typically open cell rubber foams or melamine sponges, absorb noise by friction within the cell structure. Porous open cell foams are highly effective noise absorbers across a broad range of medium-high frequencies. Performance is less impressive at low frequencies. The exact absorption profile of porous open cell foam will be determined by a number of factors including the following:
  • Resonant panels, Helmholtz resonators and other resonant absorbers work by damping a sound wave as they reflect it. Unlike porous absorbers, resonant absorbers are most effective at low-medium frequencies and the absorption of resonant absorbers is always matched to a narrow frequency range.
  • MLV is a highly dense, flexible membrane sold under various brand names such as AcoustiblokTM and SheetBlokTM. This is a good source of mass, but expensive.
  • Loosely packed fiber provides some limited degree sound absorption, which is a factor in soundproofing, albeit a minor one.
  • Standard fiberglass insulation is as effective as mineral wool, and much less costly. Foams give great thermal insulation but are actually poor for soundproofing.
  • Viscoelastic adhesive such as Green GlueTM or Decibel DropTM. Used as the damping layer between layers of drywall, plywood, or subflooring. This substance is a somewhat effective and economical noise reducer and is one of the few ways to address the low-frequency noise from music, home theaters, construction machinery, etc.
  • decoupling is an effective element of soundproofing, note that it can actually increase transmission of low-frequency noise, by creating a new resonance chamber.
  • a typical wall will have a sheet of drywall/stud/drywall. The wall will have air spaces in between the studs. Drywall is very rigidly connected to the studs. Sound waves will hit that wall, and attempt to vibrate through to the room next door (or floor below, etc. . . . ). As such, sound can vibrate into an adjoining room through one of two paths: a) through the rigid drywall-stud-drywall connection path or b) through the open drywall-airspace-drywall path.
  • the present invention provides a soundproofing barrier system which may be installed as a wall or floor and comprises a plurality of barrier panels said blocks.
  • the prevent invention provides a block for use in interlocking, conjoined alignment with a plurality of like blocks to form a soundproofing barrier, said block comprising:
  • a proximal panel comprising a proximal upper edge, a proximal lower edge, a proximal right edge and proximal left edge; b) a distal panel comprising a distal upper edge, a distal lower edge, a distal right edge and distal left edge, the distal panel and the proximal panel being immovably coupled together in both vertical and horizontal offset thereby creating four engagement platforms: an upper engagement platform (between proximal upper edge and distal upper edge), a lower engagement platform (between proximal lower edge and distal lower edge), a right engagement platform (between proximal right edge and distal right edge), and a left engagement platform (between proximal left edge and distal left edge) and wherein at least one of the proximal panel and the distal panel comprises at least one corrugated flute.
  • the present invention further provides a soundproofing barrier comprising a plurality of interlocking blocks, including block one and block two, each block comprising
  • a) panel comprising a proximal upper edge, a proximal lower edge, a proximal right edge and proximal left edge; b) a distal panel comprising a distal upper edge, a distal lower edge, a distal right edge and distal left edge, the distal panel and the proximal panel being immovably coupled together in both vertical and horizontal offset thereby creating four engagement platforms: an upper engagement platform (between proximal upper edge and distal upper edge), a lower engagement platform (between proximal lower edge and distal lower edge), a right engagement platform (between proximal right edge and distal right edge), and a left engagement platform (between proximal left edge and distal left edge), wherein at least one of the proximal panel and the distal panel comprises at least one corrugated flute, and wherein one engagement platform of block one engages and overlaps (docks with) another engagement platform on block two to form a conjoined connection there between.
  • the prevent invention provides a block for use in interlocking, conjoined alignment with a plurality of like blocks to form a soundproofing barrier, said block comprising:
  • a proximal panel having a proximal right side and a proximal left side
  • a distal panel having a distal right side and a distal left side, said distal panel being longer, at its distal left side than the respective proximal right side forming a distal panel platform; the distal panel and the proximal panel being immovably coupled together and wherein at least one of the proximal panel and the distal panel comprises at least one corrugated flute.
  • the present invention further provides a method of making a sound proofing barrier which comprises
  • each block comprising a) panel comprising a proximal upper edge, a proximal lower edge, a proximal right edge and proximal left edge; b) a distal panel comprising a distal upper edge, a distal lower edge, a distal right edge and distal left edge, the distal panel and the proximal panel being immovably coupled together in both vertical and horizontal offset thereby creating four engagement platforms: an upper engagement platform (between proximal upper edge and distal upper edge), a lower engagement platform (between proximal lower edge and distal lower edge), a right engagement platform (between proximal right edge and distal right edge), and a left engagement platform (between proximal left edge and distal left edge), wherein at least one of the proximal panel and the distal panel comprises at least one corrugated flute; joining and overlapping at least part of one engagement platform of block one with at least part of an adjacent engagement platform
  • the blocks, barriers, systems and methods of the present invention are especially suited to use in walls, ceilings and floors, in residential, commercial and industrial contexts.
  • FIG. 1 is front view of a block comprising two offset panels in accordance with one aspect of the present invention
  • FIG. 2 is a front view of a two adjacent but not yet interlocked blocks, each comprising two panels;
  • FIG. 3 is a side view of a block comprising two offset panels
  • FIG. 4 is a side view of two adjacent but not yet interlocked blocks, each comprising two panels;
  • FIG. 5 is side view of the two blocks of FIG. 4 , but interlocked;
  • FIG. 6 is a front view of a four adjacent and interlocked blocks, each comprising two panels;
  • FIG. 7 is a side view, in cross-section, through a block comprising two panels comprising corrugations and wherein one panel comprises two layers of corrugations and is thereby thicker than the other panel, which comprises only one layer of corrugation;
  • FIG. 8 is a side view, in cross-section of two adjacent but not yet interlocked blocks each comprising two panels and wherein one panel in each block comprises two layers of corrugations and is thereby thicker than the other panel in each block, which comprises only one layer of corrugation;
  • FIG. 9 is a side view of the two blocks of FIG. 8 , interconnected;
  • FIG. 10 a side view, in cross-section, through a block comprising two panels comprising corrugations and wherein both panels comprise two layers of corrugations;
  • FIG. 11 is a side view, in cross-section of two adjacent but not yet interlocked blocks each comprising two panels with two layers of corrugation;
  • FIG. 12 is a side view of the two blocks of FIG. 11 , interconnected;
  • FIG. 13 is a side view, in cross-section, through a section of a block comprising one panel comprising a line of flute/corrugation with an amplitude (height) of approximately 3.5 mm and a a peak to peak distance of approximately 7.95 mm;
  • FIG. 14 is a side view, in cross-section, through a section of a block comprising one panel comprising a line of flute/corrugation with an amplitude (height) of approximately 4.6 mm and a a peak to peak distance of approximately 8.9 mm;
  • FIG. 15 is a side view of a block comprising two offset panels (offset at one side) in accordance with one aspect of the present invention.
  • FIG. 16 is front view of a block comprising two offset panels (offset at one side) in accordance with one aspect of the present invention.
  • FIG. 17 is an end view of a wall and floor join, showing the block/panel of the present invention in operation in both places;
  • FIG. 18 another end view of a wall and floor join, showing the block/panel of the present invention in operation in both places;
  • FIG. 19 is side view of a wall, in partial cut-away
  • FIG. 20 is side view of a wall showing centre line of studs.
  • FIG. 21 is a further side view of a wall showing centre line of studs.
  • lay is used herein to describe the way in which one block (comprising at least two panels) engages with an adjacent block by way of the engagement platforms which are created by the offset in engagement of the panels, relative to one another.
  • this term refers to the rabbeting of boards so that the edges of each board lap over the edges of adjacent boards to make a flush joint.
  • a similar principle is applied here to soundproofing panels and wherein at least one of such panels comprises a corrugated flute.
  • the function of the first machine may or may not be the same as the function of the second machine.
  • the present invention provides a soundproofing barrier system which may be installed as a wall or floor and comprises a plurality of barrier blocks.
  • the prevent invention provides a block for use in interlocking, conjoined alignment with a plurality of like blocks to form a soundproofing barrier, said block comprising:
  • a proximal panel comprising a proximal upper edge, a proximal lower edge, a proximal right edge and proximal left edge; b) a distal panel comprising a distal upper edge, a distal lower edge, a distal right edge and distal left edge, the distal panel and the proximal panel being immovably coupled together in both vertical and horizontal offset thereby creating four engagement platforms: an upper engagement platform (between proximal upper edge and distal upper edge), a lower engagement platform (between proximal lower edge and distal lower edge), a right engagement platform (between proximal right edge and distal right edge), and a left engagement platform (between proximal left edge and distal left edge) and wherein at least one of the proximal panel and the distal panel comprises at least one corrugated flute.
  • the present invention further provides a soundproofing barrier comprising a plurality of interlocking blocks, including block one and block two, each block comprising
  • a) panel comprising a proximal upper edge, a proximal lower edge, a proximal right edge and proximal left edge; b) a distal panel comprising a distal upper edge, a distal lower edge, a distal right edge and distal left edge, the distal panel and the proximal panel being immovably coupled together in both vertical and horizontal offset thereby creating four engagement platforms: an upper engagement platform (between proximal upper edge and distal upper edge), a lower engagement platform (between proximal lower edge and distal lower edge), a right engagement platform (between proximal right edge and distal right edge), and a left engagement platform (between proximal left edge and distal left edge), wherein at least one of the proximal panel and the distal panel comprises at least one corrugated flute, and wherein one engagement platform of block one engages and overlaps (docks with) another engagement platform on block two to form a conjoined connection there between.
  • the prevent invention provides a block for use in interlocking, conjoined alignment with a plurality of like blocks to form a soundproofing barrier, said block comprising:
  • the proximal left side and the distal left side are aligned or flush.
  • the proximal left side and the distal left side are offset creating an additional engagement platform (either proximal or distal).
  • the present invention further provides a method of making a sound proofing barrier which comprises
  • each block comprising a) panel comprising a proximal upper edge, a proximal lower edge, a proximal right edge and proximal left edge; b) a distal panel comprising a distal upper edge, a distal lower edge, a distal right edge and distal left edge, the distal panel and the proximal panel being immovably coupled together in both vertical and horizontal offset thereby creating four engagement platforms: an upper engagement platform (between proximal upper edge and distal upper edge), a lower engagement platform (between proximal lower edge and distal lower edge), a right engagement platform (between proximal right edge and distal right edge), and a left engagement platform (between proximal left edge and distal left edge), wherein at least one of the proximal panel and the distal panel comprises at least one corrugated flute; joining and overlapping at least part of one engagement platform of block one with at least part of an adjacent engagement platform
  • one block is inter-connectable to other blocks in either an overlapping or a ship-lap like manner and 2) to achieve this, the offset of the constituent panels creates at least one, preferably two and most preferably a plurality of engagement platforms (for example, four per block), as described further herein.
  • the “offset” of the panels may be horizontal, vertical or both horizontal and vertical, the latter dual offset creating four engagement platforms for interconnection of one block to adjacent blocks.
  • the blocks each preferably comprise two panels and at least one of these panels comprise at least one corrugated flute.
  • one panel in a block may be the same depth as another panel in the block.
  • one panel in a block may be double or triple the depth of a second panel in that same block. In this way, and with greater depth, one panel may comprise more than one layer of corrugated flutes.
  • FIG. 1 there is provided generally at 10 a single block 12 for use with a plurality of other blocks in a uniquely interlocking soundproofing barrier system.
  • a system may be used in walls, floor or ceilings, as desired.
  • the panels are substantially rectangular, other shapes and configurations (such as square) are certainly within the scope of the present invention.
  • Some of the figures depict the blocks with the “length” of the rectangular panel oriented vertically. It is; however, preferred in situ that the “length” of the rectangular panel be oriented horizontally.
  • Block 12 comprises proximal panel 14 and distal panel 16 , both panels being immovably coupled together in both vertical and horizontal offset thereby creating four engagement platforms: an upper engagement platform 18 (between proximal upper edge and distal upper edge), a lower engagement platform 20 (between proximal lower edge and distal lower edge), a right engagement platform 22 (between proximal right edge and distal right edge), and a left engagement platform 24 (between proximal left edge and distal left edge).
  • an upper engagement platform 18 between proximal upper edge and distal upper edge
  • a lower engagement platform 20 between proximal lower edge and distal lower edge
  • a right engagement platform 22 between proximal right edge and distal right edge
  • a left engagement platform 24 between proximal left edge and distal left edge
  • FIG. 2 depicts block 12 adjacent to but not yet interconnected with block 26 . It is apparent that as the blocks are moved into proximity, right engagement platform 22 of block 12 will engage by sliding under left engagement platform 28 of block 26 . Such interconnections or docking, as shown further in FIG. 6 , may involve more than one block engaging adjacent blocks.
  • FIGS. 3 to 5 illustrate the alignment and interconnection of block(s) from a side view.
  • proximal panel 30 and distal panel 32 are offset forming platform A and platform B.
  • An adjacent block comprises proximal panel 34 and distal panel 36 which are offset forming platform C and platform D.
  • FIG. 5 it can be seen that platform C and platform B have been slid into interconnection or “docking” with each other.
  • FIG. 6 shows the interconnection or docking of four blocks, 38 , 40 , 42 and 44 to form soundproofing barrier generally indicated at 45 .
  • each block align, end to end with its adjacent counterpart. Such is illustrated in FIG. 6 , in which block 40 (with ends 46 and 48 and sides 50 and 52 ) is engaged on side 50 with blocks 38 and 42 and on end 48 with block 44 . It is preferred that a block align, on at least two of its four sides, with more than one adjacent block.
  • the preferred off-set, ship-lap like arrangement creates strength in the connection, a greater seal formation and concomitantly, with the further corrugation feature of the invention, provides the enhanced soundproofing barrier properties.
  • FIGS. 7 through 12 depict various corrugation embodiments.
  • the corrugations in panels 14 and 16 are of the same height (amplitude) and frequency.
  • a proximal panel 54 comprises one layer of corrugated flutes and distal panel 56 comprises two layers ( 60 and 62 ) of corrugated flutes (a 1:2 ratio). It is equally possible that other differentials may be used (1:3 or 1:4, for example), as desired. It is preferred that in the occasion that two or more corrugated flutes are included within a panel, that one or more separator sheets 64 are disposed there between. A separator sheet may also be included as backing even if only one layer of corrugated flutes is selected for use.
  • FIG. 8 shows the alignment of proximal panel 54 and distal panel 56 just prior to docking with proximal panel 72 and distal panel 70 of block 68 .
  • the offset alignment of proximal panel 54 and distal panel 56 creates platform E and likewise the offset alignment of proximal panel 70 and distal panel 72 creates platform F.
  • Platforms E and F define the docking interconnection as depicted best in FIG. 9 .
  • proximal panel 74 and the distal panel 76 each comprises two layers of corrugated flutes or waves 66 . Each layer is separated from it adjacent layer by at least one separator sheet 64 .
  • FIG. 11 shows the alignment of proximal panel 74 and distal panel 76 just prior to docking with proximal panel 78 and distal panel 80 of block 82 .
  • the offset alignment of proximal panel 74 and distal panel 76 creates platform G and likewise the offset alignment of proximal panel 78 and distal panel 80 creates platform H.
  • Platforms G and H define the docking interconnection as depicted best in FIG. 12 .
  • each panel comprises a corrugated laminar material, which defines a plurality of corrugations or waves 66 , most preferably waves that extend in a direction substantially linear and parallel to one another.
  • the linear waves present regular shapes and dimensions.
  • each wave 66 has a length approximately the same as its height or amplitude, advantageously wherein length and height are approximately between 4 mm and 10 mm.
  • the height and length of a wave may differ, for example a length of between approximately 6 mm and 12 mm, preferably between 8 mm and 10 mm, and a height between 3 mm and 6 mm, preferably between 4 mm and 5 mm.
  • FIG. 13 is a side view, in cross-section, through a section of a block comprising one panel 83 comprising a line of flute/corrugation 84 with an amplitude 87 (height) of approximately 3.5 mm and a peak to peak distance 88 of approximately 7.95 mm
  • FIG. 14 is a side view, in cross-section, through a section of a block comprising one panel 85 comprising a line of flute/corrugation 86 with an amplitude (height) of approximately 4.6 mm and a a peak to peak distance 89 a of approximately 8.9 mm.
  • corrugated flutes separated by a separator sheet and wherein disposition of the flutes relative to one another is such that a trough on one flute is aligned with a peak on an adjacent flute and likewise a peak on one flute is aligned with a trough on an adjacent flute, thereby forming a plurality of alignment points 82 ( FIG. 12 ).
  • this preferred arrangement creates a plurality of channel spaces between the flutes and the sheet. It is preferred that the channel spaces are filled with filler, more preferably a particulate material.
  • the particulate material may preferably be selected from the group comprising sand (preferably fine silica sand), gravel, industrial sand, stone powder, etc. . . . .
  • the filler is fine (washed and dried) silica sand with a US mesh of between 100 (0.152 mm) and 140 (0.104 mm).
  • a US mesh of between 100 (0.152 mm) and 140 (0.104 mm.
  • the finer the particularity or granularity of the filler the better for use herein.
  • the tighter the channels are packed with the filler the better for use herein.
  • FIG. 15 is a side view of a block (shown generally at 91 ) comprising two offset panels proximal panel 90 and distal panel 92 (offset at one side) in accordance with one aspect of the present invention.
  • the offset (distal panel 92 being longer than proximal panel 90 ) creates distal engagement platform 94 .
  • FIG. 16 is front view of block 91 .
  • FIG. 17 is an end view of a wall and floor join (shown generally at 95 ) with:
  • Soundproofing wall block 98 (comprising panels 99 and 100 , 5 ⁇ 8′′/15 mm) Soundproofing floor block 102 (comprising panels 104 and 106 , 5 ⁇ 8′′/15 mm) Soundproofing floor block 107 (comprising panels 108 and 110 , 5 ⁇ 8′′/15 mm) Shiplap between block 102 and 107 (1.5′′ reference to size of engagement platform) Concrete Floor 115
  • FIG. 18 is an end view of a wall and floor join (shown generally at 114 ) with:
  • Soundproofing wall block 98 (comprising panels 99 and 100 , 5 ⁇ 8′′/15 mm) Soundproofing floor block 102 (comprising panels 104 and 106 , 5 ⁇ 8′′/15 mm) Soundproofing floor block 107 (comprising panels 108 and 110 , 5 ⁇ 8′′/15 mm) Shiplap between block 102 and 107 (1.5′′ reference to size of engagement platform)
  • FIG. 19 is side view of a wall (shown generally at 120 ), in partial cut-away wherein a plurality of studs 122 (for example, woodstuds) are exposed beneath a plurality of panel/blocks 124 of the present invention. Panels 124 are partially exposed beneath drywall 126 . With the North American building standards, there are 16′′ between each stud (distance shown as 127 ). FIG. 19 depicts that, for panels of the present invention having a 2′ ⁇ 4′ dimension, there is overlap of four studs (A, B, C and D). FIG. 19 further shows that for a North American standard drywall sheet size of 4′ ⁇ 8′, under-coverage is supplied by two 2′ ⁇ 4′ panels/blocks. So, preferably one drywall sheet is covered by two panels which in turn covers four studs.
  • a North American standard drywall sheet size of 4′ ⁇ 8′ under-coverage is supplied by two 2′ ⁇ 4′ panels/blocks. So, preferably one drywall sheet is covered by two panels which in
  • FIG. 20 is side view of a wall (shown generally at 128 ) having studs 122 , shiplap 112 and “on centre” line of stud 130 (shown as stippled lines running down each stud). This figure illustrates that the preferred 48′′ ⁇ 24′′ panel/block of the present invention extends from centre line 130 of one stud to centre line 130 of the adjacent stud.
  • FIG. 21 is a side view of a wall (shown generally at 132 ) having studs 122 , shiplap 112 and “on centre” line of stud 130 (shown as stippled lines running down each stud). This figure further illustrates that the preferred 48′′ ⁇ 24′′ panel/block of the present invention extends from centre line 130 of one stud to centre line 130 of the adjacent stud across 16′′ distance between two centre lines ( 127 ).
  • each panel is sealed on all edges. Furthermore, it is preferred that each panel has a thickness of from 5 mm to 30 mm. Furthermore, it is preferred that each is sealed by cardboard sheets, most preferably a 1 mm (420 gr/m2) cardboard sheet. In an overall preferred embodiment, the corrugations (waves) and separator sheets are made of cardboard.
  • each layer of fluting will be selected by one skilled in the art depending on the desired vertical strength required in the final corrugated product, and the capacity for sound damping required, etc. . . . . It is more than clear that some applications (for example heavy industrial may require that each panel comprise a plurality of corrugation layers).
  • the panels are coated with a barrier coating.
  • at least one panel is coated with a multi-function barrier coating, for example: Spectra-Guard 763A or Spectra-Guard 763A-Flexo or like coatings.
  • a block comprises two panels, immovably joined.
  • these “panels” may actually be one integral unit, formed with the 1-4 engagement platforms.
  • the proximal panel and distal panel are seamless and integral or “one unit” divided into layer of corrugations.
  • more than two adjacent panels are joined to form a block. It is contemplated that, within such a block, panels may be attached together by any conventional joining means (for example, glue, nails, other sealers) but, at the periphery, there are engagement panels for overlapping for shiplap-like attachment to adjacent blocks.
  • any conventional joining means for example, glue, nails, other sealers
  • the present invention also provides a method of making a sound proofing barrier which comprises
  • each block comprising a) panel comprising a proximal upper edge, a proximal lower edge, a proximal right edge and proximal left edge; b) a distal panel comprising a distal upper edge, a distal lower edge, a distal right edge and distal left edge, the distal panel and the proximal panel being immovably coupled together in both vertical and horizontal offset thereby creating four engagement platforms: an upper engagement platform (between proximal upper edge and distal upper edge), a lower engagement platform (between proximal lower edge and distal lower edge), a right engagement platform (between proximal right edge and distal right edge), and a left engagement platform (between proximal left edge and distal left edge); wherein at least one of the proximal panel and the distal panel comprises at least one corrugated flute; joining and overlapping at least part of one engagement platform of block one with at least part of an adjacent engagement platform
  • the barrier of the present invention is preferably installed over studs.
  • stud in construction refers to beams of wood, steel or other material that form the framework of a structure.
  • Wall studs are generally covered with drywall to form the interior wall surfaces. Studs for walls are usually two-by-four- or two-by-six-inch wooden beams, depending on the desired width of the walls. Typically, wall studs are placed 16 inches apart. Occasionally, they are placed 24 inches apart. The distance between studs is measured from the center of one stud to the center of the next. Therefore, studs are said to be 16 inches “on center.” As such, it is most preferred that the blocks of the present invention be of a size to extend from one stud to an adjacent stud. Once in situ, for walls the barrier may further be covered by dry wall paneling, as desired.
  • the barrier so created is cost effective, relatively lightweight and space effective. It can be installed by conventionally trained construction labour, using conventional tools and with a minimum of special training.
  • the “seal” arrangement created by the docking engagement platforms (and preferably wherein one block aligns, on at least two of its four sides, with more than one adjacent block) creates a highly advantageous “non-leaky” sound barrier system which has not been achieved by any other prior products.
  • the various acts may be performed in a different order than that illustrated and described. Additionally, the methods can omit some acts, and/or employ additional acts.

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  • Physics & Mathematics (AREA)
  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Acoustics & Sound (AREA)
  • Electromagnetism (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Building Environments (AREA)
  • Vehicle Interior And Exterior Ornaments, Soundproofing, And Insulation (AREA)
US14/344,592 2011-09-12 2012-09-12 Interlocking soundproofing block system and method Abandoned US20150075901A1 (en)

Priority Applications (1)

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US14/344,592 US20150075901A1 (en) 2011-09-12 2012-09-12 Interlocking soundproofing block system and method

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
US201161533529P 2011-09-12 2011-09-12
PCT/IB2012/001760 WO2013038253A1 (en) 2011-09-12 2012-09-12 Interlocking soundproofing block system and method
US14/344,592 US20150075901A1 (en) 2011-09-12 2012-09-12 Interlocking soundproofing block system and method

Publications (1)

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US20150075901A1 true US20150075901A1 (en) 2015-03-19

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US (1) US20150075901A1 (es)
CA (1) CA2844036A1 (es)
MX (1) MX2014002940A (es)
WO (1) WO2013038253A1 (es)

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US9683366B2 (en) * 2013-01-24 2017-06-20 Daiwa House Industry Co., Ltd. Soundproof room
US20190153721A1 (en) * 2017-09-20 2019-05-23 Louisiana-Pacific Corporation Integrated joint sealing system
US20190161962A1 (en) * 2017-11-28 2019-05-30 Cretice BENEFIELD Wood blocking blank for creating wood blocking for metal studs and methods of manufacture and use thereof
US11207863B2 (en) 2018-12-12 2021-12-28 Owens Corning Intellectual Capital, Llc Acoustic insulator
US11280096B1 (en) * 2018-10-31 2022-03-22 Harry Bussey Cushioning preform for flooring
US11377848B2 (en) * 2015-09-03 2022-07-05 Awi Licensing Llc Ceiling system
US11408169B2 (en) * 2017-11-28 2022-08-09 Cretice BENEFIELD Z-shaped bracket for wood backing and fireproofing
US11557937B2 (en) 2018-11-15 2023-01-17 Cummins Power Generation Ip, Inc. Genset enclosures with low acoustic noise
US11598087B2 (en) * 2017-06-03 2023-03-07 Gold Bond Building Products, Llc Sound damping wallboard and method of constructing a sound damping wallboard
SE2151214A1 (en) * 2021-10-04 2023-04-05 Alexander Palosaari Overlapping sheets of wall cladding, arrangement thereof and method for forming such an arrangment
US11666199B2 (en) 2018-12-12 2023-06-06 Owens Corning Intellectual Capital, Llc Appliance with cellulose-based insulator
US20240301696A1 (en) * 2023-03-08 2024-09-12 Bmic Llc Roofing material, and roof system including the roofing material

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* Cited by examiner, † Cited by third party
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US9683366B2 (en) * 2013-01-24 2017-06-20 Daiwa House Industry Co., Ltd. Soundproof room
US11377848B2 (en) * 2015-09-03 2022-07-05 Awi Licensing Llc Ceiling system
US12180700B2 (en) 2017-06-03 2024-12-31 Gold Bond Building Products, Llc Sound damping wallboard and method of constructing a sound damping wallboard
US11598087B2 (en) * 2017-06-03 2023-03-07 Gold Bond Building Products, Llc Sound damping wallboard and method of constructing a sound damping wallboard
US20190153721A1 (en) * 2017-09-20 2019-05-23 Louisiana-Pacific Corporation Integrated joint sealing system
US10927542B2 (en) * 2017-09-20 2021-02-23 Louisiana-Pacific Corporation Integrated joint sealing system
US11408169B2 (en) * 2017-11-28 2022-08-09 Cretice BENEFIELD Z-shaped bracket for wood backing and fireproofing
US10655326B2 (en) * 2017-11-28 2020-05-19 Cretice BENEFIELD Wood blocking blank for creating wood blocking for metal studs and methods of manufacture and use thereof
US20190161962A1 (en) * 2017-11-28 2019-05-30 Cretice BENEFIELD Wood blocking blank for creating wood blocking for metal studs and methods of manufacture and use thereof
US11280096B1 (en) * 2018-10-31 2022-03-22 Harry Bussey Cushioning preform for flooring
US11557937B2 (en) 2018-11-15 2023-01-17 Cummins Power Generation Ip, Inc. Genset enclosures with low acoustic noise
US11207863B2 (en) 2018-12-12 2021-12-28 Owens Corning Intellectual Capital, Llc Acoustic insulator
US11666199B2 (en) 2018-12-12 2023-06-06 Owens Corning Intellectual Capital, Llc Appliance with cellulose-based insulator
SE2151214A1 (en) * 2021-10-04 2023-04-05 Alexander Palosaari Overlapping sheets of wall cladding, arrangement thereof and method for forming such an arrangment
US20240301696A1 (en) * 2023-03-08 2024-09-12 Bmic Llc Roofing material, and roof system including the roofing material
US12215503B2 (en) * 2023-03-08 2025-02-04 Bmic Llc Roofing material, and roof system including the roofing material

Also Published As

Publication number Publication date
WO2013038253A1 (en) 2013-03-21
MX2014002940A (es) 2014-04-30
CA2844036A1 (en) 2013-03-21

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