SOUND DAMPING DOOR
20210071470 ยท 2021-03-11
Inventors
Cpc classification
E06B7/2316
FIXED CONSTRUCTIONS
E06B3/7015
FIXED CONSTRUCTIONS
E06B2003/7051
FIXED CONSTRUCTIONS
E06B3/827
FIXED CONSTRUCTIONS
E06B7/18
FIXED CONSTRUCTIONS
E06B7/2312
FIXED CONSTRUCTIONS
E05D3/186
FIXED CONSTRUCTIONS
International classification
E06B1/18
FIXED CONSTRUCTIONS
Abstract
A sound damping door system having a door frame, a compression seal, a door slab, a bottom seal, and a concealed hinge assembly. The door frame includes male and female components adapted to engage each other in a rough door opening between first and second wall faces; and at least one isolation gasket adapted to be disposed between the male and female components. The compression seal is mounted to the door frame. The door slab includes an outer skin; an arched constrainment sheet inside the outer skin; a damping fill material inside the outer skin; and an acoustic insert inside the outer skin. The bottom seal is mounted to a bottom surface of the door slab such that the bottom seal is permitted to move relative to the door slab.
Claims
1. A door slab, comprising: an outer skin; a curved constrainment sheet inside the outer skin; and a damping fill material inside the outer skin.
2. The door slab of claim 1, wherein the constrainment sheet spans substantially the entire width of the door slab.
3. The door slab of claim 2, wherein the constrainment sheet is arched from a center of the outer skin to first and second ends of the outer skin as measured along the width of the outer skin.
4. The door slab of claim 3, wherein the constrainment sheet is arched between 1 and 2 degrees as measured between a plane of the door slab and a tangent line of the constrainment sheet.
5. The door slab of claim 2, wherein the constrainment sheet spans substantially the entire height of the door slab.
6. The door slab of claim 1, wherein the damping fill material forms a layer on an interior surface of the outer skin, and wherein the constrainment sheet is at least partially embedded in the damping fill material.
7. The door slab of claim 1, wherein the damping fill material comprises a blend of a silicone polymer material and a powdered recycled rubber material, wherein the damping fill material has a combined durometer in the range of Shore 27 to Shore 35A.
8. The door slab of claim 7, wherein the damping fill material has a combined durometer of Shore 29A.
9. The door slab of claim 1, further comprising an acoustic insert inside the outer skin.
10. The door slab of claim 1, further comprising a first hinge bracket disposed in a first hinge pocket of the outer skin, wherein the first hinge bracket is adapted such that, when the door slab is installed in a door frame having a corresponding second hinge bracket disposed in a second hinge pocket of the door frame, a hinge connected to the first and second hinge brackets is concealed within the first and second hinge brackets when the door slab is in a closed position in the door frame.
11. A door frame, comprising: a male component adapted to engage with a first wall face; a female component adapted to engage with a second wall face, wherein the male and female components are adapted to engage each other in a rough door opening between the first and second wall faces; at least one angle bracket having a first panel for securing to the rough door opening and a second panel for securing to at least one of the male and female components; and at least one isolation gasket adapted to be disposed between the male and female components.
12. The door frame of claim 11, further comprising a sill seal material disposed between the door frame and the first wall face, the second wall face, and the rough door opening.
13. The door frame of claim 11, further comprising a first hinge bracket disposed in a first hinge pocket of the female component, wherein the first hinge bracket is adapted such that, when a door having a corresponding second hinge bracket disposed in a second hinge pocket of the door is installed in the door frame, a hinge connected to the first and second hinge brackets is concealed within the first and second hinge brackets when the door is in a closed position in the door frame.
14. A door seal, comprising: a first damping component comprising a plurality of shaped surfaces; and a second damping component, the second damping component is at least partially enclosed in the first damping component.
15. The door seal of claim 14, wherein the first damping component only partially surrounds the second damping component such that, when a door compresses the seal, the first damping component does not completely surround the second damping component.
16. The door seal of claim 14, wherein two of the plurality of shaped surfaces partially surround the second damping component such that, when a door compresses the seal, the compressed seal forms a pseudo-Helmholtz filter.
17. The door seal of claim 16, wherein the compressed seal forms a pseudo-Helmholtz filter that dissipates noise in a frequency bandwidth of 500 Hz to 4,000 Hz.
18. A door bottom seal, comprising: a seal pan; a pressure member at least partially disposed in the seal pan; a sealing strip attached to a bottom surface of the seal pan; and a dampening material disposed in the seal pan.
19. The door bottom seal of claim 18, further comprising a low-friction fabric cover layer disposed on a bottom surface of the sealing strip.
20. The door bottom seal of claim 18, further comprising at least one mounting slot for mounting the seal to a door such that the seal is permitted to move relative to the door.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
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DETAILED DESCRIPTION
[0078] Embodiments of the present technology will now be described, by way of example only, with references to the accompanying drawing figures.
[0079] In some embodiments, the slab 110 includes a damping fill 112, which helps provide acoustic flanking path termination due to orthogonal facing surfaces. The perimeter of the door edge utilizes internal shapes and the damping fill 112 to terminate the phenomena before it can bypass the seal. In some embodiments, a single seal attains sound transmission loss values equivalent to, or better than, a double seal system found in many prior art designs.
[0080] In some embodiments, the damping fill 112 is formed of a low durometer blend of silicone polymer and powdered recycled rubber. In preferred embodiments, the combined durometer of the damping fill is Shore 29A. In some embodiments, the combined durometer of the damping fill 112 is in the range of Shore 27 to 35A. In other embodiments, the combined durometer of the damping fill 112 is in the range of Shore 28A to 32A.
[0081] In some embodiments, the slab 110 includes a constrainment sheet 113. In some embodiments, the constrainment sheet 113 is formed of 22 gauge sheet metal, though other thicknesses and materials are used in other embodiments. Preferably, the constrainment sheet 113 is curved. In some embodiments, the constrainment sheet 113 spans approximately the entire width of the door slab 110. In some embodiments, the constrainment sheet 113 spans approximately the entire height of the door slab 110. In some embodiments, the constrainment sheet 113 spans approximately the entire thickness of the door slab 110. In some embodiments, the constrainment sheet 113 is arched across the width of the door slab, as shown in
[0082] In some embodiments, the arched constrainment sheet 113 improves stiffness so that the door slab 110 can be made thinner. For example, in some embodiments, the door slab 110 is about 1.75 inches thick, which is thinner than typical prior art sound damping doors that have a thickness of 2.5 inches. Decreasing the thickness of the door decreases the air-gap, volume of absorptive material, resonance frequencies, and bending moment forces of the door system. Vertical strength of the door face sheet is often reduced in thinner doors because the attachment angles are all shorter in height (by approximately 30%), which reduces their stiffness by a factor of 1.8.
[0083] In some embodiments, damping fill 112 is injected between the outer skin 111 and the constrainment sheet 113 such that damping fill 112 provides a shear medium that both dampens and provides elasticity. The design in such embodiments allows the face of the door slab 110 to rebound to its original position if struck with projectiles. Preferably, as long as the projectile force is less than the system deformation rate of the combined outer skin 111, damping fill 112, and constrainment sheet 113, then the door slab face will rebound to its original position and be able to withstand multiple projectile impacts without structural damage or failure.
[0084] In some embodiments, the design of the constrainment sheet 113 and damping fill 112 helps address material resonance issues due to the modified passive viscoelastic constrained layer damping technique. In some embodiments, the constrainment sheet 113 provides a non-symmetrical structure for minimal coincidence transmission, and becomes the underlying replacement for bent angle type stiffeners in the door structure. Elimination of the orthogonal face cavity by utilizing a damping fill 112 and constrainment sheet 113 allows the door slab 110 to be made with less mass, smaller thickness (i.e., smaller distance between door faces), and to perform at equal or higher transmission loss levels than prior art designs. In the embodiment shown in
[0085] Some embodiments of the present technology provide similar transmission loss characteristics to older systems that weigh approximately 20% more and are significantly thicker, i.e. 10.1 lbs/ft.sup.2 vs. 12.1 lbs/ft.sup.2, and 1.75 inches vs. 2.5 inches thick.
[0086] In some embodiments, the door slab 110 includes an acoustic damping panel 114. In some embodiments, a 6 pcf panel is used. As used herein, the term pcf is a measure of density meaning pounds per cubic foot. In some embodiments, the acoustic damping panel 114 is formed of such materials as fiberglass, polymers, natural fibers, and composites.
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[0088] In some embodiments, a foam insert 407 is disposed within the seal pan 402 of the bottom seal 400. In some embodiments, the foam insert 407 is a 2 psi polyurethane closed cell foam. In some embodiments, the foam insert 407 is contoured such that its bottom surface 408 has a shape that does not correspond to the shape of the seal pan 402, forming one or more gaps between the foam insert 407 and the seal pan 402. In some embodiments, the bottom surface 408 of foam insert 407 has a convex shape. In some embodiments, the gaps between the foam insert 407 and the seal pan 402 are filled with a damping fill 409. In some embodiments, the damping fill 409 is the same material as the damping fill 112 inside the door slab 110, as described above. In other embodiments, different materials with different characteristics are used for the damping fill 409 in the bottom seal 400, such as a silicone polymer material.
[0089] Preferably, the distributed 2 psi force provided by the foam insert 407 combined with the strip 405 wrapped in the cover 406 allows the bottom seal 400 to conform to small non-linear surface variations found in a raised threshold 19. In the embodiment shown, friction forces from the bottom seal and level swing hinges are substantially less than prior art cam lift bottom seal designs and allow the door to be opened with less than 1.5 lbf. The bottom seal 400, in this embodiment, provides an acoustic transmission loss characteristic in a 1.75 inches thick seal that is equal to the prior art 2.5 inches thick seals. In some embodiments, the bottom seal 400 provides an acoustic transmission loss characteristic that is better than the prior art designs, despite bottom seal 400 being significantly thinner than the prior art designs.
[0090] In some embodiments, the bottom seal 400 articulates and rotates about the longitudinal axis 410 of the bottom seal 400 (i.e. the axis running along the bottom edge of the door slab 110 as measured along the width of the door 100) to automatically adjust to small elevation differences as the bottom seal 400 interfaces with the threshold, floor, or other surface 19 below the door 100. Preferably, the low compression force and superior sealing ability allow the door 100 to at least equal the transmission loss characteristics of the typical prior art type seal and pass the ADA pull test.
[0091] In some embodiments, the bottom seal 400 articulates and rotates about the lateral axis 411 of the bottom seal 400 (i.e. an axis that is perpendicular to the plane of the door slab 110), as shown in
[0092] In preferred embodiments, the bottom seal 400 articulates and rotates about both the longitudinal axis 410 and the lateral axis 411 to provide an improved seal between the door 100 and surface 19 that accounts for variations in the surface 19 across multiple dimensions.
[0093] In some embodiments, the bottom seal 400 includes a top cap 412 that connects to the seal pan 402 to enclose the foam insert 407 and damping fill 409 within the bottom seal 400, as shown in
[0094] Some embodiments of the present technology are directed to a compression seal 300 that the door slab 110 is pressed against when the door 100 is closed within the door frame 200, as shown in
[0095] In some embodiments, the compression seal 300 includes a seal mounting slot 304 that is configured to encapsulate a mounting edge or protrusion 210 of the door frame 200. The compression seal mounting slot 304 preferably provides vibration dampening to the entire perimeter of the seal mounting surface in the door frame 200. In some embodiments, the compression seal 300 is retainer in the door frame 200 via constant pressure provided by a cylindrical strip or second damping component 305. In some embodiments, the strip 305 is partially enclosed in a cavity 303 of the body 301 by at least two of the sealing surfaces 302. The strip 305 preferably provides high frequency absorption in its respective cavity 303. In some embodiments, when the compression seal 300 is in its compressed position, the strip 305 remains partially enclosed (i.e. not completely surrounded) by the sealing surfaces 302 such that a gap 306 remains between the sealing surfaces 302, as shown in
[0096] In some embodiments, the compression seal 300 includes a deceleration bump-stop 307 to absorb the force associated with the door 100 being closed at a high velocity. The force is absorbed and then distributed equally across the perimeter interface of the door 100 and frame 200. In some embodiments, the bump-stop 307 is formed of one of the sealing surfaces 302, as shown in
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[0100] In some embodiments, the male and female frames 201/202 are also fastened together via an isolation system 204, as shown in
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[0102] In some embodiments, the sound damping door 100 is mounted to a frame 200 via a hinge assembly 500. In some embodiments, the hinge assembly 500 includes a hinge bracket 501 installed and concealed in a hinge pocket 502 of the door slab 110, as discussed above. In the same manner, a corresponding hinge bracket 501 is installed and concealed in a hinge pocket 502 of the female frame 202. In other embodiments, the corresponding hinge bracket 501 is installed in a hinge pocket 502 of the male frame 201. Preferably, a swing hinge 506 connects the two hinge brackets 501, as shown in
[0103] In some embodiments, a compression seal 300 is mounted to the door frame 200 via mounting slot 204 that encapsulates a mounting edge or protrusion 210 of the female frame 202. In some embodiments, the compression seal 300 is mounted to a mounting edge or protrusion 210 of the male frame 201. As discussed above, the compression seal 300 is preferably retained in the frame 200 by the constant pressure provided by the cylindrical strip 305 of the compression seal 300. In preferred embodiments, the compression seal 300 provides a continuous compression seal at the frame hinge jamb 211, the frame strike jamb 212, and the frame head 213, such that the compression seal spans the perimeter of the door frame 200, as shown in
[0104] Although the technology has been described and illustrated with respect to exemplary embodiments thereof, it should be understood by those skilled in the art that the foregoing and various other changes, omissions, and additions may be made there and thereto, without departing from the spirit and scope of the present technology. For example, although embodiments of the present technology have been described with reference to a sound damping door system having the components and their respective features as described above, the present technology is not limited thereto. Indeed, the present technology contemplates separate embodiments directed to each of the individual components described above, as well as any possible combination of the components used in a door, door system, or door kit.