Sound reducing panel

Abstract

An improved sound reducing panel is disclosed comprising a front porous sheet for enabling sound to enter into the sound reducing panel and a rear non-porous sheet. A sound absorbing member dissipates sound entering into the front porous sheet. A sound blocking member blocks sound from exiting from the sound absorbing member. A decoupling member reduces sonic vibration from being transferred from the sound blocking member to the rear non-porous sheet.

Claims

1. A sound reducing panel, comprising: a front porous sheet for enabling sound to enter into said sound reducing panel; a rear non-porous sheet; a fiber glass fiber board sound absorbing member located adjacent to said front porous sheet for dissipating sound entering into said front porous sheet; a sound blocking member comprising a sheet of polymeric material having a weight equal to or greater than one pound per square foot located adjacent to said sound absorbing member for blocking sound propagating through said sound absorbing member; an aerogel material decoupling member for reducing sonic vibration from being transferred from said sound blocking member to said rear non-porous sheet; and said sound blocking member being interposed between said fiber glass fiber board sound absorbing member and said aerogel material decoupling member for insulating said sound blocking member from fire or excessive heat.

2. The sound reducing panel as set forth in claim 1, wherein said front porous sheet comprises a metallic porous sheet.

3. The sound reducing panel as set forth in claim 1, wherein said rear non-porous sheet comprises a rear non-porous metallic sheet.

4. The sound reducing panel as set forth in claim 1, including a metallic frame surrounding said sound reducing panel for further protecting said sound blocking member from fire or excessive heat.

5. The sound reducing panel as set forth in claim 1, wherein said decoupling member comprises an aerogel material having a thickness between 1/16 and of an inch.

6. The sound reducing panel as set forth in claim 1, wherein said decoupling member comprises an aerogel material having preferred thickness of of an inch.

7. The sound reducing panel as set froth in claim 1, wherein said decoupling member comprises an aerogel material having a density of 10 pounds per cubic foot.

8. A sound reducing panel, comprising: a first layer comprising a porous sheet for enabling sound to enter into said sound reducing panel; a second layer comprising a fiber glass fiber board sound absorbing member for dissipating sound within the sound reducing panel; a third layer comprising a sound blocking member comprising a sheet of polymeric material having a weight equal to or greater than one pound per square foot for blocking the transmission of sound through the sound reducing panel; a fourth layer comprising an aerogel material; a fifth layer comprising a non-porous sheet; said fourth layer decoupling said third layer from said fifth layer; said sound blocking member being interposed between said fiber glass fiber board sound absorbing member and said aerogel material decoupling member for insulating said sound blocking member from fire or excessive heat; and a metallic frame surrounding said sound reducing panel for further protecting said sound blocking member from fire or excessive heat.

9. The sound reducing panel as set forth in claim 8, wherein said first layer comprises a metallic porous sheet.

10. The sound reducing panel as set forth in claim 8, wherein said fifth layer comprises a non-porous metallic sheet.

11. The sound reducing panel as set forth in claim 8, wherein said decoupling member comprises an aerogel material having a thickness between 1/16 and of an inch.

12. The sound reducing panel as set forth in claim 8, wherein said decoupling member comprises an aerogel material having preferred thickness of of an inch.

13. The sound reducing panel as set forth in claim 8, wherein said decoupling member comprises an aerogel material having a density of 10 pounds per cubic foot.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) For a fuller understanding of the nature and objects of the invention, reference should be made to the following detailed description taken in connection with the accompanying drawings in which:

(2) FIG. 1 is an isometric cut away view of a sound reducing panel of the prior art;

(3) FIG. 2 is an isometric view of the sound reducing panel of the prior art installed on a support in an outdoor or a hazardous environment;

(4) FIG. 3 is an enlarged isometric view along line 3-3 in FIG. 2;

(5) FIG. 4 is an enlarged sectional view along line 4-4 in FIG. 2 with the support being removed;

(6) FIG. 5 is an enlarged sectional view along line 5-5 in FIG. 2 with the support being removed;

(7) FIG. 6 is a graph of sound transmission report for the prior art sound reducing panel of FIGS. 1-5 illustrating the transmission loss as a function of frequency;

(8) FIG. 7 is an isometric cut away view of an improved sound reducing panel of the present invention;

(9) FIG. 8 is an isometric view of the improved sound reducing panel of the present invention;

(10) FIG. 9 is an enlarged isometric view along line 9-9 in FIG. 8;

(11) FIG. 10 is an enlarged sectional view along line 10-10 in FIG. 8;

(12) FIG. 11 is an enlarged sectional view along line 11-11 in FIG. 8; and

(13) FIG. 12 is a graph of a sound transmission report for the improved art sound reducing panel of FIGS. 7-11 illustrating the transmission loss as a function of frequency.

(14) Similar reference characters refer to similar parts throughout the several Figures of the drawings.

DETAILED DISCUSSION

(15) FIGS. 1-5 are various views of a sound reducing panel 10 of the prior art shown in my U.S. Pat. No. 7,063,184 which is incorporated by reference as if fully set forth herein. The prior art sound reducing panel 10 comprises a front face surface 11 and a rear face surface 12 and a plurality of peripheral edges 14-17.

(16) A porous covering sheet 20 comprises a first covering sheet face 21 and a second covering sheet face 22. The first covering sheet face 21 of the porous covering sheet 20 forms the front face surface 11 of the prior art sound reducing panel 10.

(17) The prior art sound reducing panel 10 comprises a water resistant sound absorbing member 30. The water resistant sound absorbing member 30 comprises a first and a second face surface 31 and 32 and peripheral edges 34-37. The improved sound reducing panel 10 is formed from a multiplicity of fibers 38 defining a multiplicity of pores 39 between adjacent fibers 38.

(18) The prior art sound reducing panel 10 includes a water resistant sound blocking member 40 for blocking the transmission of sound through the prior art sound reducing panel 10. The water resistant sound blocking member 40 comprises a first and a second face surface 41 and 42. The water resistant sound blocking member 40 is located adjacent to the water resistant sound absorbing member 30.

(19) The water resistant sound absorbing member 30 enables sound entering the first face surface 31 of the sound absorbing member 30 to be absorbed and/or dissipated by the sound absorbing member 30. The water resistant sound blocking member 40 inhibits sound from exiting from the second face surface 32 of the sound absorbing member 30. The water resistant sound blocking member 40 inhibits sound from passing from the rear face surface 12 of the sound reducing panel 10.

(20) A non-porous covering sheet 60 comprises a first covering sheet face 61 and a second covering sheet face 62. The first covering sheet face 61 of the non-porous covering sheet 60 is located adjacent to the second face surface 42 of the water resistant sound blocking member 40. The second covering sheet face 62 forms the rear face surface 12 of the prior art sound reducing panel 10.

(21) The prior art sound reducing panel 10 includes a frame 70 is shown as a generally U-shape metallic member located about the porous covering sheet 20, the sound absorbing member 30, the sound blocking member 40 and the non-porous covering sheet 60. The U-shape metallic member 70 includes a first and a second leg 71 and 72 connected by an intermediate leg 73. The external frame 70 includes frame portions 74-77 which form the peripheral edges 14-17 of the sound reducing panel 10. The first and second legs 71 and 72 are disposed adjacent to the front face surface 11 and a rear face surface 12 of the sound reducing panel 10

(22) FIGS. 2-4 are enlarged views illustrating a mounting 80 for supporting the prior art sound reducing panel 10. The mounting 80 includes bores 81 extending through the frame portion 74-77. The bores 81 extend through the porous covering sheet 20, the sound absorbing member 30, the sound blocking member 40 and the non-porous covering sheet 60. A metallic sleeve 90 extends between a first and a second end 91 and 92 within each of the bores 81. The first and second ends 91 and 92 of the metallic sleeve 90 include flares 93 and 94 for engaging the first and second legs 71 and 72 of the frame 70.

(23) FIGS. 2 and 3 illustrate the prior art sound reducing panel 10 secured by mounting fasteners 90 to a support 98 shown a chain link fence of conventional design. The mounting fasteners 95 extend through the bore 81 for mounting the prior art sound reducing panel 10 to the support 98. The mounting fasteners 90 are shown as wire, fiber or plastic fasteners for securing the prior art sound reducing panel 10 to the support 98.

(24) FIG. 6 is a graph of sound transmission report for the prior art sound reducing panel 10 of FIGS. 1-5 illustrating the transmission loss as a function of frequency. The prior art sound reducing panel 10 provides an excellent sound transmission coefficient (STC) of 29. The prior art sound reducing panel 10 shows a reduction in transmission loss at lower frequencies.

(25) FIGS. 7-11 illustrate the improved sound reducing panel 110 of the present invention. The improved sound reducing panel 110 comprises a front face surface 111 and a rear face surface 112 and a plurality of peripheral edges 114-117. Although the improved sound reducing panel 110 has been shown as having a rectangular configuration with four peripheral edges 114-117, it should be understood that the improved sound reducing panel 110 may have configurations different than a rectangular configuration.

(26) The improved sound reducing panel 110 comprises a front porous sheet 120 for enabling sound to enter into said sound reducing panel. The porous covering sheet 120 defines a first covering sheet face 121 and a second covering sheet face 122. The first covering sheet face 121 of the porous covering sheet 120 forms the front face surface 111 of the improved sound reducing panel 110. In one example, the front porous sheet comprises a metallic porous sheet.

(27) A water resistant sound absorbing member 130 is located adjacent to said front porous sheet 120 for dissipating sound entering into the front porous sheet 120. The water resistant sound absorbing member 130 comprises a first and a second face surface 131 and 132 and peripheral edges 134-137. The first face surface 131 of the water resistant sound absorbing member 130 engages the second covering sheet face 122 of the porous covering sheet 120.

(28) The improved sound reducing panel 110 is formed from a multiplicity of fibers 138 defining a multiplicity of pores 139 between adjacent fibers 134. The multiplicity of fibers 38 enables the sound and/or noise to enter through the multiplicity of pores 136 and to be dispersed by the multiplicity of fibers 138 within the water resistant sound absorbing member 130. In one example of the invention, the water resistant sound absorbing member 130 is formed from one to two inch thick fiber glass fiber board having a density of 6 pounds per square foot.

(29) The improved sound reducing panel 110 includes a water resistant sound blocking member 140 for blocking the transmission of sound through the improved sound reducing panel 110. The water resistant sound blocking member 140 comprises a first and a second face surface 141 and 142.

(30) The water resistant sound blocking member 140 is located adjacent to the water resistant sound absorbing member 130. Preferably, the first face surface 141 of water resistant sound blocking member 140 engages the second face surface 132 of the water resistant sound absorbing member 130

(31) The water resistant sound blocking member 140 acts in concert with the water resistant sound absorbing member 130. The water resistant sound absorbing member 130 enables sound entering the first face surface 131 of the sound absorbing member 130 to be absorbed and/or dissipated by the sound absorbing member 130. The water resistant sound blocking member 130 inhibits sound from exiting from the second face surface 132 of the sound absorbing member 130. The water resistant sound blocking member 140 inhibits sound from passing from the rear face surface 112 of the sound reducing panel 110.

(32) The water resistant sound blocking member 140 comprises a sheet of mineral filled vinyl polymeric material having a thickness of between 1/16 of an inch and of an inch. Preferably, the water resistant sound blocking member 140 has a thickness of one-eighth of an inch and having a weight equal to or greater than one pound per square foot. A suitable material is sold under the Registered Trademark Acoustiblok by Acoustiblok, Inc. of Tampa, Fla. (www.acoustiblok.com).

(33) An important aspect of the improved sound reducing panel 110 is the addition of a decoupling member 150. The decoupling member 150 comprises a first and a second face surface 151 and 152. The decoupling member 150 is interposed between the sound blocking member 140 and a non-porous covering sheet 160. The decoupling member 150 reduces sonic vibration from being transferred from the sound blocking member 140 to the rear non-porous sheet 160.

(34) Preferably, the first face surface 151 of the decoupling member 150 engages the second face surface 142 of water resistant sound blocking member 140. The first face surface 151 of the decoupling member 150 engages a first covering sheet face 161 of the non-porous covering sheet 160. The second covering sheet face 162 of the non-porous covering sheet 160 forms the rear face surface 112 of the improved sound reducing panel 110. In one example, the rear non-porous sheet 160 comprises a metallic non-porous sheet.

(35) The improved sound reducing panel 110 includes a frame 170 shown as a generally U-shape metallic member located about the porous covering sheet 120, the sound absorbing member 130, the sound blocking member 140, the decoupling member 150 and the non-porous covering sheet 160. The U-shape metallic member of the frame 170 includes a first and a second leg 171 and 172 connected by an intermediate leg 173. The external frame 170 includes frame portions 174-77 which form the peripheral edges 114-117 of the improved sound reducing panel 110. The first and second legs 171 and 172 are disposed adjacent to the front face surface 111 and a rear face surface 112 of the sound reducing panel 110

(36) A mounting 180 is provided for supporting the improved sound reducing panel 110. The mounting 180 includes bores 181 extending through the frame portion 174-177. The bores 181 extend through the porous covering sheet 120, the sound absorbing member 130, the sound blocking member 140, the decoupling member 150 and the non-porous covering sheet 160. A metallic sleeve 190 extends between a first and a second end 191 and 192 within each of the bores 181. The first and second ends 191 and 192 of the metallic sleeve 190 include flares 193 and 194 for engaging the first and second legs 171 and 172 of the frame 170. A fastener as shown in FIGS. 2 and 3 mounts the improved sound reducing panel 110 to a support (not shown). it should be appreciated that numerous other ways and methods may be used for supporting and or hanging or otherwise spending the improved sound reducing panel 110 within an environment. The improved sound reducing panel 110 of the present invention is suitable for use in an outdoor, hazardous environment or manufacturing environment.

(37) The improved sound reducing panel 110 includes a frame 170 shown as a generally U-shape metallic member located about the porous covering sheet 120, the sound absorbing member 130, the sound blocking member 140, the decoupling member 150 and the non-porous covering sheet 160. The U-shape metallic member 170 includes a first and a second leg 171 and 172 interconnected by an intermediate member 173.

(38) The first and second legs 171 and 172 of the U-shape metallic frame 170 are dimensioned for slightly compressing the sound absorbing member 130 to achieve engagement between the porous covering sheet 120, the sound absorbing member 130, the sound blocking member 140, the decoupling member 150 and the non-porous covering sheet 160.

(39) Typically, sonic decoupling is achieved by spacing a first member from a second member with an air gap located therebetween. The air gap between the first member and second member impedes the transfer of vibration from the first member to the second member. Unfortunately, an air gap was not a solution for the decoupling member 150 due to the engagement of the porous covering sheet 120, the sound absorbing member 130, the sound blocking member 140, the decoupling member 150 and the non-porous covering sheet 160.

(40) The solution to this problem was found through the use of an aerogel material for the decoupling material 150. The aerogel material is a light weight, slightly compressible material with extraordinary thermal blocking properties.

(41) The decoupling material 150 comprises a sheet of aerogel material having a thickness of between 1/16 of an inch and of an inch. Preferably, the decoupling material 150 comprises a sheet of aerogel material having a thickness of 0.125 inch having a density of 10 pounds per cubic foot. A highly incompressible aerogel material that is suitable for use as the decoupling material 150 is available at Thermablok LLC of Tampa, Fla. (www.acoustiblok.com).

(42) It has been found that the inclusion of the 0.125 inch thickness of aerogel material as the decoupling material 150 substantially reduces sound transmission between the sound blocking member 140 and the non-porous covering sheet 160. Furthermore, the inclusion of the aerogel material as the decoupling material 150 does not appreciably increase the weight or the cost of the improved sound reducing panel 10.

(43) Preferably, the improved sound reducing panel 110 comprises a metallic porous covering sheet 120, a fiber glass fiber board sound absorbing member 130, a mineral filled vinyl polymeric sound blocking member 140, an aerogel decoupling member 150 and the non-porous metallic covering sheet 160 enclosed by a metallic frame 170. The mineral filled vinyl polymeric sound blocking member 140 represents the greatest source of smoke in the event the improved sound reducing panel 110 is subjected to a fire or excessive heat.

(44) The inclusion of the aerogel decoupling member 150 acts in concert with the fiber glass fiber board sound absorbing member 130 to insulate the mineral filled vinyl polymeric sound blocking member 140 from fire or excessive heat. The metallic porous covering sheet 120 and the non-porous metallic covering sheet 160 enclosed by the metallic frame 170 further protects the mineral filled vinyl polymeric sound blocking member 140. Flame tests will be conducted on the improved sound reducing panel 110 in the near future. It is expected that the inclusion of the aerogel decoupling member 150 will significantly reduce the smoke developed by the improved sound reducing panel 110 relative to the prior art sound reducing panel 10 at the same temperature.

(45) FIG. 12 is a graph of sound transmission report for the improved sound reducing panel 110 of FIGS. 7-11 illustrating the transmission loss as a function of frequency. The improved sound reducing panel 110 provides an improved sound transmission coefficient (STC) of 35 over the excellent sound transmission coefficient (STC) of 29 of the prior art sound reducing panel 10.

(46) This difference of 6 db of the improved sound reducing panel 110 represents a 34% difference in the average STC over the sound transmission coefficient (STC) of 29 of the prior art sound reducing panel 10. Furthermore, a comparison of FIGS. 6 and 12 illustrates an extraordinary improvement (8 db) in the very low frequencies of the improved sound reducing panel 110 which are exceptionally more difficult to control.

(47) For example, this eight db in the 100 Hz frequency range represents over 40% improvement to the human ear. A comparison of FIGS. 6 and 12 also indicates as much as a 20 db improvement in the higher frequency of 5,000 Hz. A 20 db difference represents approximately a 75% improvement to the human ear.

(48) The improved sound reducing panel 110 of the present invention provides a significant improvement over my prior art sound reducing panel 10 illustrated in U.S. Pat. No. 7,063,184. The improved sound reducing panel 110 provides an improved sound transmission coefficient (STC) of 35 over the sound transmission coefficient (STC) of 29 of the prior art sound reducing panel 10. The increased sound reducing properties of the improved sound reducing panel 110 in achieved without substantially increasing the weight or size of the sound reducing panel. The improved sound reducing panel 110 is believed to be more fire or smoke resistant over the prior art sound reducing panel 10. The above advantages have been obtained without substantially increasing the cost of the sound reducing panel.

(49) The present disclosure includes that contained in the appended claims as well as that of the foregoing description. Although this invention has been described in its preferred form with a certain degree of particularity, it is understood that the present disclosure of the preferred form has been made only by way of example and that numerous changes in the details of construction and the combination and arrangement of parts may be resorted to without departing from the spirit and scope of the invention.