INTERLOCKING SOUNDPROOFING BLOCK SYSTEM AND METHOD

Abstract

A block (12) for use in interlocking, conjoined alignment with a plurality of like blocks to form a soundproofing barrier, said block (12) comprises a) a proximal panel (14) having a proximal right side and a proximal left side; b) a distal panel (16) having a distal right side and a distal left side, said distal panel (16) being longer, at its distal left side than the respective proximal right side forming a distal panel platform; the distal panel (16) and the proximal panel (14) being immovably coupled together and wherein at least one of the proximal panel (14) and the distal panel (16) comprises at least one corrugated flute.

Description

FIELD OF THE INVENTION

The present invention relates to the field of soundproofing panels for use in construction of buildings.

BACKGROUND ON THE INVENTION

More than ever before we are experiencing noise disturbances in our work and personal lives. Diminishing privacy and noise pollution can affect peace of mind, increase tension levels, interfere with communication between people, and jeopardize safety in the workplace.

Two distinct 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.

In other words, soundproofing is any means of reducing the sound pressure with respect to a specified sound source and receptor. There are several basic approaches to reducing sound: increasing the distance between source and receiver, using noise barriers to reflect or absorb the energy of the sound waves, using damping structures such as sound baffles, or using active antinoise sound generators.

Furthermore, there is the issue of sound “type”. In the acoustics industry, “bass” is known as low frequency sound. It's the boom-boom music sound heard in adjacent cars while driving. Likewise it is the sound of jets flying overhead near a major airport.

Bass, or low frequency sound, 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.

The standard that measures a structure's ability to hold back sound is called STC (an acronym for “Sound Transmission Coefficient”) and is the most recognized and discussed sound isolation term in North America.

Building codes will dictate what STC level a building needs to have. A new condominium/apartment/flat or town home will have to comply with these building codes and build walls, ceilings and floors that meet these STC requirements. Why is there still a problem? The reason is that STC does not measure any of the worst sound of all. It stops measuring at 125H, exactly where the most offending sound starts. Code is met but life can still be difficult.

In terms of 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) are far too costly. Contrary to common usage, 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.

There are several ways in which 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

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:

• • Cell size
  • Torosity
  • Porosity
  • Material thickness
  • Material density

Resonant Absorbers

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.

In summary, here are the current, most commonly used materials for soundproofing in walls, floors, and ceilings:

Panels

(For Walls, Floors, and Ceilings):

• • Drywall (also called wallboard, plasterboard, or gypsum board), such as Sheetrock™. An inexpensive source of mass, which may have some effect on soundproofing.
  • Damped drywall. Drywall which incorporates a sound damping layer; examples are QuietRock™, Supress™, and SoundBreak™.
  • Sound-deadening fiberboard (also call soundboard or acoustical board), such as SoundChoice™ or Homasote™. Because of their low mass, these are not the best choice for soundproofing walls, but are sometimes useful in floors as a spacing layer if additional mass is not needed. They do not provide damping, decoupling, or absorption.

Mass-Loaded Vinyl (“MLV”)

MLV is a highly dense, flexible membrane sold under various brand names such as Acoustiblok™ and SheetBlok™. This is a good source of mass, but expensive.

• • MLV can fill gaps and wrap ducts, pipes, and metal columns, where a flexible sound barrier is needed.
  • As a layer in soundproofing walls, floors, and ceilings, there are alternatives that are more effective and cheaper than MLV. (Drywall is a cheaper source of mass, and Green Glue™ generally provides better damping across all frequencies.)

Insulation

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.

Sound Curtains.

While ordinary curtains or blankets won't help with soundproofing, there are noise control curtains, which are industrial products that incorporate a heavy layer of mass-loaded vinyl.

Damping Compound

Viscoelastic adhesive such as Green Glue™ or Decibel Drop™. 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.

Acoustical Sealant

Sometimes called acoustical caulk, this is important for sealing seams, to prevent sound leakage. Within conventional systems, without proper sealing, the effectiveness of all the other soundproofing components will be dramatically reduced, as the noise will simply find its way through the cracks.

Hardware for Decoupling.

Includes resilient sound clips and drywall furring channel or hat channel (sometimes confused with resilient channel, which covers an assortment of non-standard items). Correct installation of decoupling hardware is very important. Although decoupling is an effective element of soundproofing, note that it can actually increase transmission of low-frequency noise, by creating a new resonance chamber.

Pre-Built Units.

In addition to raw building supplies, there are also pre-built units such as windows and doors engineered to be soundproof, which work very well and can save time and money.

Insulation as a Solution

One of the oldest and most established methods for improving the sound isolation of walls is the use of insulation. It is fast, reasonably inexpensive and easy to install. In any analysis of soundproofing, it might be useful to first consider how sound moves from one edge of a wall to the other. 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.

Given this structure, insulation will only be able to affect the vibration traveling through the airspace between the studs. The rigid drywall-stud-drywall connection is not reduced with insulation and will conduct vibration just as effectively whether insulated or uninsulated. This drawback of insulation has been confirmed by extensive laboratory testing: low frequencies are not stopped by the addition of insulation—high frequencies are not reduced significantly and mid-frequencies are only reduced somewhat.

There remains a need for a soundproofing system which can adequately address these and other challenges.

It is an object of the present invention to obviate or mitigate the above disadvantages.

SUMMARY OF THE INVENTION

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.

In one aspect, 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) 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.

In another aspect, 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.

In another aspect, 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) a proximal panel having a proximal right side and a proximal left side;
b) 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.

In another aspect, the present invention further provides a method of making a sound proofing barrier which comprises

aligning a plurality of interlocking blocks, starting with 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;
joining and overlapping at least part of one engagement platform of block one with at least part of an adjacent engagement platform on block two to form a conjoined connection there between;
joining and overlapping at least part of another (as yet unengaged) engagement platform of block one with at least part of an adjacent engagement platform on block three to form a conjoined connection there between;
joining and overlapping at least part of another (as yet unengaged) engagement platform of block one with at least part of an adjacent engagement platform on block four to form a conjoined connection there between
and thereafter joining and overlapping further engagement platforms, on blocks one, two, three and four and additional blocks, until a full surface of the barrier is created by a multitude of ship lathe-like interconnections of the panels.

The soundproofing barrier in accordance with the present invention:

1) Creates an interlocking, overlapped and docked arrangement of blocks which resist sound transference. In other words, within the barrier, there are no “seams”.
2) Reduces impact and airborne sound by way of a corrugation system within the panels.

Without limiting the general range of applications, 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.

These and other objects and advantages of the present invention will become more apparent to those skilled in the art upon reviewing the description of the preferred embodiments of the invention, in conjunction with the figures and examples.

BRIEF DESCRIPTION OF THE DRAWINGS

The following figures set forth embodiments in which like reference numerals denote like parts. Embodiments are illustrated by way of example and not by way of limitation in all of the accompanying figures in which:

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; and

FIG. 21 is a further side view of a wall showing centre line of studs.

PREFERRED EMBODIMENTS OF THE INVENTION

A detailed description of one or more embodiments of the invention is provided below along with accompanying figures that illustrate the principles of the invention. As such this detailed description illustrates the invention by way of example and not by way of limitation. The description will clearly enable one skilled in the art to make and use the invention, and describes several embodiments, adaptations, variations and alternatives and uses of the invention, including what we presently believe is the best mode for carrying out the invention. It is to be clearly understood that routine variations and adaptations can be made to the invention as described, and such variations and adaptations squarely fall within the spirit and scope of the invention.

In other words, the invention is described in connection with such embodiments, but the invention is not limited to any embodiment. The scope of the invention is limited only by the claims and the invention encompasses numerous alternatives, modifications and equivalents. Numerous specific details are set forth in the following description in order to provide a thorough understanding of the invention. These details are provided for the purpose of example and the invention may be practiced according to the claims without some or all of these specific details. For the purpose of clarity, technical material that is known in the technical fields related to the invention has not been described in detail so that the invention is not unnecessarily obscured. Similar reference characters denote similar elements throughout various views depicted in the figures.

This description of preferred embodiments is to be read in connection with the accompanying drawings, which are part of the entire written description of this invention. In the description, corresponding reference numbers are used throughout to identify the same or functionally similar elements. Relative terms such as “right”, “left” “horizontal,” “vertical,” “up,” “down,” “top” and “bottom” as well as derivatives thereof (e.g., “horizontally,” “downwardly,” “upwardly,” etc.) should be construed to refer to the orientation as then described or as shown in the drawing figure under discussion. These relative terms are for convenience of description and are not intended to require a particular orientation unless specifically stated as such. Terms including “inwardly” versus “outwardly,” “longitudinal” versus “lateral”, “adjacent” and the like are to be interpreted relative to one another or relative to an axis of elongation, or an axis or center of rotation, as appropriate. Terms concerning attachments, coupling and the like, such as “connected” and “interconnected,” refer to a relationship wherein structures are secured or attached to one another either directly or indirectly through intervening structures, as well as both movable or rigid attachments or relationships, unless expressly described otherwise. Interconnected, as used herein, generally refers to the relationship between the platforms and adjacent blocks. The term “operatively connected” is such an attachment, coupling or connection that allows the pertinent structures to operate as intended by virtue of that relationship. In particular, the terms “right” and “left” are used in the claims but could easily be substituted for one another. In fact, as a panel is rotated 180 degrees in either direction, right becomes left, as so on.

The term “shiplap” 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. In woodworking terms and for wooden sheathing, 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. Essentially, a similar principle is applied here to soundproofing panels and wherein at least one of such panels comprises a corrugated flute. As will be clear from the description and figures, it is not required that there be four engagement platforms (forming points of engagement with an adjacent block). In fact there can be one, two or four.

In the present disclosure and claims (if any), the word “comprising” and its derivatives including “comprises” and “comprise” include each of the stated integers but does not exclude the inclusion of one or more further integers.

The terms “an aspect”, “an embodiment”, “embodiment”, “embodiments”, “the embodiment”, “the embodiments”, “one or more embodiments”, “some embodiments”, “certain embodiments”, “one embodiment”, “another embodiment” and the like mean “one or more (but not all) embodiments of the disclosed invention(s)”, unless expressly specified otherwise.

The term “variation” of an invention means an embodiment of the invention, unless expressly specified otherwise. A reference to “another embodiment” or “another aspect” in describing an embodiment does not imply that the referenced embodiment is mutually exclusive with another embodiment (e.g., an embodiment described before the referenced embodiment), unless expressly specified otherwise.

The terms “a”, “an” and “the” mean “one or more”, unless expressly specified otherwise.

The term “plurality” means “two or more”, unless expressly specified otherwise.

The term “herein” means “in the present application, including anything which may be incorporated by reference”, unless expressly specified otherwise.

The term “whereby” is used herein only to precede a clause or other set of words that express only the intended result, objective or consequence of something that is previously and explicitly recited. Thus, when the term “whereby” is used in a claim, the clause or other words that the term “whereby” modifies do not establish specific further limitations of the claim or otherwise restricts the meaning or scope of the claim.

The term “e.g.” and like terms mean “for example”, and thus does not limit the term or phrase it explains. For example, in a sentence “the car is coloured (e.g., red, blue or green) the term “e.g.” explains that “red, blue or green” are examples of “colour”. However, those colours listed are merely examples of “colours”, and other colours are equally applicable.

The term “respective” and like terms mean “taken individually”. Thus if two or more things have “respective” characteristics, then each such thing has its own characteristic, and these characteristics can be different from each other but need not be. For example, the phrase “each of two machines has a respective function” means that the first such machine has a function and the second such machine has a function as well. The function of the first machine may or may not be the same as the function of the second machine.

The term “i.e.” and like terms mean “that is”, and thus limits the term or phrase it explains.

The present invention provides a soundproofing barrier system which may be installed as a wall or floor and comprises a plurality of barrier blocks.

In one aspect, 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) 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.

In another aspect, 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.

In another aspect, 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) a proximal panel having a proximal right side and a proximal left side;
b) 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 engagement 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. In one aspect, the proximal left side and the distal left side are aligned or flush. In another aspect, the proximal left side and the distal left side are offset creating an additional engagement platform (either proximal or distal).

In another aspect, the present invention further provides a method of making a sound proofing barrier which comprises

aligning a plurality of interlocking blocks, starting with 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;
joining and overlapping at least part of one engagement platform of block one with at least part of an adjacent engagement platform on block two to form a conjoined connection there between;
joining and overlapping at least part of another (as yet unengaged) engagement platform of block one with at least part of an adjacent engagement platform on block three to form a conjoined connection there between;
joining and overlapping at least part of another (as yet unengaged) engagement platform of block one with at least part of an adjacent engagement platform on block four to form a conjoined connection there between
and thereafter joining and overlapping further engagement platforms, on blocks one, two, three and four and additional blocks, until a full surface of the barrier is created by a multitude of ship lathe-like interconnections of the panels.

With the scope of the present invention, regardless of shape of panel, size of panel or panel orientation: 1) 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. As depicted in the description and figures, the blocks each preferably comprise two panels and at least one of these panels comprise at least one corrugated flute.

There is no requirement that one panel in a block be the same depth as another panel in the block. In fact, in one embodiment, 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.

Turning to 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. Such a system may be used in walls, floor or ceilings, as desired. While it is preferred that 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 (for example FIGS. 1, 2 and 6) 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).

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. In FIGS. 3 and 4, 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. In 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. Within the scope of the present invention, it is not required that 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.

It is preferred that at least one of the proximal panel and the distal panel comprises at least one corrugated flute. FIGS. 7 through 12 depict various corrugation embodiments. In one aspect, the corrugations in panels 14 and 16 are of the same height (amplitude) and frequency. In a further aspect, as shown in FIGS. 7 through 9, 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.

In FIG. 10, 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.

As can be seen in the figures, it is preferred that the interior of 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. Preferably, the linear waves present regular shapes and dimensions. For example, 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. Alternatively, 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. By increasing or reducing the amplitude and the height of said waves 66, it is possible, respectively, to reduce and increase the strength of the base structure 10. It is most preferred that flute type A be used. This is an industry understood term.

To illustrate, 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 and 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 89a of approximately 8.9 mm.

It is most preferred that 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). Furthermore, 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. . . . . In a most preferred embodiment, the filler is fine (washed and dried) silica sand with a US mesh of between 100 (0.152 mm) and 140 (0.104 mm). Generally, the finer the particularity or granularity of the filler, the better for use herein. Generally, 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:

Steelstud 96

Drywall 97

Soundproofing wall block 98 (comprising panels 99 and 100, ⅝″/15 mm)
Soundproofing floor block 102 (comprising panels 104 and 106, ⅝″/15 mm)
Soundproofing floor block 107 (comprising panels 108 and 110, ⅝″/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:

Woodstud 116

Drywall 97

Soundproofing wall block 98 (comprising panels 99 and 100, ⅝″/15 mm)
Soundproofing floor block 102 (comprising panels 104 and 106, ⅝″/15 mm)
Soundproofing floor block 107 (comprising panels 108 and 110, ⅝″/15 mm)
Shiplap between block 102 and 107 (1.5″ reference to size of engagement platform)

Plywood 118.

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.

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).

It is preferred that 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.

The number of layers and the thicknesses of 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).

It is preferred that the panels are coated with a barrier coating. Preferably, 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.

Throughout the above disclosure, it is described that a block comprises two panels, immovably joined. In another aspect, however, these “panels” may actually be one integral unit, formed with the 1-4 engagement platforms. So, in this aspect, the proximal panel and distal panel are seamless and integral or “one unit” divided into layer of corrugations.

In another aspect, 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.

The present invention also provides a method of making a sound proofing barrier which comprises

aligning a plurality of interlocking blocks, starting with 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;
joining and overlapping at least part of one engagement platform of block one with at least part of an adjacent engagement platform on block two to form a conjoined connection there between;
joining and overlapping at least part of another (as yet unengaged) engagement platform of block one with at least part of an adjacent engagement platform on block three to form a conjoined connection there between;
joining and overlapping at least part of another (as yet unengaged) engagement platform of block one with at least part of an adjacent engagement platform on block four to form a conjoined connection there between
and thereafter joining and overlapping further engagement platforms, on blocks one, two, three and four and additional blocks, until a full surface of the barrier is created by a multitude of ship lathe-like interconnections of the panels.

In operation, the barrier of the present invention is preferably installed over studs. The term “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.

It has been found that the creation of a barrier with a combination of adaptive micro level (preferred flute arrangement) and macro level (interlocking/docking platforms) innovations results in a superior yet easily installable product. 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.

While the forms of panels, blocks, barrier, method and system described herein constitute preferred embodiments of this invention, it is to be understood that the invention is not limited to these precise forms. As will be apparent to those skilled in the art, the various embodiments described above can be combined to provide further embodiments. Aspects of the present panels, blocks, barrier, method and system (including specific components thereof) can be modified, if necessary, to best employ the panels, blocks, barrier, method and system of the invention. These aspects are considered fully within the scope of the invention as claimed. For example, the various methods described above may omit some acts, include other acts, and/or execute acts in a different order than set out in the illustrated embodiments.

Further, in the methods taught herein, 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.

These and other changes can be made to the present systems, methods and articles in light of the above description. In general, in the following claims, the terms used should not be construed to limit the invention to the specific embodiments disclosed in the specification and the claims, but should be construed to include all possible embodiments along with the full scope of equivalents to which such claims are entitled. Accordingly, the invention is not limited by the disclosure, but instead its scope is to be determined entirely by the following claims.

Claims

1. A block for use in interlocking, conjoined alignment with a plurality of like blocks to form a soundproofing barrier, said block comprising:

a) a proximal panel comprising a proximal upper edge, a proximal lower edge, a proximal right edge and proximal left edge; and

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 the proximal upper edge and the distal upper edge, a lower engagement platform between the proximal lower edge and the distal lower edge, a right engagement platform between the proximal right edge and distal right edge, and a left engagement platform between the 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.

2. The block of claim 1 wherein both the proximal panel and distal panel comprise at least one corrugated flute.

3. The block of claim 1 wherein both the proximal panel and distal panel comprise at least two corrugated flutes.

4. The block of claim 1 wherein both the proximal panel and distal panel comprise three corrugated flutes.

5. The block of claim 1 comprising 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 of an upper or lower adjacent flute and a peak on one flute is aligned with a trough on an upper or lower adjacent flute, thereby forming a plurality of discrete channel spaces between the flutes and the sheet.

6. The block of claim 5 wherein the plurality of discrete channel spaces are filled with a filler.

7. The block of claim 5 wherein the plurality of discrete channel spaces are filled with a particulate material.

8. The block of claim 5 wherein the plurality of discrete channel spaces are filled with a filler selected from the group consisting of sand, gravel,....

9. The block of claim 5 wherein the plurality of discrete channel spaces are filled with dried silica sand.

10. The block of claim 1 wherein each panel is sealed on all edges.

11. The block of claim 1 wherein each panel has a thickness of from 5 mm to 30 mm.

12. The block of claim 1 wherein each corrugation is the same height and shape.

13. The block of claim 1 wherein entirety of each panel is sealed by cardboard sheets.

14. A soundproofing barrier comprising a plurality of interlocking blocks, including a first block and a second block, each block comprising:

a) a proximal panel comprising a proximal upper edge, a proximal lower edge, a proximal right edge and proximal left edge; and

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 the proximal upper edge and the distal upper edge, a lower engagement platform between the proximal lower edge and the distal lower edge, a right engagement platform between the proximal right edge and distal right edge, and a left engagement platform between the 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 the first block engages and overlaps another engagement platform on the second block to form a conjoined connection there between.

15. The barrier of claim 14 wherein both the proximal panel and distal panel comprise at least one corrugated flute.

16. The barrier of claim 14 wherein both the proximal panel and distal panel comprise at least two corrugated flutes.

17. The barrier of claim 14 wherein both the proximal panel and distal panel comprise three corrugated flutes.

18. The barrier of claim 14 wherein the corrugated flutes are 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 of an upper or lower adjacent flute and a peak on one flute is aligned with a trough on an upper or lower adjacent flute, thereby forming a plurality of discrete channel spaces between the flutes and the sheet.

19. The barrier of claim 18 wherein the plurality of discrete channel spaces are filled with a filler.

20. The barrier of claim 18 wherein the plurality of discrete channel spaces are filled with a particulate material.

21. The barrier of claim 18 wherein the plurality of discrete channel spaces are filled with sand or gravel.

22. The barrier of claim 18 wherein the plurality of discrete channel spaces are filled with dried silica sand.

23. The barrier of claim 14 wherein each panel is sealed on all edges.

24. The barrier of claim 14 wherein each panel has a thickness of from 5 mm to 30 mm.

25. The barrier of claim 14 wherein each corrugation is the same height and shape.

26. The barrier of claim 14 wherein the entirety of each panel is sealed by cardboard sheets.

27. A method of making a sound proofing barrier which comprises:

aligning a plurality of interlocking blocks, starting with a first block and a second block, each block comprising: a) 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 the proximal upper edge and the distal upper edge, a lower engagement platform between the proximal lower edge and the distal lower edge, a right engagement platform between the proximal right edge and distal right edge, and a left engagement platform between the 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 the first block with at least part of an adjacent engagement platform on the second block to form a conjoined connection therebetween;

joining and overlapping at least part of another as yet unengaged engagement platform of the first block with at least part of an adjacent engagement platform of a third engagement block to form a conjoined connection therebetween;

joining and overlapping at least part of another as yet unengaged engagement platform of the first block with at least part of an adjacent engagement platform on of a fourth engagement block to form a conjoined connection therebetween and thereafter joining and overlapping further engagement platforms, on the first, second, third and fourth blocks and additional blocks, until a full surface of the barrier is created by a multitude of ship lathe-like interconnections of the panels.

28. The block of claim 1 wherein the panels are substantially rectangular.

29. The block of claim 1 wherein one of the proximal and distal panels is thicker than the other panel.

30. A block for use in interlocking, conjoined alignment with a plurality of like blocks to form a soundproofing barrier, said block comprising:

a) a proximal panel having a proximal right side and a proximal left side; and

b) 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.

31. The block of claim 30 wherein the proximal left side and the distal left side are aligned.

32. The block of claim 1 wherein at least one panel is coated with a barrier coating.

33. The block of claim 1 wherein at least one panel is coated with one of SPECTRA GUARD 763A and SPECTRA-GUARD 763A-Flexo.

34. The block of claim 1 wherein the proximal panel and distal panel are seamless and integral.