CA3038560A1 - Sound absorbing panel and system - Google Patents
Sound absorbing panel and system Download PDFInfo
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- CA3038560A1 CA3038560A1 CA3038560A CA3038560A CA3038560A1 CA 3038560 A1 CA3038560 A1 CA 3038560A1 CA 3038560 A CA3038560 A CA 3038560A CA 3038560 A CA3038560 A CA 3038560A CA 3038560 A1 CA3038560 A1 CA 3038560A1
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- frame
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- truss
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Abstract
A noise reducing/sound absorption barrier system comprises one or more panels, each of which comprise a 3D frame, preferably filled with an acoustic fill and wherein at least one of the 3D frames is conjoined with a desired face, which may be a public face. The panel, comprising the 3D frame which is filled with acoustic material, is surface covered with one or two public faces (for example, on either side of the frame, thereby effectively covering the 3D frame) in order to: i) to meet required acoustical criteria, ii) to be dimensionally large for installation efficiency, due to the incorporation of the unique 3D frame as the lightweight "holder" for desired acoustic fill and also, a secure and rigid point for the desired public faces to be attached; iii) to have flexibility to meet diverse insertion loss and absorptive requirements for noise reduction, and iv) to have a selection of public faces (conjoinable to the 3D frames) for any desired functional, aesthetic and branding needs.
Description
TITLE: SOUND ABSORBING PANEL AND SYSTEM
INVENTOR: Maureen Connelly FIELD OF THE INVENTION
The present invention relates to the field of noise reducing and sound absorbing structures for use in the construction of buildings, retaining walls, berms, and other residential, commercial and industrial structures in which it is desired to control sound conveyance.
BACKGROUND ON THE INVENTION
More than ever before, there are noise disturbances in our daily lives.
Diminishing privacy and noise pollution can affect peace of mind, increase tension levels, interfere with communication between people, and jeopardize safety in public and private places, for example in areas of high traffic and in industrial regions.
Outdoor noise propagation is often attenuated with noise barriers. Commonly, noise barriers are used along transportation corridors specifically to reduce sound levels in exterior areas associated with residential, institutional and park lands. The noise attenuation is quantified in terms of insertion loss and is based on the acoustical principle of transmission loss and optionally may also be based on the principle of sound absorption. The most common barriers are modular panel systems which meet the majority of guidelines of authorities having jurisdiction. These panels are over 20 kg/m2, have substantial width and/or small dimensions for structural integrity resulting in inefficiencies and high installation cost.
Currently used noise barriers leave much to be desired. They have limited aesthetic value and as such are not utilized for applications beyond transportation corridors.
Reduction of transportation noise to meet World Health Organization guidelines for outdoor spaces is required in dense urban setting for residential courtyards, outdoor cafes, and urban parks yet the options now available do not offer any panel systems which i) meet required acoustical criteria, ii) are dimensionally large for installation efficiency, iii) have flexibility to meet diverse insertion loss and absorptive requirements for noise reduction, and/or iv) have a selection of public faces for aesthetic and branding needs.
DM_VAN/287559.00005/8402956.1 1 There remains a need for structures or systems which can adequately and flexibly 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 noise reducing/sound absorption barrier system which may be installed as all or part of a wall in residential, commercial or industrial (whether public or private) contexts and which comprises one or more panels, each of said panels comprising a filled three-dimensional (3D) frame and at least one face conjoined thereto.
In one aspect, the present invention provides a noise reducing/sound absorption barrier system comprising one or more panels, each of said panels comprising a 3D frame wherein at least one of the 3D frames is filled with an acoustic fill, which may be a sound absorptive material as described further hereinbelow.
In another aspect, the present invention provides a noise reducing/sound absorption barrier system comprising one or more panels, each of said panels comprising a 3D
frame wherein at _ least one of the 3D frames is filled with an acoustic fill and wherein at least one of the 3D frames is conjoined with a desired face, which may be a public face.
In another aspect, the present invention provides a noise reducing/sound absorption barrier system comprising one or more panels, each of said panels comprising a 3D
frame wherein at least one of the 3D frames provides support for a garden/green wall.
In another aspect, the present invention provides a noise reducing/sound absorption barrier system comprising one or more panels, each of said panels comprising a 3D
frame wherein at least one of the 3D frames is filled with an acoustic fill and wherein at least one of the 3D frames is conjoined with a desired face, which may be a public face, said face having a degree of sound absorption as desired for a particular use and operation of the barrier system.
In another aspect, the present invention provides a noise reducing/sound absorption barrier system comprising one or more panels, each of said panels comprising a 3D
frame wherein at least one of the 3D frames is filled with an acoustic fill and wherein at least one of the 3D frames DM_VAN/287559 00005/8402956.1 2 is conjoined with a desired face, wherein one or more of said panels are capped with an additional 3D top piece.
Society, as a whole, benefits from lower noise levels. For people, these advantages include better concentration levels, improved performance at work, and enhanced energy level.
Lower noise levels assist the environment, for example, by making sure that birds and other migrating species can hear each other when communicating while in the area. Environmental noise pollution is reduced by the use of sound-absorptive barriers. For instance, it is common to see typical sound-reflective noise barriers along the highway. Generally, these are concrete or brick walls which are solid and dense, causing the noise to hit the walls and bounce back into the traffic---they are "reflective". The other solution is a sound-absorptive acoustical barrier system which allows sound waves to enter into the barrier, then takes them on a "winding tour"
within the barrier to ultimately diminish the sound waves.
The sound absorption panel system of the present invention offers a much more effective and attractive abatement option. Not only does the system of the invention absorb or "kill" sound waves, significantly reducing overall noise but it provides solutions to all of commercial and usability challenges, referred to hereinabove. Some advantages of the invention include, without limitation, the ability of the panel of the invention which comprises a 3D
frame, filled with acoustic material, said frame being surface covered with one or two public faces (for example, on either side of the frame, thereby effectively covering the 3D frame) i) to meet required acoustical criteria, ii) to be dimensionally large for installation efficiency, due to the incorporation of the unique 3D frame as the lightweight "holder" for desired acoustic fill and also, a secure and rigid point for the desired public faces to be attached;
iii) to have flexibility to meet diverse insertion loss and absorptive requirements for noise reduction, and iv) to have a selection of public faces (conjoinable to the 3D frames) for any desired functional, aesthetic and branding needs. All of the above speaks to customizability of the panels on several levels. For example, the size and dimensions of the 3D frame may vary as per use in operations. In roadway and larger installation, the 3D frame may be larger than uses in a residence, while retaining all the advantages offered by the panel. Further, acoustic fill is customizable, depending on desired DM_VAN/287559.00005/8402956 1 3 use. Further, public faces (to be joined to surfaces of 3D frame) are fully customizable, based upon degree of sound absorption as desired for a particular use and operation of the barrier system. Finally, without limiting the generality of the foregoing, it is to be understood that each component of the panel (3D frame, fill, and face {s}) operates synergistically to offer an improved and highly effective noise reducing/sound absorption barrier. There is no known and available noise reducing panel system with this adaptability, flexibility, customizability and ease of transport, installation and use.
Without limiting the general range of applications, the panel and systems and methods of the present invention are especially suited to use in walls and ceilings primarily (although not exclusively) in outdoor commercial, municipal (for example roadways) 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:
Figure 1 is a perspective view of one embodiment of an empty, unfilled 3D
frame of the panel of the invention;
Figure 2 is a side view of an empty 3D frame and conjoined face of the panel of the invention;
Figure 3 is a top plan view of an empty 3D frame and top piece of the panel of the invention;
Figure 4 a is a perspective view of two 3D frames of the panel of the invention, either/both of which are fillable with acoustic fill and either of which may be covered with a desired public DM_VAN/287559 00005/8402956 1 4 face, such as, for example, a laminate and/or steel, and/or conjoined with a desired mass-embedded back. Further detail on faces provided below;
Figure 5 is an isometric view of a panel of the invention, comprising a perforated face;
Figure 6 is an isometric view of a panel of the invention, comprising a solid mass face;
Figure 7 is an exploded view of a panel of the invention;
Figure 8 is an isometric view of four conjoined panels of the invention, forming a noise reduction system;
Figure 9 is one exemplary system configuration;
Figure 10 is another exemplary system configuration;
Figure 11 is another exemplary system configuration;
Figure 12 is another exemplary system configuration;
Figure 13 is another exemplary system configuration;
Figure 14 is another exemplary system configuration;
Figure 15 is another exemplary system configuration; and Figure 16 is another exemplary system configuration.
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, DM_VAN/287559.00005/8402956.1 5 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 DM_VAN/287559.00005/8402956 1 6 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 "3D frame" is used herein to refer to a three-dimensional chord truss or chord truss-like structure. Simply, these structures preferably comprise, in 3D form, straight members, connected together with pin joints and connected only at the ends of those members.
Typically, but not always, these structures generally consist of longitudinal members joined only by angled cross-members, forming alternately inverted equilateral triangle-shaped spaces along its length. Often, this is made up of wires which are formed in a zigzag configuration between two parallel wires with angles of approximately 30 degrees.
There are a variety of truss and truss-like structures which may form the 3D
frame of the invention. These include but are not limited to: Warren Truss (truss members form a series of isosceles triangles, alternating up and down), Pratt Truss, Howe Truss, Ladder Truss, and King Post Truss (two angled supports leaning into a common vertical support). The Warren Truss is recognized as a very popular architectural truss structure system and is easily identified by its construction from equilateral triangles and is considered a preferred 3D
frame, within the context of the invention. The 3D Frame may be formed of various materials, purpose driven and this includes but is not limited to metals, aluminium, steel or wood or the like.
The 3D frame of the invention is lightweight yet sturdy, providing a structural means to embed/fill and substantially retain in place acoustic fill and providing a sufficiently strong and secure structural means to attach/conjoin public faces.
In the present disclosure and claims, the panel of the invention comprises at least a 3D frame, fill within the structure of the 3D frame and a face or faces affixed to an exterior of the structural form of the 3D frame. It is further preferred that the panel of the invention, comprising the 3D
om_vAN/287559.00005/8402956.1 7 frame is buildable and stackable, forming modular elements to form a vertically and/or horizontally continuous structure or arrangement of panels. Building, stacking or otherwise conjoining the panels can be achieved in a variety of ways, for example, an inner "mating member" within the 3D frame can be placed hanging out the bottom of each frame (or out of the top of the frame below) such that, when that 3D frame is placed in situ, (for example in a noise reducing wall construction), the mating member enables the 3D frame (and thus the panel of which it forms part) to be perfectly positioned on top of the 3D frame below (and panel of which it forms part) and the mating member also immediately holds the panel being installed. The 3D
frames are manufactured to desired and precise dimensional consistency, so assembly of a multi-story configuration of panels (comprising such 3D frames) is "LegoTM like,"
with identical pieces aligning with one another. It is well within the purview of a skilled artisan in this field to devise a variety of methods of stacking and building multi-panel configurations. A key advantage is that the panel of the invention, even with a filled 3D frame and faces attached thereto, will be substantially lightweight and easy to arrange for desired constructions.
In the present disclosure and claims acoustic fill refers to a plurality of fill material, with sound absorption properties. Preferred are materials which are i) open pore with a substantially high tortuosity, making them extremely resistant to airflow and excellent at noise reduction and sound absorption and ii) capable structurally of being filled or embedded within the 3D frame.
Preferred are materials which block and absorb unwanted sound, with the context of use of the panel, and which meet required robustness characteristics. For example, it may be desired to employ fill which has specific fire-retardant and/or water repellant or mould resistant properties.
It may be desired to employ fill, in panels for indoor use, which assist in the regulation of temperature maintenance in order to reduce heating, cooling, and ventilation costs, and reduce a building's carbon footprint. Non-limiting examples of fill include mineral wool, sheep wool, rock wool (RockwallTm), moss (for example, reindeer moss) and other materials with similar sound absorptive properties.
DM_VAN/287559.00005/8402956.1 8 In the present disclosure and claims, a face, also called a public face refers to the outer surface of the panel, which face is attached to the 3D frame. The face provides, on one or both sides of the 3D frame, a means to conceal the frame and fill while at the same time contributing to the overall functionality of the panel, with its own sound transmission properties. Faces are selected based upon acoustic specificity and in particular upon sound transmission loss and sound absorption properties. The acoustic performance of a panel (which is created for specific custom usages) depends on a combination of feature including: the public faces (and properties thereof), the selected fill (and acoustic properties thereof) and the dimensions of the panel and larger system of which it forms part. For example, in some cases it is desired that the face blocks sound to a greater degree or conversely absorbs sound to a greater degree. Non-limiting examples of faces which are more sound-absorptive include those with openings, pores, holes, membranes, fissures, apertures, and gaps. These include but are not limited to fabrics, mesh, screens and perforated metals. More specifically more sound absorptive faces may comprise moisture retention fabrics, microperforated fabrics, aluminum screens, and perforated metal sheets. Faces which block sound to a greater degree are generally of greater mass and are solid (i.e.
substantially devoid of openings, pores, holes, membranes, fissures, apertures, and gaps). These include, but are not limited to solid metal sheets, laminates (for example, rubber/metal laminates), aluminum sheets, stucco and slate. It is to be understood that the sound blocking vs. sound absorption characteristics in regard to any face runs on a wide spectrum from highly blocking, such as slate and stucco, to most highly sound absorptive such as microperforated fabrics, with a great number of material types "in between" those extremes. As will be discussed further below, one aspect of the customizability of the panels of the invention relates to the adoption of use-specific faces having desired acoustic specificity. So, not only is fill selected on this basis, but facing as well.
Furthermore, any of the faces may comprise a transparent view portion and/or a door for easy access to interior 3D frame and fill.
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.
DM_VAN/287559.00005/8402956.1 9 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 telm "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 teim "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 tem' "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 DM_VAN/287559.00005/8402956.1 10 "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 sound absorption barrier system which may be installed in a variety of contexts and applications, as a sound absorbing wall or barricade.
Panels comprising 3D Frames:
The system of the present invention comprises one or more panels of the invention which may be built, conjoined and stacked as needed for larger noise redcution constructions. Each panel of the invention comprises at least one 3D frame, which may preferably be a Warren Truss, as described and claimed herein. The use of 3D frames in this context of sound absorption is new and unexplored and the advantages unappreciated. As noted above, a preferred form of the 3D
frame is a parallel chord truss, which generally consists of longitudinal members joined only by angled cross-members, forming alternately inverted spaces along its length (in the case of Warren trusses, those spaces are equilateral triangle-shaped). Within the context of the present invention, one or more 3D frames are spatially aligned, joined and framed, thereby forming a rigid yet lightweight, fillable 3D structure.
The use of the 3D frame as the centre of the sound absorption system of the present invention, provides not only a holder or "wireframe" for alternative types of fill material within the 3D
frame itself but also provides a rigid, secure attachment surface for any desired face (public face). As a "holder" or wireframe for fill and attachment surface, the 3D
frame and attachment surface can be used to house acoustic fill and can be used to support the addition of a 3D frame DM_VAN/287559.00005/8402956 1 11 on one or both surfaces for the growth of a living or green wall, such plants generally being ground-grown or container grown.
There is a myriad of possible face surfaces, which can be tailored to specific requirements and contexts. For example, it may be desired that the desired face provide additional sound absorption or alternatively reflective characteristics. It may be desired that an outwardly (for example public facing view) exterior face of the panel be a conjoined coloured wall. It may be desired that an outwardly (for example public facing view) exterior face of the panel be a conjoined graphic wall. It may be desired that a face of the panel be conjoined perforated metal wall or a screen. It may be desired that a face of the panel be a conjoined rubber laminated panel.
Any combination of surfaces can be conjoined as the "front and back" faces of the 3D frame within the scope and spirit of the invention.
In one aspect of the invention, there is provided a system comprising a primary panel and one or more secondary panels. Some or all panels may comprise a filled 3D frame. One or both of the outward faces of the primary panel and secondary panels may be conjoined with an additional surface or backing, as described herein. In one aspect of the invention, the panel or panels may be topped or capped with an additional topper pieces ("T-top"), as shown preferably in Figure 3.
The system of the invention, comprising one or more panels enables the customized creation of large-dimension sound absorbers for commercial, industrial and residential uses.
In one preferred aspect, a panel comprises a 3D frame filled with mineral wool to reduce noise through sound absorption. In another preferred aspect, public or outward faces of the panel are varied and dependent on the selection of site-specific acoustic characteristics. For example, a face of an acoustical transparent perforated finished metal may be used to facilitate sound absorption, whereas a face of a metal / rubber laminated panel may be used to facilitate sound isolation. Visually transparent faces or sections thereof may be integrated into the face of the primary panel.
DM_VAN/287559.00005/8402956 1 12 In one aspect of the invention, a primary panel may be used as the total noise barrier solution within the system. Within another aspect of the invention, a primary panel is coupled with one or more additional 3D frames and/or secondary panels to meet sound attenuation or aesthetic goals or commercial goals. For example, one 3D frame and its associated panel or panels (or without a conjoined panel) may be coupled with and an additional 3D frame and the additional 3D frame(s) may be used to support the growth of climbing plants. Further, one 3D frame and its associated panel or panels (or without a conjoined panel) may be coupled with and an additional 3D frame and its associated panel or panels.
As is clear, there are a variety of permutations of 3D frame structures, acoustic fills, face types/surfaces. In each permutation, there may optionally be provided an additional T-top piece to increase insertion loss. Preferably the T-top is also a 3D frame with a fill. The selection of the permutation, public face options, finishes and use of the T-top profile are driven by the desired acoustical criteria/goals and site context/requirements.
The capacity to support living architecture, a high aesthetic finish and public face branding broadens the urban context in which the system of the invention can be used.
Turning to the figures, wherein like numerals refer to like elements throughout, Figure 1 provides generally at 10 a 3D frame formed of substantially parallel longitudinal reinforcing chords 12 (front) and 14 (back) including transverse web 16 between front and back and which travel along the full length of the truss in a zig-zag manner. The angular bends of the zig-zag or transverse web 16 are welded to reinforcing chords 12 and 14 forming a series of rigid triangles.
Reinforcing chords 12 and 14 are support-framed by tops 18 and 19, bottoms 20 and 21, left sides 22 and 23 and right sides 24 and 25.
Figure 2 illustrates a 3D frame, as per Figure 1 but additionally providing a conjoined face, herein mass laminate 30.
Figure 3 illustrates a 3D frame and 3D top piece.
DM_VAN/287559 00005/8402956.1 13 Figure 4 illustrates a 3D frame 10, as per Figure 1 but additionally providing a conjoined secondary 3D frame, 32. Secondary 3D frame, 32, is formed of substantially parallel longitudinal reinforcing web 34 (front of frame 10 conjoined with back of frame 10) and 36 (back of frame) including transverse chords 38 between front of frame and back of frame and which travel along the full length of the truss in a zig-zag manner. The angular bends of the zig-zag or transverse chords 38 are welded to alternate web 40 and 42 forming a series of rigid triangles. Reinforcing web 34 and 36 are support-framed by tops 44 and 46, bottoms 48 and 50, left sides 52 and 53 and right sides 54 and 55.
Figure 5 is an isometric view of panel generally indicated at 60 and comprising 3D frame 62, acoustic fill 64, perforated face 66 (comprising a plurality of perforations 67) on side 68 of 3D
frame 62 and face 70 (more solid in configuration than perforated face 60) on side 72 o f 3D
frame 62. Top piece 74 comprising downwardly extending flange 75 encases top 76 of 3D frame 62. Face 70 includes an extension portion 71, which, in use, rests over top 76 of 3D frame 62 and under top piece 74. In one embodiment, there is no requirement for a top piece 74 and extension portion 71 is an exposed "public face". In a further embodiment, face 70 may be a contiguous sheet which "wraps" all or substantially all of the 3D frame. In some of those instances, instead of perforated face 66, face 70 would simply wrap around all or substantially all surfaces of the 3D frame.
Bracket 78 extends horizontally across 3D frame 62, and comprises screw aperture 80, in aid of securing face 66 to 3D frame 62. 3D frame 62 comprises horizontal chords 82 and diagonal/vertical web members 84.
Figure 6 is an isometric view of a panel generally indicated at 86 and comprising 3D frame 62, acoustic fill 64, solid mass face 88 on side 68 of 3D frame 62 and face 90 on side 72 o f 3D
frame 62. Top piece 74 comprising downwardly extending flange 75 encases top 76 of 3D frame 62. Face 90 includes an extension portion 91 which, in use, rests over top 76 of 3D frame 62 and DM_VAN/287559.00005/8402956.1 14 under top piece 74. Bracket 78 extends horizontally across 3D frame 62, and comprises bolt/screw aperture 80, in aid of securing face 88 to 3D frame 62. 3D frame 62 comprises horizontal chords 82 and diagonal/vertical web members 84.
Figure 7 is an exploded view of panel 60 (of Figure 5) and more clearly shows the "empty frame" of 3D frame 62, perforated face 66 (comprising a plurality of perforations 67) and face 70. Continuous cleats 92 on runner 94 illustrate one means by which perforated face 66 may be removably conjoined to 3D frame 62. Within this same figure, an alterative means of face/frame attachment is shown. Bolts 96 may be used to traverse face 70 and serve as connection means with a mating bore hole (not shown in this figure but best shown in Figure 5).
It is to be understood, however, that there are a plurality of means by which a face may be removably attached to a 3D frame such as, for example, adhesives, prongs or grips extending form the faces for engagement with diagonal or vertical web members of the 3D frame or by attachment with horizonal chords of the 3D frame. 3D frame 62 comprises horizontal chords 82 and diagonal/vertical web members 84.
Figure 8 is an isometric view of four conjoined panels 98, 100, 102 and 104 forming noise reduction system generally indicated at 106. of the invention, forming a noise reduction system.
Illustrative in this figure is the mating of panels 98, 100, 102 and 104 within other structures (for example structures of third parties, existing structures etc...) which here includes support posts 108, 110 and 112, as well as adjustable noise attenuating base 114.
Figures 9-14 are illustrative panels (combinations of frame, fill, face) for exemplary use cases thereby highlighting the versatility and adaptability of the system of the invention. In each of these figures, the following legend can be referenced:
116 =3D frame which is filled with acoustic fill ("core") DM_VAN/287559.00005/8402956.1 15 118=substantially absorptive public face 120=public face (on the spectrum, at least less absorptive than 118) 122=3D frame unfilled, which may, in some embodiments, be used to support plants (such as, for example, vines and other climbing plants) Figure 9 is one exemplary panel configuration wherein public faces are both substantially absorptive public faces 118 conjoined to 3D frame filled with acoustic fill 116. The acoustical functions of this panel configuration are noise reduction through absorption and insertion loss.
This panel configuration will reduce noise build-up around specific noise sources. In large areas with high ambient sound levels and sound reverberation, these types of panels can reduce sound reverberation and noise level areas by creating breakout zones. Typical interior uses include conference and recreational facilities, multi-use foyers, art and music venues. Typical exterior uses include street cafes, outdoor galleries and music festival venues.
Figure 10 is another exemplary panel configuration wherein both public faces are substantially less absorptive public faces 120 conjoined to 3D frame filled with acoustic fill 116. The public faces on both aspects contribute to noise reduction from the source to the receiver via the acoustical function of insertion loss. This is the most common approach to the assembly of a noise barrier when there is no concern of noise build-up around the source.
Typical exterior uses include one side only of highways and rapid transit corridors, airport fields, large construction sites.
Figure 11 is another exemplary panel configuration wherein public face 118 on the source aspect is substantially absorptive to reduce noise build up around the source. The public face 120 on the receiver side contributes to noise reduction from the source to the receiver via the acoustical function of insertion loss. Both are conjoined on opposites sides to filled 3D
frame 116. Typical uses as a wall barrier, include parallel barrier walls on both sides of transportation corridors;
transit hubs; loading and distribution docks; rooftop equipment, residential heat pumps. Typical uses, as an enclosure, with the horizontal use of panel 124 as a roof:
industrial machine and equipment; the noise isolation is through the acoustical function of sound transmission loss.
DM_VAN/287559.00005/8402956.1 16 Figure 12 is another exemplary panel configuration wherein public face 120 on the source aspect contributes to noise reduction from the source to the receiver through the acoustical function of insertion loss. The public face 118 on the receiving aspect is substantially absorptive and alters the sound quality through the reduced reflection of ambient sound sources.
Both are conjoined on opposites sides to filled 3D frame 116. This is ideally suited for specific uses such as, for example, wildlife corridors, ecological protected zones, rooftop gardens, urban parks.
Figure 13 is another exemplary panel configuration wherein there is a single public face of a wall mounted panel, and that face is substantially absorptive 118 and conjoined to filled 3D frame 116. The acoustical functions achieved by this configuration are reduced reverberation and noise reduction through absorption. To meet room criteria and increase speech intelligibility the required wall area of panel installation is modelled. Typical uses include enclosed and semi-enclosed spaces with excessive sound reverberation. Typical interior uses include conference and recreational facilities, academic facilities, multi-use foyers, art and music venues. Typical exterior uses include street cafes, outdoor galleries and music festival venues.
The core (filled 3D frame 116) and all assemblies illustrated in Figures 9 to 13 may be coupled with additional 3D frames (empty 122) on one or both sides to support living architecture without reducing acoustical performance. The additional 3D frames may support growth of vine plants from the ground base or planters which alters the aesthetic value of the panel systems, provides biophilic benefits, improves air quality and supports biodiversity and habitat. As examples:
Figure 14 is another exemplary panel configuration similar to Figure 9 but with added non-filled 3D frame. Typical uses and acoustical functions are the same as the system illustrated in Figure 9. Figure 15 illustrates the coupled 3D Frame in the wall-mounted application, but with added non-filled 3D frame. The typical uses and acoustical functions are the same as the system illustrated in Figure 13. Figure 16 illustrates an example of coupled unfilled 3D frames on both DM_VAN/287559.00005/8402956 1 17 sides of filled core panel, as per Figure 12. The typical uses and acoustical functions are the same as the system illustrated in Figure 12.
Method of Making Panels:
Acoustic fill is injected, inserted or otherwise embedded within the 3D frame.
In one embodiment, acoustic fill is inserted with the 3D frame, during manufacture of the frame itself (for example, during wire assembly). In another embodiment, the 3D frame is filled on a per need basis, with selected fill. Faces may be conjoined to the 3D frame by any means described herein including, but not limited to cleats, bolts, adhesives or other appropriately durable fastening means.
In a preferred aspect, provided herein a is noise reducing and sound absorption barrier panel comprising a 3D frame having surfaces, wherein the 3D frame is filled with acoustic fill and conjoined on at least one of its surfaces with a face, said face substantially completely covering said surface, concealing the 3D frame and acoustic fill while at the same time providing its own sound transmission loss and sound absorption properties. In a further preferred aspect, the 3D
frame is a three-dimensional chord truss or chord truss-like structure. In a further preferred aspect, the 3D frame comprises (in 3D form) straight members, connected together with pin joints and connected only at the ends of those members. In a further preferred aspect, the 3D
frame comprises longitudinal members joined only by angled cross-members, forming alternately inverted equilateral triangle-shaped spaces along a length of said 3D frame. In a further preferred aspect, the 3D frame is a truss selected from the group consisting of Warren Truss, Pratt Truss, Howe Truss, Ladder Truss, and King Post Truss. In a further preferred aspect, the 3D frame is made of a material selected from the group consisting of metal, aluminum, metal alloys, metal matrix composites and reinforced plastics (polymers). In a further preferred aspect, the acoustic fill is material with sound absorption properties, and which is:
i) open pore with a substantially high tortuosity and ii) structurally capable of being filled or embedded within the 3D frame. In a further preferred aspect, the acoustic fill is selected from the group consisting of mineral wool, sheep wool, rock wool (RockwallTm), and moss. In a further preferred aspect, the DM_VAN/287559.00005/8402956.1 18 face is selected from a group of faces having at least one of these characteristics: greater sound blocking function, lesser sound blocking function, greater sound absorption function, and lesser sound absorption function. In a further preferred aspect, the face is sound-absorptive and comprises at least one of: an openings, pores, holes, membranes, fissures, apertures, and gaps. In a further preferred aspect, the face is sound-absorptive and is formed of a material which selected from the group comprising fabrics, mesh, screens and perforated metals. In a further preferred aspect, face is substantially sound blocking and is ft:limed of a material which is a mass or solid structural form. In a further preferred aspect, the face is substantially sound blocking and is devoid of openings, pores, holes, membranes, fissures, apertures, and gaps. In a further preferred aspect, the face is substantially sound blocking and is selected the group consisting of solid metal sheets, metal laminates, rubber laminates, aluminum sheets, stucco and slate.
It has been found that the creation of a barrier with the system of the invention results in a superior solution than other previously known panels or blocks. It is to be understood that the system of the invention may comprise a plurality of wall forming panels and that these panels can be easily customized for desired locational requirements (fill, backing material, covering surfaces etc....). While a key aspect of the invention is the use of a unique 3D frame in this context, an equally important feature is this customizability of fill and faces.
While the forms of panels, 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.
DM_VAN/287559.00005/8402956 1 19 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.
DM_VAN/287559.00005/8402956.1 20
INVENTOR: Maureen Connelly FIELD OF THE INVENTION
The present invention relates to the field of noise reducing and sound absorbing structures for use in the construction of buildings, retaining walls, berms, and other residential, commercial and industrial structures in which it is desired to control sound conveyance.
BACKGROUND ON THE INVENTION
More than ever before, there are noise disturbances in our daily lives.
Diminishing privacy and noise pollution can affect peace of mind, increase tension levels, interfere with communication between people, and jeopardize safety in public and private places, for example in areas of high traffic and in industrial regions.
Outdoor noise propagation is often attenuated with noise barriers. Commonly, noise barriers are used along transportation corridors specifically to reduce sound levels in exterior areas associated with residential, institutional and park lands. The noise attenuation is quantified in terms of insertion loss and is based on the acoustical principle of transmission loss and optionally may also be based on the principle of sound absorption. The most common barriers are modular panel systems which meet the majority of guidelines of authorities having jurisdiction. These panels are over 20 kg/m2, have substantial width and/or small dimensions for structural integrity resulting in inefficiencies and high installation cost.
Currently used noise barriers leave much to be desired. They have limited aesthetic value and as such are not utilized for applications beyond transportation corridors.
Reduction of transportation noise to meet World Health Organization guidelines for outdoor spaces is required in dense urban setting for residential courtyards, outdoor cafes, and urban parks yet the options now available do not offer any panel systems which i) meet required acoustical criteria, ii) are dimensionally large for installation efficiency, iii) have flexibility to meet diverse insertion loss and absorptive requirements for noise reduction, and/or iv) have a selection of public faces for aesthetic and branding needs.
DM_VAN/287559.00005/8402956.1 1 There remains a need for structures or systems which can adequately and flexibly 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 noise reducing/sound absorption barrier system which may be installed as all or part of a wall in residential, commercial or industrial (whether public or private) contexts and which comprises one or more panels, each of said panels comprising a filled three-dimensional (3D) frame and at least one face conjoined thereto.
In one aspect, the present invention provides a noise reducing/sound absorption barrier system comprising one or more panels, each of said panels comprising a 3D frame wherein at least one of the 3D frames is filled with an acoustic fill, which may be a sound absorptive material as described further hereinbelow.
In another aspect, the present invention provides a noise reducing/sound absorption barrier system comprising one or more panels, each of said panels comprising a 3D
frame wherein at _ least one of the 3D frames is filled with an acoustic fill and wherein at least one of the 3D frames is conjoined with a desired face, which may be a public face.
In another aspect, the present invention provides a noise reducing/sound absorption barrier system comprising one or more panels, each of said panels comprising a 3D
frame wherein at least one of the 3D frames provides support for a garden/green wall.
In another aspect, the present invention provides a noise reducing/sound absorption barrier system comprising one or more panels, each of said panels comprising a 3D
frame wherein at least one of the 3D frames is filled with an acoustic fill and wherein at least one of the 3D frames is conjoined with a desired face, which may be a public face, said face having a degree of sound absorption as desired for a particular use and operation of the barrier system.
In another aspect, the present invention provides a noise reducing/sound absorption barrier system comprising one or more panels, each of said panels comprising a 3D
frame wherein at least one of the 3D frames is filled with an acoustic fill and wherein at least one of the 3D frames DM_VAN/287559 00005/8402956.1 2 is conjoined with a desired face, wherein one or more of said panels are capped with an additional 3D top piece.
Society, as a whole, benefits from lower noise levels. For people, these advantages include better concentration levels, improved performance at work, and enhanced energy level.
Lower noise levels assist the environment, for example, by making sure that birds and other migrating species can hear each other when communicating while in the area. Environmental noise pollution is reduced by the use of sound-absorptive barriers. For instance, it is common to see typical sound-reflective noise barriers along the highway. Generally, these are concrete or brick walls which are solid and dense, causing the noise to hit the walls and bounce back into the traffic---they are "reflective". The other solution is a sound-absorptive acoustical barrier system which allows sound waves to enter into the barrier, then takes them on a "winding tour"
within the barrier to ultimately diminish the sound waves.
The sound absorption panel system of the present invention offers a much more effective and attractive abatement option. Not only does the system of the invention absorb or "kill" sound waves, significantly reducing overall noise but it provides solutions to all of commercial and usability challenges, referred to hereinabove. Some advantages of the invention include, without limitation, the ability of the panel of the invention which comprises a 3D
frame, filled with acoustic material, said frame being surface covered with one or two public faces (for example, on either side of the frame, thereby effectively covering the 3D frame) i) to meet required acoustical criteria, ii) to be dimensionally large for installation efficiency, due to the incorporation of the unique 3D frame as the lightweight "holder" for desired acoustic fill and also, a secure and rigid point for the desired public faces to be attached;
iii) to have flexibility to meet diverse insertion loss and absorptive requirements for noise reduction, and iv) to have a selection of public faces (conjoinable to the 3D frames) for any desired functional, aesthetic and branding needs. All of the above speaks to customizability of the panels on several levels. For example, the size and dimensions of the 3D frame may vary as per use in operations. In roadway and larger installation, the 3D frame may be larger than uses in a residence, while retaining all the advantages offered by the panel. Further, acoustic fill is customizable, depending on desired DM_VAN/287559.00005/8402956 1 3 use. Further, public faces (to be joined to surfaces of 3D frame) are fully customizable, based upon degree of sound absorption as desired for a particular use and operation of the barrier system. Finally, without limiting the generality of the foregoing, it is to be understood that each component of the panel (3D frame, fill, and face {s}) operates synergistically to offer an improved and highly effective noise reducing/sound absorption barrier. There is no known and available noise reducing panel system with this adaptability, flexibility, customizability and ease of transport, installation and use.
Without limiting the general range of applications, the panel and systems and methods of the present invention are especially suited to use in walls and ceilings primarily (although not exclusively) in outdoor commercial, municipal (for example roadways) 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:
Figure 1 is a perspective view of one embodiment of an empty, unfilled 3D
frame of the panel of the invention;
Figure 2 is a side view of an empty 3D frame and conjoined face of the panel of the invention;
Figure 3 is a top plan view of an empty 3D frame and top piece of the panel of the invention;
Figure 4 a is a perspective view of two 3D frames of the panel of the invention, either/both of which are fillable with acoustic fill and either of which may be covered with a desired public DM_VAN/287559 00005/8402956 1 4 face, such as, for example, a laminate and/or steel, and/or conjoined with a desired mass-embedded back. Further detail on faces provided below;
Figure 5 is an isometric view of a panel of the invention, comprising a perforated face;
Figure 6 is an isometric view of a panel of the invention, comprising a solid mass face;
Figure 7 is an exploded view of a panel of the invention;
Figure 8 is an isometric view of four conjoined panels of the invention, forming a noise reduction system;
Figure 9 is one exemplary system configuration;
Figure 10 is another exemplary system configuration;
Figure 11 is another exemplary system configuration;
Figure 12 is another exemplary system configuration;
Figure 13 is another exemplary system configuration;
Figure 14 is another exemplary system configuration;
Figure 15 is another exemplary system configuration; and Figure 16 is another exemplary system configuration.
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, DM_VAN/287559.00005/8402956.1 5 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 DM_VAN/287559.00005/8402956 1 6 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 "3D frame" is used herein to refer to a three-dimensional chord truss or chord truss-like structure. Simply, these structures preferably comprise, in 3D form, straight members, connected together with pin joints and connected only at the ends of those members.
Typically, but not always, these structures generally consist of longitudinal members joined only by angled cross-members, forming alternately inverted equilateral triangle-shaped spaces along its length. Often, this is made up of wires which are formed in a zigzag configuration between two parallel wires with angles of approximately 30 degrees.
There are a variety of truss and truss-like structures which may form the 3D
frame of the invention. These include but are not limited to: Warren Truss (truss members form a series of isosceles triangles, alternating up and down), Pratt Truss, Howe Truss, Ladder Truss, and King Post Truss (two angled supports leaning into a common vertical support). The Warren Truss is recognized as a very popular architectural truss structure system and is easily identified by its construction from equilateral triangles and is considered a preferred 3D
frame, within the context of the invention. The 3D Frame may be formed of various materials, purpose driven and this includes but is not limited to metals, aluminium, steel or wood or the like.
The 3D frame of the invention is lightweight yet sturdy, providing a structural means to embed/fill and substantially retain in place acoustic fill and providing a sufficiently strong and secure structural means to attach/conjoin public faces.
In the present disclosure and claims, the panel of the invention comprises at least a 3D frame, fill within the structure of the 3D frame and a face or faces affixed to an exterior of the structural form of the 3D frame. It is further preferred that the panel of the invention, comprising the 3D
om_vAN/287559.00005/8402956.1 7 frame is buildable and stackable, forming modular elements to form a vertically and/or horizontally continuous structure or arrangement of panels. Building, stacking or otherwise conjoining the panels can be achieved in a variety of ways, for example, an inner "mating member" within the 3D frame can be placed hanging out the bottom of each frame (or out of the top of the frame below) such that, when that 3D frame is placed in situ, (for example in a noise reducing wall construction), the mating member enables the 3D frame (and thus the panel of which it forms part) to be perfectly positioned on top of the 3D frame below (and panel of which it forms part) and the mating member also immediately holds the panel being installed. The 3D
frames are manufactured to desired and precise dimensional consistency, so assembly of a multi-story configuration of panels (comprising such 3D frames) is "LegoTM like,"
with identical pieces aligning with one another. It is well within the purview of a skilled artisan in this field to devise a variety of methods of stacking and building multi-panel configurations. A key advantage is that the panel of the invention, even with a filled 3D frame and faces attached thereto, will be substantially lightweight and easy to arrange for desired constructions.
In the present disclosure and claims acoustic fill refers to a plurality of fill material, with sound absorption properties. Preferred are materials which are i) open pore with a substantially high tortuosity, making them extremely resistant to airflow and excellent at noise reduction and sound absorption and ii) capable structurally of being filled or embedded within the 3D frame.
Preferred are materials which block and absorb unwanted sound, with the context of use of the panel, and which meet required robustness characteristics. For example, it may be desired to employ fill which has specific fire-retardant and/or water repellant or mould resistant properties.
It may be desired to employ fill, in panels for indoor use, which assist in the regulation of temperature maintenance in order to reduce heating, cooling, and ventilation costs, and reduce a building's carbon footprint. Non-limiting examples of fill include mineral wool, sheep wool, rock wool (RockwallTm), moss (for example, reindeer moss) and other materials with similar sound absorptive properties.
DM_VAN/287559.00005/8402956.1 8 In the present disclosure and claims, a face, also called a public face refers to the outer surface of the panel, which face is attached to the 3D frame. The face provides, on one or both sides of the 3D frame, a means to conceal the frame and fill while at the same time contributing to the overall functionality of the panel, with its own sound transmission properties. Faces are selected based upon acoustic specificity and in particular upon sound transmission loss and sound absorption properties. The acoustic performance of a panel (which is created for specific custom usages) depends on a combination of feature including: the public faces (and properties thereof), the selected fill (and acoustic properties thereof) and the dimensions of the panel and larger system of which it forms part. For example, in some cases it is desired that the face blocks sound to a greater degree or conversely absorbs sound to a greater degree. Non-limiting examples of faces which are more sound-absorptive include those with openings, pores, holes, membranes, fissures, apertures, and gaps. These include but are not limited to fabrics, mesh, screens and perforated metals. More specifically more sound absorptive faces may comprise moisture retention fabrics, microperforated fabrics, aluminum screens, and perforated metal sheets. Faces which block sound to a greater degree are generally of greater mass and are solid (i.e.
substantially devoid of openings, pores, holes, membranes, fissures, apertures, and gaps). These include, but are not limited to solid metal sheets, laminates (for example, rubber/metal laminates), aluminum sheets, stucco and slate. It is to be understood that the sound blocking vs. sound absorption characteristics in regard to any face runs on a wide spectrum from highly blocking, such as slate and stucco, to most highly sound absorptive such as microperforated fabrics, with a great number of material types "in between" those extremes. As will be discussed further below, one aspect of the customizability of the panels of the invention relates to the adoption of use-specific faces having desired acoustic specificity. So, not only is fill selected on this basis, but facing as well.
Furthermore, any of the faces may comprise a transparent view portion and/or a door for easy access to interior 3D frame and fill.
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.
DM_VAN/287559.00005/8402956.1 9 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 telm "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 teim "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 tem' "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 DM_VAN/287559.00005/8402956.1 10 "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 sound absorption barrier system which may be installed in a variety of contexts and applications, as a sound absorbing wall or barricade.
Panels comprising 3D Frames:
The system of the present invention comprises one or more panels of the invention which may be built, conjoined and stacked as needed for larger noise redcution constructions. Each panel of the invention comprises at least one 3D frame, which may preferably be a Warren Truss, as described and claimed herein. The use of 3D frames in this context of sound absorption is new and unexplored and the advantages unappreciated. As noted above, a preferred form of the 3D
frame is a parallel chord truss, which generally consists of longitudinal members joined only by angled cross-members, forming alternately inverted spaces along its length (in the case of Warren trusses, those spaces are equilateral triangle-shaped). Within the context of the present invention, one or more 3D frames are spatially aligned, joined and framed, thereby forming a rigid yet lightweight, fillable 3D structure.
The use of the 3D frame as the centre of the sound absorption system of the present invention, provides not only a holder or "wireframe" for alternative types of fill material within the 3D
frame itself but also provides a rigid, secure attachment surface for any desired face (public face). As a "holder" or wireframe for fill and attachment surface, the 3D
frame and attachment surface can be used to house acoustic fill and can be used to support the addition of a 3D frame DM_VAN/287559.00005/8402956 1 11 on one or both surfaces for the growth of a living or green wall, such plants generally being ground-grown or container grown.
There is a myriad of possible face surfaces, which can be tailored to specific requirements and contexts. For example, it may be desired that the desired face provide additional sound absorption or alternatively reflective characteristics. It may be desired that an outwardly (for example public facing view) exterior face of the panel be a conjoined coloured wall. It may be desired that an outwardly (for example public facing view) exterior face of the panel be a conjoined graphic wall. It may be desired that a face of the panel be conjoined perforated metal wall or a screen. It may be desired that a face of the panel be a conjoined rubber laminated panel.
Any combination of surfaces can be conjoined as the "front and back" faces of the 3D frame within the scope and spirit of the invention.
In one aspect of the invention, there is provided a system comprising a primary panel and one or more secondary panels. Some or all panels may comprise a filled 3D frame. One or both of the outward faces of the primary panel and secondary panels may be conjoined with an additional surface or backing, as described herein. In one aspect of the invention, the panel or panels may be topped or capped with an additional topper pieces ("T-top"), as shown preferably in Figure 3.
The system of the invention, comprising one or more panels enables the customized creation of large-dimension sound absorbers for commercial, industrial and residential uses.
In one preferred aspect, a panel comprises a 3D frame filled with mineral wool to reduce noise through sound absorption. In another preferred aspect, public or outward faces of the panel are varied and dependent on the selection of site-specific acoustic characteristics. For example, a face of an acoustical transparent perforated finished metal may be used to facilitate sound absorption, whereas a face of a metal / rubber laminated panel may be used to facilitate sound isolation. Visually transparent faces or sections thereof may be integrated into the face of the primary panel.
DM_VAN/287559.00005/8402956 1 12 In one aspect of the invention, a primary panel may be used as the total noise barrier solution within the system. Within another aspect of the invention, a primary panel is coupled with one or more additional 3D frames and/or secondary panels to meet sound attenuation or aesthetic goals or commercial goals. For example, one 3D frame and its associated panel or panels (or without a conjoined panel) may be coupled with and an additional 3D frame and the additional 3D frame(s) may be used to support the growth of climbing plants. Further, one 3D frame and its associated panel or panels (or without a conjoined panel) may be coupled with and an additional 3D frame and its associated panel or panels.
As is clear, there are a variety of permutations of 3D frame structures, acoustic fills, face types/surfaces. In each permutation, there may optionally be provided an additional T-top piece to increase insertion loss. Preferably the T-top is also a 3D frame with a fill. The selection of the permutation, public face options, finishes and use of the T-top profile are driven by the desired acoustical criteria/goals and site context/requirements.
The capacity to support living architecture, a high aesthetic finish and public face branding broadens the urban context in which the system of the invention can be used.
Turning to the figures, wherein like numerals refer to like elements throughout, Figure 1 provides generally at 10 a 3D frame formed of substantially parallel longitudinal reinforcing chords 12 (front) and 14 (back) including transverse web 16 between front and back and which travel along the full length of the truss in a zig-zag manner. The angular bends of the zig-zag or transverse web 16 are welded to reinforcing chords 12 and 14 forming a series of rigid triangles.
Reinforcing chords 12 and 14 are support-framed by tops 18 and 19, bottoms 20 and 21, left sides 22 and 23 and right sides 24 and 25.
Figure 2 illustrates a 3D frame, as per Figure 1 but additionally providing a conjoined face, herein mass laminate 30.
Figure 3 illustrates a 3D frame and 3D top piece.
DM_VAN/287559 00005/8402956.1 13 Figure 4 illustrates a 3D frame 10, as per Figure 1 but additionally providing a conjoined secondary 3D frame, 32. Secondary 3D frame, 32, is formed of substantially parallel longitudinal reinforcing web 34 (front of frame 10 conjoined with back of frame 10) and 36 (back of frame) including transverse chords 38 between front of frame and back of frame and which travel along the full length of the truss in a zig-zag manner. The angular bends of the zig-zag or transverse chords 38 are welded to alternate web 40 and 42 forming a series of rigid triangles. Reinforcing web 34 and 36 are support-framed by tops 44 and 46, bottoms 48 and 50, left sides 52 and 53 and right sides 54 and 55.
Figure 5 is an isometric view of panel generally indicated at 60 and comprising 3D frame 62, acoustic fill 64, perforated face 66 (comprising a plurality of perforations 67) on side 68 of 3D
frame 62 and face 70 (more solid in configuration than perforated face 60) on side 72 o f 3D
frame 62. Top piece 74 comprising downwardly extending flange 75 encases top 76 of 3D frame 62. Face 70 includes an extension portion 71, which, in use, rests over top 76 of 3D frame 62 and under top piece 74. In one embodiment, there is no requirement for a top piece 74 and extension portion 71 is an exposed "public face". In a further embodiment, face 70 may be a contiguous sheet which "wraps" all or substantially all of the 3D frame. In some of those instances, instead of perforated face 66, face 70 would simply wrap around all or substantially all surfaces of the 3D frame.
Bracket 78 extends horizontally across 3D frame 62, and comprises screw aperture 80, in aid of securing face 66 to 3D frame 62. 3D frame 62 comprises horizontal chords 82 and diagonal/vertical web members 84.
Figure 6 is an isometric view of a panel generally indicated at 86 and comprising 3D frame 62, acoustic fill 64, solid mass face 88 on side 68 of 3D frame 62 and face 90 on side 72 o f 3D
frame 62. Top piece 74 comprising downwardly extending flange 75 encases top 76 of 3D frame 62. Face 90 includes an extension portion 91 which, in use, rests over top 76 of 3D frame 62 and DM_VAN/287559.00005/8402956.1 14 under top piece 74. Bracket 78 extends horizontally across 3D frame 62, and comprises bolt/screw aperture 80, in aid of securing face 88 to 3D frame 62. 3D frame 62 comprises horizontal chords 82 and diagonal/vertical web members 84.
Figure 7 is an exploded view of panel 60 (of Figure 5) and more clearly shows the "empty frame" of 3D frame 62, perforated face 66 (comprising a plurality of perforations 67) and face 70. Continuous cleats 92 on runner 94 illustrate one means by which perforated face 66 may be removably conjoined to 3D frame 62. Within this same figure, an alterative means of face/frame attachment is shown. Bolts 96 may be used to traverse face 70 and serve as connection means with a mating bore hole (not shown in this figure but best shown in Figure 5).
It is to be understood, however, that there are a plurality of means by which a face may be removably attached to a 3D frame such as, for example, adhesives, prongs or grips extending form the faces for engagement with diagonal or vertical web members of the 3D frame or by attachment with horizonal chords of the 3D frame. 3D frame 62 comprises horizontal chords 82 and diagonal/vertical web members 84.
Figure 8 is an isometric view of four conjoined panels 98, 100, 102 and 104 forming noise reduction system generally indicated at 106. of the invention, forming a noise reduction system.
Illustrative in this figure is the mating of panels 98, 100, 102 and 104 within other structures (for example structures of third parties, existing structures etc...) which here includes support posts 108, 110 and 112, as well as adjustable noise attenuating base 114.
Figures 9-14 are illustrative panels (combinations of frame, fill, face) for exemplary use cases thereby highlighting the versatility and adaptability of the system of the invention. In each of these figures, the following legend can be referenced:
116 =3D frame which is filled with acoustic fill ("core") DM_VAN/287559.00005/8402956.1 15 118=substantially absorptive public face 120=public face (on the spectrum, at least less absorptive than 118) 122=3D frame unfilled, which may, in some embodiments, be used to support plants (such as, for example, vines and other climbing plants) Figure 9 is one exemplary panel configuration wherein public faces are both substantially absorptive public faces 118 conjoined to 3D frame filled with acoustic fill 116. The acoustical functions of this panel configuration are noise reduction through absorption and insertion loss.
This panel configuration will reduce noise build-up around specific noise sources. In large areas with high ambient sound levels and sound reverberation, these types of panels can reduce sound reverberation and noise level areas by creating breakout zones. Typical interior uses include conference and recreational facilities, multi-use foyers, art and music venues. Typical exterior uses include street cafes, outdoor galleries and music festival venues.
Figure 10 is another exemplary panel configuration wherein both public faces are substantially less absorptive public faces 120 conjoined to 3D frame filled with acoustic fill 116. The public faces on both aspects contribute to noise reduction from the source to the receiver via the acoustical function of insertion loss. This is the most common approach to the assembly of a noise barrier when there is no concern of noise build-up around the source.
Typical exterior uses include one side only of highways and rapid transit corridors, airport fields, large construction sites.
Figure 11 is another exemplary panel configuration wherein public face 118 on the source aspect is substantially absorptive to reduce noise build up around the source. The public face 120 on the receiver side contributes to noise reduction from the source to the receiver via the acoustical function of insertion loss. Both are conjoined on opposites sides to filled 3D
frame 116. Typical uses as a wall barrier, include parallel barrier walls on both sides of transportation corridors;
transit hubs; loading and distribution docks; rooftop equipment, residential heat pumps. Typical uses, as an enclosure, with the horizontal use of panel 124 as a roof:
industrial machine and equipment; the noise isolation is through the acoustical function of sound transmission loss.
DM_VAN/287559.00005/8402956.1 16 Figure 12 is another exemplary panel configuration wherein public face 120 on the source aspect contributes to noise reduction from the source to the receiver through the acoustical function of insertion loss. The public face 118 on the receiving aspect is substantially absorptive and alters the sound quality through the reduced reflection of ambient sound sources.
Both are conjoined on opposites sides to filled 3D frame 116. This is ideally suited for specific uses such as, for example, wildlife corridors, ecological protected zones, rooftop gardens, urban parks.
Figure 13 is another exemplary panel configuration wherein there is a single public face of a wall mounted panel, and that face is substantially absorptive 118 and conjoined to filled 3D frame 116. The acoustical functions achieved by this configuration are reduced reverberation and noise reduction through absorption. To meet room criteria and increase speech intelligibility the required wall area of panel installation is modelled. Typical uses include enclosed and semi-enclosed spaces with excessive sound reverberation. Typical interior uses include conference and recreational facilities, academic facilities, multi-use foyers, art and music venues. Typical exterior uses include street cafes, outdoor galleries and music festival venues.
The core (filled 3D frame 116) and all assemblies illustrated in Figures 9 to 13 may be coupled with additional 3D frames (empty 122) on one or both sides to support living architecture without reducing acoustical performance. The additional 3D frames may support growth of vine plants from the ground base or planters which alters the aesthetic value of the panel systems, provides biophilic benefits, improves air quality and supports biodiversity and habitat. As examples:
Figure 14 is another exemplary panel configuration similar to Figure 9 but with added non-filled 3D frame. Typical uses and acoustical functions are the same as the system illustrated in Figure 9. Figure 15 illustrates the coupled 3D Frame in the wall-mounted application, but with added non-filled 3D frame. The typical uses and acoustical functions are the same as the system illustrated in Figure 13. Figure 16 illustrates an example of coupled unfilled 3D frames on both DM_VAN/287559.00005/8402956 1 17 sides of filled core panel, as per Figure 12. The typical uses and acoustical functions are the same as the system illustrated in Figure 12.
Method of Making Panels:
Acoustic fill is injected, inserted or otherwise embedded within the 3D frame.
In one embodiment, acoustic fill is inserted with the 3D frame, during manufacture of the frame itself (for example, during wire assembly). In another embodiment, the 3D frame is filled on a per need basis, with selected fill. Faces may be conjoined to the 3D frame by any means described herein including, but not limited to cleats, bolts, adhesives or other appropriately durable fastening means.
In a preferred aspect, provided herein a is noise reducing and sound absorption barrier panel comprising a 3D frame having surfaces, wherein the 3D frame is filled with acoustic fill and conjoined on at least one of its surfaces with a face, said face substantially completely covering said surface, concealing the 3D frame and acoustic fill while at the same time providing its own sound transmission loss and sound absorption properties. In a further preferred aspect, the 3D
frame is a three-dimensional chord truss or chord truss-like structure. In a further preferred aspect, the 3D frame comprises (in 3D form) straight members, connected together with pin joints and connected only at the ends of those members. In a further preferred aspect, the 3D
frame comprises longitudinal members joined only by angled cross-members, forming alternately inverted equilateral triangle-shaped spaces along a length of said 3D frame. In a further preferred aspect, the 3D frame is a truss selected from the group consisting of Warren Truss, Pratt Truss, Howe Truss, Ladder Truss, and King Post Truss. In a further preferred aspect, the 3D frame is made of a material selected from the group consisting of metal, aluminum, metal alloys, metal matrix composites and reinforced plastics (polymers). In a further preferred aspect, the acoustic fill is material with sound absorption properties, and which is:
i) open pore with a substantially high tortuosity and ii) structurally capable of being filled or embedded within the 3D frame. In a further preferred aspect, the acoustic fill is selected from the group consisting of mineral wool, sheep wool, rock wool (RockwallTm), and moss. In a further preferred aspect, the DM_VAN/287559.00005/8402956.1 18 face is selected from a group of faces having at least one of these characteristics: greater sound blocking function, lesser sound blocking function, greater sound absorption function, and lesser sound absorption function. In a further preferred aspect, the face is sound-absorptive and comprises at least one of: an openings, pores, holes, membranes, fissures, apertures, and gaps. In a further preferred aspect, the face is sound-absorptive and is formed of a material which selected from the group comprising fabrics, mesh, screens and perforated metals. In a further preferred aspect, face is substantially sound blocking and is ft:limed of a material which is a mass or solid structural form. In a further preferred aspect, the face is substantially sound blocking and is devoid of openings, pores, holes, membranes, fissures, apertures, and gaps. In a further preferred aspect, the face is substantially sound blocking and is selected the group consisting of solid metal sheets, metal laminates, rubber laminates, aluminum sheets, stucco and slate.
It has been found that the creation of a barrier with the system of the invention results in a superior solution than other previously known panels or blocks. It is to be understood that the system of the invention may comprise a plurality of wall forming panels and that these panels can be easily customized for desired locational requirements (fill, backing material, covering surfaces etc....). While a key aspect of the invention is the use of a unique 3D frame in this context, an equally important feature is this customizability of fill and faces.
While the forms of panels, 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.
DM_VAN/287559.00005/8402956 1 19 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.
DM_VAN/287559.00005/8402956.1 20
Claims (15)
1. A noise reducing and sound absorption barrier panel comprising a 3D frame having surfaces, wherein the 3D frame is filled with acoustic fill and conjoined on at least one of its surfaces with a face, said face substantially completely covering said surface, concealing the 3D frame and acoustic fill while at the same time providing its own sound transmission loss and sound absorption properties.
2. The panel of claim 1 wherein the 3D frame is a three-dimensional chord truss or chord truss-like structure.
3. The panel of claim 1 wherein the 3D frame comprises (in 3D form) straight members, connected together with pin joints and connected only at the ends of those members.
4. The panel of claim 1 wherein the 3D frame comprises longitudinal members joined only by angled cross-members, forming alternately inverted equilateral triangle-shaped spaces along a length of said 3D frame.
5. The panel of claim 1 wherein the 3D frame is a truss selected from the group consisting of Warren Truss, Pratt Truss, Howe Truss, Ladder Truss, and King Post Truss.
6. The panel of claim 1 wherein the 3D frame is made of a material selected from the group consisting of metal, aluminum, metal alloys, metal matrix composites and reinforced plastics (polymers).
7. The panel of claim 1 wherein the acoustic fill is material with sound absorption properties, and which is: i) open pore with a substantially high tortuosity and ii) structurally capable of being filled or embedded within the 3D frame.
8. The panel of claim 1 wherein the acoustic fill is selected from the group consisting of mineral wool, sheep wool, rock wool (Rockwall .TM.), and moss.
9. The panel of claim 1 wherein the face is selected from a group of faces having at least one of these characteristics: greater sound blocking function, lesser sound blocking function, greater sound absorption function, and lesser sound absorption function.
10. The panel of claim 1 wherein the face is sound-absorptive and comprises at least one of:
an openings, pores, holes, membranes, fissures, apertures, and gaps.
an openings, pores, holes, membranes, fissures, apertures, and gaps.
11. The panel of claim 1 wherein the face is sound-absorptive and is formed of a material which selected from the group comprising fabrics, mesh, screens and perforated metals.
12. The panel of claim 1 wherein the face is substantially sound blocking and is formed of a material which is a mass or solid structural form.
13. The panel of claim 1 wherein the face is substantially sound blocking and is devoid of openings, pores, holes, membranes, fissures, apertures, and gaps.
14. The panel of claim 1 wherein the face is substantially sound blocking and is selected the group consisting of solid metal sheets, metal laminates, rubber laminates, aluminum sheets, stucco and slate.
15. A system comprising a plurality of conjoined panels of claim 1.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US201862650226P | 2018-03-29 | 2018-03-29 | |
| US62/650,226 | 2018-03-29 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA3038560A1 true CA3038560A1 (en) | 2019-09-29 |
Family
ID=68095938
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA3038560A Abandoned CA3038560A1 (en) | 2018-03-29 | 2019-03-29 | Sound absorbing panel and system |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA3038560A1 (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN112820264A (en) * | 2021-01-07 | 2021-05-18 | 深圳市航天新材科技有限公司 | Assembled type acoustic ultrastructure and sound baffle |
-
2019
- 2019-03-29 CA CA3038560A patent/CA3038560A1/en not_active Abandoned
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN112820264A (en) * | 2021-01-07 | 2021-05-18 | 深圳市航天新材科技有限公司 | Assembled type acoustic ultrastructure and sound baffle |
| CN112820264B (en) * | 2021-01-07 | 2023-10-20 | 深圳市航天新材科技有限公司 | Assembled acoustic super-structure and sound baffle |
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