EP4235642A1

EP4235642A1 - Soundproof panel for building applications

Info

Publication number: EP4235642A1
Application number: EP23158186.9A
Authority: EP
Inventors: Giorgio CELLERINO; Roberto Cellerino
Original assignee: Sts Isolamenti Srl
Current assignee: Sts Isolamenti Srl
Priority date: 2022-02-24
Filing date: 2023-02-23
Publication date: 2023-08-30
Also published as: IT202200003503A1

Abstract

A soundproof panel (1; 1'; 1"; 1‴; 1^iv) is described for building applications apt to be mounted on an existing wall (2) to define a counterwall or partition wall or soundproof false ceiling, and comprising at least one slab (4) of building material, such as plasterboard or plasterboard-like material, at least one layer of sound-absorbing material (5) and a frame (6) for fixing the panel (1; 1'; 1"; 1‴; 1^iv) to said existing wall (2); the slab (4) of building material has a first front surface (4a) apt to be exposed to an acoustic source for being struck by sound waves (S), a first rear surface (4b) opposite the first front surface (4a), and a first lateral surface (4c) delimited between the first front surface (4a) and the first rear surface (4b); the layer of sound-absorbing material (5) has a second front surface (5a) facing towards said first rear surface (5b) and separated from the acoustic source by means of the slab (4) of building material, a second rear surface (5b) opposite the second front surface (5a), and a second lateral surface (5c) delimited between the second front surface (5a) and the second rear surface (5b); the frame (6) comprises a metal profile (8) defining at least part of a perimeter edge of the panel (1; 1'; 1"; 1‴; 1^iv) and having a central flange (10) and at least one wing (11) extending from the flange (10), the layer of sound-absorbing material (5) is coupled to the frame (6), the slab (4) of building material is rigidly fixed to said wing (11), the flange (10) is configured to be rigidly fixed to the existing wall (2) to determine the fixation of the panel (1; 1'; 1"; 1‴; 1^iv) to said existing wall (2); the panel (1; 1'; 1"; 1‴; 1^iv) further comprises a first layer of anti-vibration material (12) coupled to the metal profile (8) at said flange (10) and extending to completely cover the perimeter edge of the panel (1; 1'; 1"; 1‴; 1^iv) so as to be interposed, in assembled conditions, between the flange (10) and the existing wall (2), between the first lateral surface (4c) and the existing wall (2), and between the second lateral surface (5c) and the existing wall (2).

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This patent application claims priority from Italian patent application no. 102022000003503 filed on February 24, 2022 , the entire disclosure of which is incorporated herein by reference.

TECHNICAL SECTOR

This invention relates to a soundproof panel for building applications, preferably to insulate or deaden sound waves emitted in a domestic or industrial environment, more particularly a soundproof panel comprising slabs of plasterboard or plasterboard-like material and which can be applied to existing walls or roof slabs, in order to define a counterwall, a partition wall, or a false ceiling.

PRIOR ART

Soundproof panels used in the construction sector and applicable to existing walls or roof slabs to define counterwalls, partition walls, or false ceilings are known.
Usually, the soundproof panels of this type comprise:

one or more slabs of plasterboard or plasterboard-like material (i.e., plasterboard coupled to wood, natural or synthetic rubber, etc.) defining the external surface of the panel or that designed to be exposed to the sound source and struck by sound waves;
one or more layers of sound-absorbing or soundproof material, for example glass wool or mineral wool;
a containment structure, generally including a series of metallic crossbars arranged so that the layers of sound-absorbing material are interposed between the plasterboard and the containment structure; and
a fixing frame for fixing the panel to the existing wall or roof slab.

If the soundproof panel needs to define a counterwall covering an existing wall, the containment structure is interposed between the existing wall and the soundproof layers, usually with a gap of air between the existing wall and the containment structure.
If the soundproof panel needs to define a new partition wall, additional plasterboard slabs are arranged to cover the containment structure to define an additional external surface of the panel designed to be struck by sound waves emitted by an additional acoustic source.
The fixing frame typically comprises a metal profile, usually having a flange or central core and at least one wing extending from the flange and arranged at a perimeter edge of the panel, thus defining a perimeter edge element of the same.
For example, the profile has a U-shaped (or C-shaped) cross-section with a central flange and two wings projecting from the latter.
In one known configuration, the sound-absorbing layers are inserted into the metal profile, so that the metal profile defines a perimeter edge element for the sound-absorbing layers, leaving the plasterboard free to the side, so that the latter may be arranged resting to the side directly on the walls (for example, the ceiling and the floor) orthogonal to the existing wall to be covered.
In order to mount the soundproof panel on the existing wall, the plasterboard or plasterboard-like material slabs are rigidly fixed to one of the wings (or to both, in the case of partition walls) of the metal profile; the central flange of the metal profile is, in turn, rigidly fixed to the existing wall.
If the soundproof panel needs to define a partition wall, the central flange of the metal profile is fixed to the existing walls that will be orthogonal to the partition wall when assembled.
If the soundproof panel needs to define a false ceiling, the fixing frame also comprises multiple hangers fixed, on one side, to the containment structure and to the layers of sound-absorbing material, and on the opposite side to the existing roof slab, while the metal profile is fixed, at its central flange, to the existing walls that support this roof slab.
According to a known configuration, the plasterboard slabs are coupled to the frame, i.e. to the wing of the metal profile, via first plugs or similar clamping means.
In addition, it is known, in the sector, to couple the frame, i.e., the central flange of the metal profile, to the existing walls via second plugs or similar clamping means.
The Applicant has proven that the soundproof performance of the panels of the type described above does not depend solely on the nature of the sound-absorbing material and the thickness of the sound-absorbing layers, but also on the coupling interface between the panel and the existing walls adjacent to the wall or roof slab to be insulated.
In particular, the Applicant has been able to verify that the first plugs used for fixing the plasterboard slabs to the frame (metal profile) and the second plugs used to fix the frame to the existing wall/s define unwanted passages for transmitting vibrations and, thus, for sound waves.
In practice, the sound waves break on the plasterboard slabs, making them vibrate. Despite the presence of the sound-absorbing layers, part of the vibrations produced is transmitted to the metal profile through the first plugs, and from the metal profile to the existing walls through the second plugs.
Therefore, the Applicant has observed how the panels of the type described above could be further improved, in particular in terms of the soundproof performance.

SUBJECT AND SUMMARY OF THE INVENTION

The purpose of this invention is to produce a soundproof panel for building applications which is highly reliable and inexpensive, and makes it possible to avoid at least some of the drawbacks specified above and connected to known soundproof panels for building applications.
According to the invention, this purpose is achieved with a panel for building applications as claimed in claim 1.

BRIEF DESCRIPTION OF THE DRAWINGS

To better understand this invention, some preferred, but non-limiting, embodiments of this invention are described below, merely by way of example, and with the aid of the attached figures in which:

Figure 1 is a schematic perspective view, with parts removed for clarity, of a soundproof panel according to this invention;
Figure 2 illustrates, on an enlarged scale and with parts removed for clarity, the soundproof panel in Figure 1 in a side cross-section view;
Figure 3 illustrates, on an enlarged scale and with parts removed for clarity, a second embodiment of the soundproof panel in a side cross-section view;
Figure 4 illustrates, on an enlarged scale and with parts removed for clarity, a third embodiment of the soundproof panel in a side cross-section view;
Figure 5 illustrates, on an enlarged scale and with parts removed for clarity, a fourth embodiment of the soundproof panel in a side cross-section view; and
Figure 6 illustrates, on an enlarged scale and with parts removed for clarity, a fifth embodiment of the soundproof panel in a side cross-section view.

DETAILED DESCRIPTION

With reference to Figures 1 and 2, the reference number 1 indicates, as a whole, a soundproof panel for building applications to insulate or deaden sound waves emitted in a domestic or industrial environment, especially a soundproof panel 1 that can be applied to existing walls or roof slabs in order to define a counterwall, a partition wall, or a false ceiling to which panel 1 this description will refer without any loss of generality thereby.
In the case illustrated in Figures 1 and 2, the panel 1 is designed to be fixed to at least one existing wall 2, in particular two existing walls 2 parallel to each other, in order to define a counterwall covering a wall 3 to be insulated that is transversal to the existing walls 2.
The panel 1 comprises:

at least one slab 4 of building material, preferably plasterboard or plasterboard-like material (i.e., plasterboard coupled to a layer of natural or artificial rubber, wood, etc.);
at least one layer 5 of sound-absorbing material (below, a "sound-absorbing layer 5"), preferably glass wool, alternatively mineral wool or wood wool or polyester or frayed cotton;
a frame 6 configured to mount the panel 1 to the existing walls 2; and
a longitudinal axis A perpendicular to the slab 4 and to the sound-absorbing layer 5.

Specifically, the slab 4 has a first front surface 4a apt to be exposed to an acoustic source (not illustrated) for being struck by sound waves S, a first rear surface 4b opposite the front surface 4a, and a first lateral surface 4c delimited between the front surface 4a and the rear surface 4b.
More specifically, the panel 1 comprises a pair of slabs 4 arranged axially resting on each other with the interposition of a layer of damping material 7 (below, a "damping layer 7"), preferably made of polymer-plastic-based bituminate or EPDM rubber.
More precisely, these slabs 4 are arranged so that the front surface 4a of a slab 4 rests on the rear surface 4b of the other slab 4, with the interposition of the damping layer 7.
In practice, the pair of slabs 4 defines a single external, protecting construction element, having an external surface corresponding to the front surface 4a of a slab 4 and an internal surface corresponding to the rear surface 4b of the other slab 4 and a lateral surface corresponding to the adjacent lateral surfaces 4c of both slabs 4, with the interposition of the damping layer 7.
Below, the pair of slabs 4, with the interposed damping layer 7, will be considered as the above-mentioned single construction element, and, therefore, solely the external, internal, and lateral surfaces of the latter will be indicated, to be understood as the front 4a, rear 4b, and lateral 4c surfaces.
Conveniently, the panel 1 also comprises a containment structure (known in itself and not illustrated), generally including a series of metallic crossbars axially arranged so that the layer of sound-absorbing material is interposed between the slabs 4 and the containment structure.
The sound-absorbing layer 5 has a second front surface 5a facing towards the rear surface 4b and separated from the acoustic source by means of the pair of slabs 4, a second rear surface 5b opposite the front surface 5a, and a second lateral surface 5c delimited between the front surface 5a and the rear surface 5b.
More specifically, the sound-absorbing layer 5 is defined by a kind of (thin, parallelepipedal) rectangular-shaped mattress of sound-absorbing material, which is, preferably, basically smooth.
Alternatively, this layer 5 could have any other form (triangular, circular, polygonal, curved, regular or irregular) to adapt to the type of wall 3 to be insulated.
The frame 6 comprises a metal profile 8 defining at least part of a perimeter edge of the panel 1.
In particular, the perimeter edge of the panel 1 can be defined as the edge of the panel facing, in use, the existing walls 2.
According to this preferred embodiment, the profile 8 has a U-shaped (or C-shaped) cross-section and comprises a central flange 10 and two wings 11.
Specifically, the flange 10 has an external surface 10a configured to face towards the respective existing wall 2 and an internal surface 10b opposite the external surface 10a.
The wings 11 extend in a cantilever manner from the internal surface 10b of the flange 10.
The sound-absorbing layer 5 is coupled to the frame 6, i.e., to the profile 8. In the case illustrated, the sound-absorbing layer 5 is inserted in, or better a peripheral portion 55 of the sound-absorbing layer 5 engages, the profile 8 between the wings 11, so that the profile 8 defines a perimeter edge element of the sound-absorbing layer 5.
In other words, the profile 8 surrounds the peripheral portion 55 and the sound-absorbing layer 5 is inserted in the profile 8 with the lateral surface 5c abutting against the internal surface 10b of the flange 10.
The slabs 4, together with the damping layer 7, are rigidly fixed to one of the wings 11 of the profile 8, as schematically illustrated in Figure 2. In one embodiment, this fixing is carried out by means of plugs. Alternatively, other, similar fixing means (nails, rivets, screws, etc.) could be used.
In turn, the profile 8 is designed to be fixed to the existing walls 2, in particular by means of plugs as schematically illustrated in Figure 2.
Specifically, the flange 10 is designed to be fixed to the existing walls 2 using a series of plugs, to determine the fixing of the panel 1 to the existing walls 2 and the covering of the wall 3 to be insulated.
In one alternative embodiment not illustrated, the sound-absorbing layer 5 is arranged outside the space delimited between the wings 11, i.e., it is arranged on the opposite side of the profile 8 in relation to the slabs 4, preferably fixed (for example glued) to the other wing 11, or glued, when assembled, to the wall 3 to be insulated.
According to one aspect of this invention, the panel 1 also comprises a first layer of anti-vibration material 12 (below, an "anti-vibration layer 12") coupled to the profile 8 at the flange 10 and extending to completely cover the perimeter edge of the panel 1 so as to be interposed, when assembled, between the flange 10 and the existing walls 2, between the lateral surface 4c and the existing walls 2, and between the lateral surface 5c and the existing walls 2.
In practice, the anti-vibration layer 12 completely covers the external surface 10a of the flange 10 and the lateral surfaces 4c of the slabs 4 (and of the damping layer 7 interposed between the latter), so as to be interposed, along a direction orthogonal to the axis of the panel 1, between said pair of slabs 4 and the existing walls 2 and between the damping layer 7 and the existing walls 2.
If the sound-absorbing layer 5 is arranged outside the profile 8, the anti-vibration layer 12 also covers the lateral surface 5c (as in the case illustrated in Figure 5, which will be discussed below).
Basically, the panel 1 is mounted on the existing walls 2 with the complete interposition of the anti-vibration layer 12.
Thanks to the fact that the anti-vibration layer 12 completely covers the perimeter edge of the panel 1, i.e., the lateral surfaces 4c, 5c and the external surface 10a, the soundproof performance of the panel 1 is improved. In fact, the Applicant has observed that the transmission of the vibrations must not be impeded solely between the panel 1 and the wall 3 to be insulated, but also, and especially, between the panel 1 and the existing walls 2. Thanks to the anti-vibration layer 12, arranged according to this invention, there is less transmission of vibrations compared to the case where the anti-vibration layer 12 only covers the flange 10 of the profile 8.
According to an additional aspect of this invention, the panel 1 comprises a second layer of anti-vibration material 13 (below, an "anti-vibration layer 13") coupled to the profile 8 at the flange 10 and positioned so as to cover the internal surface 10b, so that the flange 10 is interposed between the anti-vibration layer 12 and the anti-vibration layer 13.
In other words, the lateral surface 5c of the sound-absorbing layer 5 is arranged abutting against the internal surface 10b of the flange 10, with the interposition of the anti-vibration layer 13.
In this way, when the profile 8 is fixed to the existing walls 2, i.e., when assembled, the flange 10 is basically compressed, by means of the plugs' clamping, between the first anti-vibration layer 12 and the second anti-vibration layer 13.
Thanks to this peculiar configuration, the vibrations of the flange 10 are drastically reduced compared to the case where there is no anti-vibration layer 13. In this way, the transmission of the vibrations to the existing walls 2 is reduced and, thus, the soundproof performance of the panel 1 is further improved.
The anti-vibration layer 12 preferably comprises polyethylene, in particular it consists of polyethylene, preferably polyethylene having a reticular structure, especially physically reticular, i.e., which is obtained via a physical and not a chemical process.
The anti-vibration layer 13 preferably comprises, in particular consists of, rubber, preferably natural rubber of the para type, or any other type of natural or synthetic rubber with suitable elastic performance.
The Applicant has observed, via an extended experimental campaign, that these materials make it possible to achieve excellent soundproof performance.
The panel 1 is preferably mounted on the existing walls 2 so as to leave a gap 14 of air between the rear surface 5b of the sound-absorbing layer 5 and the wall 3 to be insulated.
Advantageously, the sound-absorbing layer 5 has an axial thickness greater than the axial distance between the two wings 11, in relation to the axis A.
As a result, the sound-absorbing layer 5 is inserted, via interference, in the profile 8.
In this way, compression is created in the peripheral portion 55 engaging the profile 8, thus obtaining a "spring effect" in the soundproof material, which reduces the resonance in the gap 14 and deadens the vibration of the slabs 4.
Therefore, the soundproof performance of the panel 1 is additionally improved.
With reference to Figure 3, the reference number 1' denotes an alternative embodiment of the soundproof panel according to this invention. The panel 1' being similar to the panel 1, only the differences compared to the latter, using, where possible, the same reference numbers for corresponding parts, will be described below.
In particular, the panel 1' includes an additional layer of sound-absorbing material 15 arranged facing the rear surface 5b of the sound-absorbing layer 5 so as to be interposed, when assembled, between the wall 3 to be insulated and the sound-absorbing layer 5 itself.
In particular, the additional sound-absorbing layer 15 has a third front surface 15a facing the rear surface 5b, and preferably separated from it by the gap 14, a third rear surface 15b designed to face the wall 3 to be insulated, and a third lateral surface 15c delimited between the front surface 15a and the rear surface 15b.
In light of the above, the sound-absorbing layer 15 is arranged outside the profile 8, with the rear surface 15b resting, in use, against the wall 3 to be insulated.
According to the invention, the anti-vibration layer 12 completely covers the lateral surface 15c, so as to be interposed, when assembled, between the further layer of sound-absorbing material 15 and the existing walls 2.
Conveniently, the sound-absorbing layer 15 comprises resin-bonded cotton fibres or immersed in a resinous matrix, in particular it is defined by frayed, resin-bonded cotton comprising 75% cotton and 25% epoxy or phenolic resin.
Thanks to the presence of the additional sound-absorbing layer 15, the performance of the panel 1' is further improved compared to the panel 1.
With reference to Figure 4, the reference number 1" denotes an alternative embodiment of the soundproof panel according to this invention. The panel 1" being similar to the panel 1, only the differences compared to the latter, using, where possible, the same reference numbers for corresponding parts, will be described below.
In particular, the panel 1" differs from the panel 1 due to the fact that it comprises at least one additional slab 4 of building material, preferably plasterboard or plasterboard-like material, arranged on the opposite side of the sound-absorbing layer 5 compared to the slab 4, the front surface 4a of this additional slab 4 being designed to be struck by sound waves S', so that the panel 1" defines, when assembled, a partition wall whose external surfaces are defined by the front surfaces 4a of said slabs 4.
More particularly, the panel 1" comprises an additional pair of slabs 4 resting axially between them with the interposition of an additional damping layer 7 exactly like the pair of slabs 4 already described above.
According to the invention, the anti-vibration layer 12 completely covers the lateral surface 4c of the additional pair of slabs 4 too, so as to be interposed, when assembled, between this additional pair and the existing walls 2.
Thanks to this configuration, for the panel 1" defining a partition wall too, the soundproof performance is improved.
With reference to Figure 5, the reference number 1‴ denotes an alternative embodiment of the soundproof panel according to this invention. The panel 1‴ being similar to the panel 1, only the differences compared to the latter, using, where possible, the same reference numbers for corresponding parts, will be described below.
In particular, the panel 1‴ differs from the panel 1 due to the fact that the frame 6 comprises at least one fixing hanger 16, in this case multiple hangers 16, each comprising a fixing flange 18 and each designed to be fixed to an existing roof slab 17 at its fixing flange 18, so that the panel 1‴ defines a false ceiling.
More precisely, as can be seen in Figure 5, the panel 1‴ is fixed to the existing walls 2 below the existing roof slab 17 using the profile 8 with the interposition of the anti-vibration layer 12 and with the presence of the anti-vibration layer 13 on the internal surface 10b of the flange 10, similarly to what was described for the panel 1. Additionally, the panel 1‴ is fixed to the existing roof slab 17 using hangers 16.
More specifically, the fixing flange 18 of each hanger 16 is designed to be fixed to the existing roof slab 17 using one or more plugs or other clamping elements.
According to an additional aspect of this invention, the panel 1‴ comprises, for each hanger 16:

a third layer of anti-vibration material 19 (below, an "anti-vibration layer 19") coupled to an external surface 18a of the fixing flange 18 for being interposed, when assembled, between the hanger 16 and the existing roof slab 17; and
a fourth layer of anti-vibration material 20 (below, an "anti-vibration layer 20") coupled to an internal surface 18b of the fixing flange 18, opposite the external surface 18a, so that the fixing flange 18 is interposed between the first anti-vibration layer 19 and the second anti-vibration layer 20.

In this way, when each hanger 16 is fixed to the roof slab 17, i.e., when assembled, the fixing flange 18 is basically compressed, by means of the plugs' clamping, between the first anti-vibration layer 19 and the second anti-vibration layer 20.
Thanks to this peculiar configuration, the vibrations of the fixing flange 18 are drastically reduced compared to the case where there is no anti-vibration layer 20. In this way, the transmission of the vibrations to the existing roof slab 17 is reduced and, thus, the soundproof performance of the panel 1‴ is further improved.
According to this preferred embodiment, the sound-absorbing layer 5 is arranged outside the profile 8, with its front surface 5a axially facing it, or, better, the wing 11 opposite the wing 11 to which the slabs 4 are fixed.
Advantageously, the panel 1‴ includes an additional layer of sound-absorbing material 21 (below, a "sound-absorbing layer 21"), preferably comprising resin-bonded cotton fibres or immersed in a resinous matrix, even more preferably defined by frayed, resin-bonded cotton comprising 75% cotton and 25% epoxy or phenolic resin, and axially interposed between the pair of slabs 4 and the sound-absorbing layer 5.
In particular, the sound-absorbing layer 21 is also arranged outside the profile 8, and is axially interposed between the latter and the sound-absorbing layer 5.
As can be seen in Figure 5, the first sound-absorbing layer 5 and the second sound-absorbing layer 21 rest on the frame 6, in particular on the metallic crossbars of the frame 6, which are carried by the fixing hangers 16. Therefore, these layers 5, 21 are carried by the hangers 16 so as to be supported in a fixed position in relation to the existing roof slab 17 when assembled.
In other words, the hangers 16 are fixed, on one side, to the sound-absorbing layers 5, 21 (and to the containment structure), and on the opposite side to the existing roof slab 17, while the profile 8 is fixed, at its flange 10, to the existing walls 2 that support this roof slab 17.
The panel 1‴ preferably also comprises a layer of damping material 22, preferably consisting of polymer-plastic-based bituminate or EPDM rubber, coupled to the sound-absorbing layer 21 and axially interposed between the first sound-absorbing layer 5 and the second sound-absorbing layer 21.
This peculiar configuration instils the panel 1‴ with additionally improved soundproof performance.
The anti-vibration layer 19 is preferably made of the same material as the anti-vibration layer 12.
The anti-vibration layer 20 is preferably made of the same material as the anti-vibration layer 13.
With reference to Figure 6, the reference number 1^iv denotes an alternative embodiment of the soundproof panel according to this invention. The panel 1^iv being similar to the panel 1, only the differences compared to the latter, using, where possible, the same reference numbers for corresponding parts, will be described below.
In particular, the panel 1^iv differs from the panel 1 due to the fact that each slab 4 of said pair of slabs 4 is defined by planar elements 44 of building material arranged adjacent to each other along said direction orthogonal to the axis A and separated from each other by first spaces 45.
In addition, the damping layer 7 interposed between the slabs 4 of said pair of slabs is defined by planar elements 46 of damping material arranged adjacent to each other along said direction orthogonal to the axis A and separated from each other by second spaces 47.
Advantageously, the first spaces 45 and the second spaces 47 are offset along said direction orthogonal to the axis A.
In other words, each first space 45 is not aligned in relation to any other second space 47, and vice versa, along the axial direction.
In addition, each first space 45 of one of the slabs 4 of said pair is not aligned in relation to any other first space 45 of the other of the slabs 4 of said pair, along the axial direction.
In this way, any preferential passages for transmitting vibrations are interrupted, additionally increasing the soundproof performance of the panel 1^iv.
From an examination of the features of the panel 1, 1', 1", 1‴, 1^iv produced according to this invention, the advantages that it enables are clear.
In particular, thanks to the fact that the anti-vibration layer 12 extends so as to cover the whole perimeter edge of the panel, and in particular the lateral surface 4c of the slabs 4, the transmission of the vibrations to the existing walls 2 is limited, with the consequent increase in the soundproof power of the panel itself.
In addition, the presence of the anti-vibration layer 13 limits or blocks the vibrations of the flange 10 of the profile 8, which is a strongly resonant element and, thus, critical as far as regards the transmission of the vibrations to the existing walls 2.
This technical effect is also reproduced by the anti-vibration layers 19 and 20, which surround the fixing flange 18 of each hanger 16, in the case of the panel 1‴ defining a false ceiling.
In summary, the Applicant has obtained a soundproof panel whose soundproof performance does not solely depend on the layers covering the wall 3 to be insulated, but also, and especially, on the interface between the panel itself and the existing walls 2 or the existing roof slab 17.
It is clear that changes may be made to the panel 1, 1', 1", 1‴, 1^iv described and illustrated herein, and variations produced thereto, without, for this reason, departing from the scope of protection defined by the claims.

Claims

A soundproof panel (1; 1'; 1''; 1‴; 1iv) for building applications apt to be mounted to an existing wall (2) to define a counterwall or partition wall or soundproof false ceiling, the soundproof panel (1; 1'; 1''; 1‴; 1iv) comprising at least one slab (4) of building material, such as plasterboard or plasterboard-like material, at least one layer of sound-absorbing material (5) and a frame (6) for fixing the panel (1; 1'; 1"; 1‴; 1iv) to said existing wall (2);
the slab (4) of building material having a first front surface (4a) apt to be exposed to an acoustic source for being struck by sound waves (S), a first rear surface (4b) opposite the first front surface (4a), and a first lateral surface (4c) delimited between the first front surface (4a) and the first rear surface (4b);

the layer of sound-absorbing material (5) having a second front surface (5a) facing towards said first rear surface (5b) and separated from the acoustic source by means of the slab (4) of building material, a second rear surface (5b) opposite the second front surface (5a), and a second lateral surface (5c) delimited between the second front surface (5a) and the second rear surface (5b);

the frame (6) comprising a metal profile (8) defining at least part of a perimeter edge of the panel (1; 1'; 1''; 1‴; 1iv) and having a central flange (10) and at least one wing (11) extending from the flange (10),

the layer of sound-absorbing material (5) being coupled to the frame (6), the slab (4) of building material being rigidly fixed to said wing (11), the flange (10) being configured to be rigidly fixed to said existing wall (2) to determine the fixation of the panel (1; 1'; 1''; 1‴; 1iv) to said existing wall (2);

wherein the panel (1; 1'; 1''; 1‴; 1iv) further comprises a first layer of anti-vibration material (12) coupled to the metal profile (8) at said flange (10) and extending for completely cover the perimeter edge of the panel (1; 1'; 1''; 1‴; 1iv) so as to be interposed, in assembled conditions, between the flange (10) and the existing wall (2), between the first lateral surface (4c) and the existing wall (2), and between the second lateral surface (5c) and the existing wall (2);

wherein the first layer of anti-vibration material (12) covers an external surface (10a) of said flange (10) configured for facing said existing wall (2),

wherein the panel (1; 1'; 1"; 1‴; 1iv) comprises a second layer of anti-vibration material (13) coupled to the metal profile (8) at said flange (10) and positioned so as to cover an internal surface (10b) of said flange (10) opposite to said external surface (10a), so that the flange (10) is interposed between the first layer of anti-vibration material (12) and the second layer of anti-vibration material (13).
The soundproof panel as claimed in claim 1, wherein:
- the first layer of anti-vibration material (12) comprises polyethylene, in particular it consists of polyethylene, preferably polyethylene having a reticular structure; and/or

- the second layer of anti-vibration material (13) comprises, in particular it consists of, rubber, preferably natural rubber of the para type.
The soundproof panel as claimed in any one of the preceding claims, and having an axis (A) perpendicular to the slab (4) of building material and to the layer of sound-absorbing material (5);
wherein the flange (10) has an external surface (10a) configured to face towards said existing wall (2) in assembled conditions, and an internal surface (10b) opposite to the external surface (10a),

wherein the metal profile (8) has a U-shaped cross-section with two wings (11) extending in a cantilever manner from the internal surface (10b) of the flange (10),

wherein the layer of sound-absorbing material (5) has an axial thickness greater than the axial distance between the two wings (11),

and wherein the layer of sound-absorbing material (5) is coupled to the frame (6) by insertion with interference of a peripheral portion (55) of its own inside the metal profile (8) between the two wings (11), so that the metal profile (8) defines a perimeter edge element of the layer of sound-absorbing material (5).
The soundproof panel as claimed in claim 3, wherein said second lateral surface (5c) is arranged in abutment against the internal surface (10b) of the flange (10), with the interposition of the second layer of anti-vibration material (13).
The soundproof panel (1') as claimed in any one of the preceding claims, and including a further layer of sound-absorbing material (15), preferably comprising resin-bonded cotton fibres or cotton fibres immersed in a resinous matrix, and arranged facing said second rear surface (5b) so as to be interposed, in assembled conditions, between a wall (3) to be insulated and the layer of sound-absorbing material (5).
The soundproof panel (1') as claimed in claim 5, wherein the further layer of sound absorbing material (15) has a third front surface (15a) facing the second rear surface (5b), a third rear surface (15b) configured to face the wall (3) to be insulated, and a third lateral surface (15c) delimited between the third front surface (15a) and the third rear surface (15b);
and wherein the first layer of anti-vibration material (12) completely covers the third lateral surface (15c), so as to be interposed, in assembled conditions, between the further layer of sound-absorbing material (15) and said existing wall (2).
The soundproof panel (1") as claimed in any one of the preceding claims, and having an axis (A) perpendicular to the slab (4) of building material and to the layer of sound-absorbing material (5);
wherein the panel (1'') further comprises at least one further said slab (4) of building material arranged on the opposite side of the layer of sound-absorbing material (5) with respect to said slab (4) of building material, the first front surface (4a) of such further slab (4) being configured to be struck by sound waves (S'), so that the panel (1'') defines, in assembled conditions, a partition wall the external surfaces of which are defined by the first front surfaces (4a) of said slabs (4) of building material;

and wherein the first layer of anti-vibration material (12) completely covers also the first lateral surface (4c) of the further slab (4) of building material for being interposed, in assembled conditions, between the further slab (4) of building material and said existing wall (2).
The soundproof panel (1; 1'; 1''; 1‴; 1iv) as claimed in any one of the preceding claims, and having an axis (A) perpendicular to the slab (4) of building material and to the layer of sound absorbing material (5);
the panel (1; 1'; 1''; 1‴; 1iv) comprising a pair of said slabs (4) of building material arranged axially in abutment to one another with the interposition of a layer of damping material (7), preferably made of polymer-plastic-based bituminate or EPDM rubber,

wherein said pair of slabs (4) of building material, with the layer of damping material (7) interposed therebetween, is rigidly fixed to the wing (11) of the metal profile (8),

and wherein the first layer of anti-vibration material (12) completely covers the first lateral surfaces (4c) of both slabs (4) of building material of said pair, so as to be interposed, along a direction orthogonal to the axis (A) of the panel, between said pair and the existing wall (2) and between the layer of damping material (7) and the existing wall (2).
The soundproof panel (1iv) as claimed in claim 8, wherein each slab (4) of building material of said pair is defined by at least two planar elements of building material (44) arranged contiguous to each other along said orthogonal direction and separated from each other by a first space (45);
wherein the layer of damping material (7) is defined by at least two planar elements of damping material (46) arranged contiguous to each other along said orthogonal direction and separated from each other by a second space (47) ;

and wherein the first space (45) and the second space (47) are offset along said orthogonal direction.
The soundproof panel (1‴) as claimed in any one of the preceding claims, wherein the frame (6) further comprises at least one fixing hanger (16) configured to be fixed, at a fixing flange (18), to an existing roof slab (17), so that the panel (1‴) defines a false ceiling;
and wherein the panel (1‴) includes:
- a third layer of anti-vibration material (19) coupled to an external surface (18a) of the fixing flange (18) for being interposed, in assembled conditions, between the fixing hanger (16) and the existing roof slab (17); and

- a fourth layer of anti-vibration material (20) coupled to an internal surface (18b) of the fixing flange (18), opposite the external surface (18a), so that the fixing flange (18) is interposed between the third layer of anti-vibration material (19) and the fourth layer of anti-vibration material (20).
The soundproof panel (1‴) as claimed in claim 10, and having an axis (A) perpendicular to the slab (4) of building material and to the layer of sound-absorbing material (5);
wherein the panel (1‴) includes a further layer of sound-absorbing material (21), preferably comprising resin-bonded cotton fibres or cotton fibres immersed in a resinous matrix, and axially interposed between the slab (4) of building material and the layer of sound-absorbing material (5),

and wherein the panel (1‴) further comprises a layer of damping material (22), preferably consisting of polymer-plastic-based bituminate or EPDM rubber, coupled to the further layer of sound-absorbing material (21) and axially interposed between the layer of sound-absorbing material (5) and the further layer of sound-absorbing material (21).