GB2590638A

GB2590638A - Sound reduction arrangement

Info

Publication number: GB2590638A
Application number: GB1919048.7A
Authority: GB
Inventors: Alexander Fowler David
Original assignee: Extra Roomz Ltd
Current assignee: Extra Roomz Ltd
Priority date: 2019-12-20
Filing date: 2019-12-20
Publication date: 2021-07-07
Anticipated expiration: 2039-12-20
Also published as: GB201919048D0; GB2590638B

Abstract

The sound reducing wall comprises a sound proof board 34 mounted on or within a wall structure. A lower end 38 of the board may be spaced from the structure or ground by a suspension member, such that the board can move perpendicular to its plane. The suspension member may comprise a wheel 40 or a flexible member which holds the board under tension. The wheel may rotate on an axis parallel to the board and may be mounted on a central portion 42 of a lower end of the board. The board may be held in a framework 30 (e.g. of studs 32), loosely so it can move freely and/or with a close or tolerance fit. The board may be spaced from the ground by up to 20 mm. There may be one or more insulation layers, optionally soft, flexible, deformable and/or comprising reflective foil. The board may be high-density plasterboard, may define a surface of the wall or be enclosed between insulation layers, and may be mounted using discrete, spaced pads e.g. of resilient material.

Description

Sound reduction arrangement The present arrangement relates to a sound reducing wall arrangement, particularly a sound reducing wall arrangement for a residential cabin.

Introduction

Residential cabins, often referred to as 'garden rooms', typically provide an extra internal space adjacent a conventional residential property. For example, a residential cabin may provide a workshop, games room, "Granny annexe" or spare room. Residential cabins are construction using prefabricated and/or lightweight materials, such as wood, thereby allowing a cost-effective product and rapid constructions.

Residential cabins may be used as an area to play, practise or produce music.

Due to the lightweight construction of the cabin, sound may easily escape the cabin and may pose noise pollution issues. Therefore, such cabins are typically sound proofed.

In a prior art arrangement, a sound proof board is mounted with a cavity in the wall of the cabin. The board is loosely held in the wall and stands on a lower end thereof. The board is at least partially free to move/vibrate in the cavity perpendicular to plane thereof (i.e. in and out of the plane of the wall) and therefore helps to absorb the sound energy passing therethrough. However, the inventor has found that as the board stand on its lower edge, the board is not free to move at the lower end. Therefore, only the upper end of the board is free to move and the board is therefore less effective at absorbing sound at the lower end thereof.

The inventor has also found that contact with the lower end can communicate vibration to the wall structure, thereby reducing the sound proofing of the wall. However the sound proofing boards are by their nature relatively dense and therefore heavy, making them difficult to support without a rigid mechanical fixture.

It is an aim of the present invention to overcome or ameliorate one or more above problems.

According to a first aspect of the invention, there is provided: a sound proof wall comprising: a wall structure; and a sound proof board mounted on or within the wall structure and comprising a suspension member configured space a lower end of the board away from the structure or the ground in use to permit movement of the board in a direction substantially perpendicular to the plane of the board.

Preferably, the suspension member comprises one or more wheel (e.g. a castor or roller).

Preferably, the wheel is configured to rotate about an axis substantially parallel to the plane of the board. Preferably, the wheel is configured to rotate about a horizontal axis in use.

Preferably, the wheel is mounted at a central portion of a lower end of the board.

Preferably, only a single wheel is provided.

Preferably, the suspension member comprises a flexible tension member configured to hold the board whilst under tension (e.g. a cable, wire, chain, length of string or the like).

Preferably, the wall structure comprises a framework, the board mounted within the framework.

Preferably, the board is loosely held within the framework, such that the board is freely movable therein.

Preferably, the board provides a close fit or tolerance with the framework (i.e. to prevent lateral movement thereof).

Preferably, the framework comprises a wall stud. Preferably, the framework comprises a plurality of vertical and/or horizontal support beams (i.e. wall stud, top plate and bottom plate). Preferably, the wall stud defines a cell. Preferably, the cell is substantially rectangular.

Preferably, the lower end of the board is spaced from the framework or the ground by less than or equal to 20mm, preferably, less than or equal to lOmm.

Preferably, the sound proof board is interposed a plurality of insulation layers.

Preferably, the framework, the board and the plurality of insulation layers are provided as a pre-fabricated or sealed unit.

Preferably, the insulation layers comprise a soft, flexible and/or deformable material (e.g. mineral wool or the like).

Preferably, a second insulation layer encloses the board within the framework.

Preferably, the second insulation layer comprises a reflective foil.

Preferably, the board is mounted to the wall structure via one or more discrete and spaced pads Preferably, the pads comprise a resiliently deformable material (e.g. an elastomer).

Preferably, the board defines an outermost structural surface of the wall structure (e.g. an interior wall).

Preferably, the board comprises a high-density core plasterboard Preferably, the wall structure comprises one or more further sound proof boards Preferably, the wall structure comprises one or more insulations layers Preferably, the wall structure comprises one or more rubber membrane layer.

Preferably, the wall structure comprises one or more waterproof cladding layer.

According to a second aspect of the invention there is provided: a residential cabin (e.g. a garden room) comprising the sound proof wall according to the first aspect of the invention.

Detailed description

Figure 1 shows an exploded side view of a sound proof wall arrangement; Figure 2 shows a sectional plan view of the sound proof layer of the wall; Figure 3 shows a front view of the sound proof layer; Figure 4 shows a side view of the sound proof layer; Figure 5 shows a front view of a further example of a sound proof layer.

Figure 1 shows a section through a sound reducing (i.e. sound-proof) wall 2. The wall 2 may be provided in a residential cabin (i.e. "Granny annexe", garden room etc.). The residential cabin comprises a permanent or semi-permanent structure (i.e. is not intended to be portable and/or may comprise a foundation structure).

The wall 2 comprises a first layer 4 configured to provide an external surface of the wall 2. The first layer 4 provides water-proof cladding. The first layer 4 may comprise an aesthetically pleasing material and/or construction. The first layer 4 may comprise inter alia: panelling; planking; tiles; shingles; brickwork; masonry; plasterwork; or other conventional cladding material.

A second layer 6 is provided adjacent the first layer 4. The second layer 6 comprises an insulating material, e.g. a thermal insulation material. The insulating material comprises a reflective insulation material, such as foil.

A third layer 8 is provided adjacent the second layer 6. The third layer 8 comprises a sound proofing layer. The third layer will be described in further detail later. The third layer may be comprised with the structural components of the wall, i.e. the timber frame members used to construct the wall.

A fourth layer 10 is provided adjacent the third layer 8. The fourth layer 10 comprises an insulating material. The insulating material comprises a reflective insulation material, such as foil. The third, sound-proofing layer 8 and/or the timber structure of the wall is thus sandwiched between two insulating layers.

A fifth layer 12 is provided adjacent the fourth layer 10. The fifth layer 10 comprises a resiliently deformable material, such as rubber.

A sixth layer 14 is provided adjacent the fifth layer 12. The sixth layer 14 comprises a lining material. The lining material comprises a wood-based material, such as plywood.

A seventh layer 16 is provided adjacent the sixth layer 14. The seventh 16 layer comprises an acoustic membrane. The membrane comprises rubber.

An eighth layer 18 is provided adjacent the seventh layer 16. The eighth layer 18 comprises a soundproof layer. The soundproof layer comprises a high-density core plasterboard layer, such as Gyproc SoundBloc (RTM).

A ninth layer 20 is provided adjacent the eighth layer 18. The ninth 20 layer comprises an acoustic membrane. The membrane comprises rubber in this example.

A tenth layer 22 is provided adjacent the ninth layer 20. The tenth layer 22 comprises a rigid board and/or soundproof layer. The soundproof layer comprises a high-density core plasterboard layer, such as Gyproc SoundBloc (RTM).

An eleventh layer 24 is provided adjacent the tenth layer 22. The tenth layer 22 comprises a soundproof layer. The soundproof layer comprises a very high-density core plasterboard layer, such as extra high-density SoundBloc (RTM).

The eleventh layer 24 is spaced form the tenth layer by a plurality of mounts 26. A cavity 28 is thus defined therebetween. The mounts 26 comprise plurality of spaced rubber pads. The pads may comprise a rubber sponge.

The eleventh layer 24 defines an internal surface (e.g. a lining). The eleventh layer 24 may comprise internal decorative elements or aesthetic materials, for example: paint; plaster; wallpaper; panelling etc. A decorative layer may be applied over the layer 24.

With respect to the layers 10-20, various individual layers or combinations of layers may be modified or removed for different constructions.

A plan view of the third layer 8 is shown in closer detail in figure 2.

The third layer 8 comprises a framework 30. The framework comprises a plurality of timber beams 32 or the like. The timber members 32 are uprights in the example shown but a similar construction could be viewed through a vertical section, e.g. showing horizontal beams. The framework 30 may comprise a plurality of rectangular cells define by said beams 32. The framework 30 may be a portion of a platform frame, with the vertical members comprising a wall stud and the horizontal members defining a top plate and a bottom/sill plate.

The fifth layer 12 may only be selectively provided on the portion of the third layer 8 comprising the framework (i.e. along the studs to define a grid-like rubber layer).

The fifth layer 12 may comprise a plurality of strips which extend along one or more of the beams 32.

A sound proof board 34 is mounted within the framework 30 (i.e. such that a beam 32 is provided at the sides thereof). For example, a sound proof board 34 may be provided within each of the cells of the framework. The sound proof board 34 provides a close fit/tolerance with framework 30, such that there a minimal gap between the board edges and the adjacent frame, whilst ensuring that direct contact between the board edge and frame is avoided. This means that there is little or no movement of the board 34 in the plane thereof within the framework 30, i.e. laterally or vertically. However, the board 34 is loosely held within the framework 30 (i.e. not rigidly fixed thereto) such that movement is permitted in a direction perpendicular to the plane of the board 34.

The soundproof board 34 comprises a high-density core plasterboard layer, such as Gyproc SoundBloc (RTM).

An insulation layer 36 is provided on each opposing side of the board. The insulation layers comprise a deformable, compressible, flexible and/or soft material, thereby permitting movement of the board in a direction perpendicular to the plane thereof. The insulation layer comprises a lightweight material having a substantial air content, e.g. by way of voids/cells therein. The insulation layers comprise a mineral wool, such as Rockwool (RTM).

The board is sandwiched within the depth of the framework 30 by the insulation layers 36. The board depth is thus typically less than the depth of the framework 30. The summation of the board depth and the depth of the insulation layers may approximately equal the depth of the frame.

The insulation layer(s) 36 and the board 34 may be sealed within the frame work by the second layer 6 and the fourth layer 10. The framework 30 may be sandwiched between layers 6 and 10.

As shown in figure 3, the board 34 is suspended within the framework 30, such that a lower end 38 of the board 34 is spaced from framework 30 (i.e. the board 34 is "floating"). The board 34 comprises a wheel 40 (e.g. a castor, roller, bearing or the like) at the lower end thereof. The wheel 40 spaces the board from the framework 30. The wheel 40 transmits a least portion or the whole weight of the board 34 onto the framework 30 or the ground, if applicable.

The wheel 40 is mounted to the lower edge of the board using a simple bracket 41, which may be affixed to the board using one or more conventional fastener, such as one or more screw.

As shown in figure 4, the wheel 40 is mounted such that axis of rotation is parallel to, and/or within, the plane of the board. Additionally or alternatively, the axis may be parallel with the lower edge of the board. The wheel permits movement of the board 34 in a direction perpendicular thereto. In such an arrangement, the entire board 34 moves in response to sound waves (as opposed to just an upper portion of the board 34), thus providing improved sound absorbing properties.

The wheel 40 is mounted in a central portion 42 of the board 34, for example at a dead centre thereof. The board 34 is therefore balanced. The framework 30 and/or insulation 36 keeps the board 34 in position. The wheel 40 may be mounted using a bracket 44 or the like.

The bracket 44 and wheel 40 may be provided as a pre-made assembly that can simply be attached to the board using one or more conventional fastener, such as screw(s) 45 or similar. The bracket may be attached simply to the lower edge of the board 34. The bracket may be formed as a corner fixture, e.g. so that it can be fixed in place using fasteners in the front/rear side of the board.

The wheels 40 have a low clearance, thus reducing the gap between lower end 38 of the board 34 and the framework 30. The clearance may be less than lOmm, preferably less than 5mm, preferably less than 2mm.

In other embodiments, a plurality of wheels 40 may be provided. For example, two or three wheels may be provided in a spaced arrangement along the lower edge 42 of the board 34. Each wheel could be carried on a corresponding bracket.

Alternatively, a single bracket could carry a plurality of wheels in a spaced arrangement.

Additionally, or alternatively, with reference to Figure 5, the board 34 is suspended by one or more flexible tension member 47 configured to hold board 34 whilst under tension (i.e. to hang the board 34). For example, the tension member may comprise one or more of: a cable; a wire; a chain; a length of string; or other such flexible members. The tension member 47 may comprise a loop or the like attached to the framework 30, such that the board 34 is slung on the tension member 47. Alternatively the tension member 47 extends between an upper end 46 of the board 34 and the framework 30 (i.e. an end of the tension member is affixed to the board 34).

A plurality of tension members 47 may be provided. The tension member 47 may spaced, such that they located proximal the side edges of the board 34.

In some embodiments, the eleventh layer 24 is suspended in similar fashion to the board 34 of the third layer 8, e.g. using either/both of the methods described above. The eleventh layer 24 may comprise a wheel and/or flexible tension member as previously described. However, the eleventh layer 24 is still held to the tenth layer 22 by the mounts 26. The wheel and/or flexible tension member prevent stretching, distortion or fatigue of the mounting member(s), as at least a portion of the eleventh layer 24 is supported by ground. It will be appreciated that the board of layer 24 may be larger than the board 34 and may be of considerable weight.

The third layer 8 (and optionally the second layer 6 and third layer 10 attached thereto) may be provided as a pre-fabricated or sealed unit. This allows easy installation and reduces the amount of dust created onsite as no trimming etc. of the sound proof boards is required.

Additionally, the suspending/supporting of the layer 24 can help to prevent cracking or distortion of the wall structure or plaster or another decorative finish applied to the wall structure caused by the weight of the layer 24.

The present invention provides improved sound proofing properties, thereby providing a sound proof wall. The walls may reduce transmitted noise by greater than 50dB. The sound absorbing properties are substantially uniform across the wall, as the third layer board is free to move in its entirety.

The arrangement prevents cracking or distortion of the internal walls.

Although the present invention has been described in the context of a residential cabin, in other embodiments, the sound proof wall 2 may be used in other conventional permanent structures (e.g. houses or offices etc.). The wall may 2 may therefore be retrofit to a pre-existing structure to provide a sound proof room therein.

Claims

Claims: 1. A sound proof wall comprising: a wall structure; and a sound proof board mounted on or within the wall structure and comprising a suspension member configured space a lower end of the board away from the structure or the ground in use to permit movement of the board in a direction substantially perpendicular to the plane of the board.
2. A sound proof wall according to claim 1, where suspension member comprises one or more wheel.
3. A sound proof wall according to claim 2, where the wheel is configured to rotate about an axis substantially parallel to the plane of the board
4. A sound proof wall according to any of claims 2 or 3, where the wheel is mounted at a central portion of a lower end of the board.
5. A sound proof wall according to any of claims 2-4, where only a single wheel is provided.
6. A sound proof wall according to any preceding claim, where the suspension member comprises a flexible tension member configured to hold the board whilst under tension.
7. A sound proof wall according to any preceding claim, where the wall structure comprises a framework, the board mounted within the framework.
8. A sound proof wall according to claim 7, where the board is loosely held within the framework, such that the board is freely movable therein.
9. A sound proof wall according to any of claims 7 or 8, where the board provides a close fit or tolerance with the framework.
10. A sound proof wall according to any of claims 7-9, where the framework comprises a wall stud.
11. A sound proof wall according to any preceding claim, where the lower end of the board is spaced from the framework or the ground by less than or equal to 20mm.
12. A sound proof wall according to any preceding claim, where the sound proof board is interposed between a plurality of insulation layers
13. A sound proof wall according to claim 12, where the insulation layers comprise a soft, flexible and/or deformable material.
14. A sound proof wall according to any preceding claim, where a second insulation layer encloses the board within the framework.
15. A sound proof wall according to claim 14, where the second insulation layer comprises a reflective foil.
16. A sound proof wall according to any preceding claim, where the board is mounted to the wall structure via one or more discrete and spaced pads
17. A sound proof wall according to claim 16, where the pads comprise a resiliently deformable material. 25
18. A sound proof wall according to any preceding claim, where the board defines an outermost structural surface of the wall structure.
19. A sound proof wall according to any preceding claim, where the board comprises a high-density core plasterboard
20. A sound proof wall according to any preceding claim, where the wall structure comprises one or more further sound proof boards
21. A sound proof wall according to any preceding claim, where the wall structure comprises one or more insulations layers
22. A sound proof wall according to any preceding claim, where the wall structure comprises one or more rubber membrane layer.
23. A sound proof wall according to any preceding claim, where the wall structure comprises one or more waterproof cladding layer.
24. A residential cabin comprising the sound proof wall of any preceding claim.