U.S. patent application number 12/533089 was filed with the patent office on 2009-11-26 for sound proofing system and method.
This patent application is currently assigned to Northern Elastomeric, Inc.. Invention is credited to Elizabeth L. Butler, Corey R. Croteau, Janet A. DeLong, Derek E. Desroches, James Karlis, John M. Lackner, Raymond D. Mailhoit, Mary E. Moore, Samuel W. Pollard, Michael W. VanWyngarden, Thomas J. Zickell.
Application Number | 20090288360 12/533089 |
Document ID | / |
Family ID | 39792332 |
Filed Date | 2009-11-26 |
United States Patent
Application |
20090288360 |
Kind Code |
A1 |
Zickell; Thomas J. ; et
al. |
November 26, 2009 |
SOUND PROOFING SYSTEM AND METHOD
Abstract
A low-cost and easy to manufacture static structure and method
for soundproofing walls, floors, and/or ceilings of rooms in new
and/or existing construction utilizes an asphalt based flexible
membrane as one or more sound absorbing layers which may be applied
to an existing wall panel or first applied to one or more unmounted
wall panels to form a laminated structure which is then affixed to
the walls, floor or ceiling to be soundproofed. The wall panel is
preferably gypsum wallboard. Each sound absorbing layer, in
addition to soundproofing, may also serve to prevent or at least
reduce air or water infiltration to and from the room.
Inventors: |
Zickell; Thomas J.; (New
Castle, NH) ; Butler; Elizabeth L.; (Kittery, ME)
; Croteau; Corey R.; (Raymond, NH) ; DeLong; Janet
A.; (Fremont, NH) ; Desroches; Derek E.;
(Nottingham, NH) ; Karlis; James; (Pelham, NH)
; Lackner; John M.; (Nashua, NH) ; Mailhoit;
Raymond D.; (Exeter, NH) ; Moore; Mary E.;
(Barrington, NH) ; Pollard; Samuel W.; (Durham,
NH) ; VanWyngarden; Michael W.; (Fort Myers,
FL) |
Correspondence
Address: |
BOURQUE & ASSOCIATES;INTELLECTUAL PROPERTY ATTORNEYS, P.A.
835 HANOVER STREET, SUITE 301
MANCHESTER
NH
03104
US
|
Assignee: |
Northern Elastomeric, Inc.
Brentwood
NH
|
Family ID: |
39792332 |
Appl. No.: |
12/533089 |
Filed: |
July 31, 2009 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
11693311 |
Mar 29, 2007 |
|
|
|
12533089 |
|
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Current U.S.
Class: |
52/511 ;
52/506.01 |
Current CPC
Class: |
E04B 2001/8263 20130101;
E04B 1/8409 20130101 |
Class at
Publication: |
52/511 ;
52/506.01 |
International
Class: |
E04B 1/84 20060101
E04B001/84; E04B 1/86 20060101 E04B001/86 |
Claims
1. A soundproofing structure for interior walls, floors or ceilings
of rooms in new and/or existing construction, comprising: a
contiguous, sound absorbing layer and structural layer adhesively
joined about substantially coextensive confronting major faces of
said sound absorbing layer and said structural layer, said sound
absorbing layer comprised of an asphalt based flexible membrane
having opposing faces, at least one of said opposing faces of said
asphalt based flexible membrane being self-adhesive, and wherein
said structural layer is comprised of sheet like material having
opposing major faces, and wherein one of the opposing major
surfaces of said structural layer is substantially coextensive with
and adhesively joined to said at least one self adhesive major face
of said asphalt based flexible membrane.
2. The soundproofing structure of claim 1, wherein said asphalt
based flexible membrane includes two self-adhesive opposing faces,
and further including a second structural layer attached to the
other self-adhesive opposing face of said asphalt based flexible
membrane.
3. A soundproofing structure for interior walls, floors or ceilings
of rooms in new and/or existing construction, comprising: a
contiguous, sound absorbing layer and structural layer adhesively
joined about substantially coextensive confronting major faces of
said sound absorbing layer and said structural layer, said sound
absorbing layer comprised of an asphalt based membrane having
opposing faces, at least one of said opposing faces of said asphalt
based membrane being self-adhesive, and wherein said structural
layer is comprised of sheet like material having opposing major
faces, and wherein one of the opposing major surfaces of said
structural layer is substantially coextensive with and adhesively
joined to said at least one self-adhesive major face of said
asphalt based membrane.
4. The soundproofing structure of claim 3, wherein said asphalt
based membrane is a flexible membrane.
5. The soundproofing structure of claim 3, wherein said asphalt
based membrane is a semi-flexible membrane.
6. The soundproofing structure of claim 5, wherein said
semi-flexible asphalt membrane includes a filler.
7. The soundproofing structure of claim 6, wherein said filler
includes an inorganic filler.
8. The soundproofing structure of claim 7, wherein said inorganic
filler is selected from the group consisting of talc, barium
sulfate, calcium carbonate, and crushed minerals.
9-18. (canceled)
Description
FIELD OF THE INVENTION
[0001] This application is a divisional of U.S. patent application
Ser. No. 11/693,311 filed on Mar. 29, 2007 titled "Sound Proofing
System and Method incorporated fully herein by reference.
[0002] This invention relates to interior building materials and
methods, and more particularly, to a novel soundproofing system and
method.
BACKGROUND OF THE INVENTION
[0003] In new and existing construction, the interior floor,
ceiling and side walls of a room are typically comprised of a
plurality of spaced, load bearing members, such as wall studs, and
finishing materials, such as gypsum sheet material or plywood,
affixed thereto. In many situations, it is desirable or necessary
to provide the interiors of rooms of such construction with sound
and/or thermal insulation. The sound and/or thermal insulation
should be low-cost, easy to manufacture and be capable of ready
installation in new or existing construction. The heretofore known
soundproofing products and methods have been disadvantageous in one
or more of these and other aspects.
SUMMARY OF THE INVENTION
[0004] The present invention features a low-cost and easy to
manufacture static structure for soundproofing interior walls,
floors or ceilings of rooms in new and/or existing construction.
Interior walls includes the interior region of walls bounding the
interior space in a structure including wood, concrete or other
walls constructed of any other type of material. According to one
embodiment, the present invention includes contiguous, sound
absorbing material and wall layers adhesively joined about
substantially coextensive confronting major faces. The sound
absorbing layer preferably comprises an asphalt based, flexible
membrane having opposing faces, at least one of which is self
adhesive while the structural layer is comprised of a sheet
material having opposing major faces, with one of the opposing
major surfaces of the sheet material of the wall structural layer
substantially coextensive with and adhesively joined to one of the
major faces of the asphalt based, flexible membrane of the sound
absorbing layer. In alternate embodiments, a silicon-based release
sheet may be releasably attached to the self-adhesive major faces
of the asphalt based, flexible membrane of the sound absorbing
layer.
[0005] In any embodiment, the static structures for soundproofing
interior walls according to the present invention are low in cost
and easy to manufacture, utilizing, for example, a readily
available asphalt based weatherproofing membrane as the sound
absorbing flexible membrane layer and readily available gypsum
board as the structural layer, and are suitable for use in new or
retrofit construction, by affixing, for example, the static
soundproofing structures of the present invention to studs in new
construction or to already existing wallboard during retrofit. The
sound-absorbing layer, in addition to soundproofing, also serves to
prevent air infiltration or air from exiting the room. This could
reduce heating and air-conditioning bills, by making the room more
"airtight."
[0006] The method of soundproofing the interior walls of a room of
the present invention comprises the steps of removing a release
sheet to expose the self-adhesive surface of a flexible sound
absorbing membrane; and adhering the exposed self-adhesive surface
to a structural panel of sheet material to provide a sound
absorbing lamination. In retrofit construction, the structural
panel may be a room interior wall panel, and in a next step another
layer of wall panel may be affixed thereto. In a next step in new
construction, the sound absorbing lamination is attached to the
interior walls of the room to be soundproofed. In addition, in new
construction, it is also contemplated that the method may comprise
"sandwiching" a sheet of self-adhesive asphalt based material
between two sheet of structural material, such as gypsum wallboard,
and then affixing the three part laminated structure to a floor,
wall or ceiling to be soundproofed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] These and other objects, inventive aspects and advantageous
features of the present invention will become apparent as it
becomes better understood by reference to the following, solely
exemplary, detailed description of the presently preferred
embodiments, and to the drawings, wherein:
[0008] FIG. 1 is a partially broken away front pictorial view of a
two-sided soundproofing membrane with release sheets on each side
in accord with the present invention;
[0009] FIG. 2 is a sectional view of the two-sided soundproofing
membrane of the present invention;
[0010] FIG. 3 is a partially pictorial, partially schematic side
view of one embodiment of a soundproofing product in accord with
the present invention; and
[0011] FIG. 4 is a partially pictorial, partially schematic side
view of another embodiment of a soundproofing product in accord
with the present invention.
DETAILED DESCRIPTION OF THE PRESENTLY PREFERRED EMBODIMENTS
[0012] Referring now to FIG. 1, generally designated at 10 is a
soundproofing membrane in accord with the present invention. The
soundproofing membrane 10 is preferably flexible and constructed
from an elastomeric sheet 12, preferably asphalt based, which
prevents sound transmission from one side to the other. The
soundproofing membrane may be flexible or semi-flexible. In the
case of a semi or less flexible membrane, the asphalt includes a
high or higher filler content. Examples of "fillers" include talc
(the preferred filler) and/or other inorganic fillers such as
barium sulfate, calcium carbonate or crushed minerals which serve
to provide "mass" to the membrane which slows the transmission of
low frequency sound by 0-60%.
[0013] The layer 12 is "sticky" or self-adhesive on one or both
sides. Each self-adhesive side is covered with a silicon-based
release sheet 14, 16 (best seen in FIG. 2) that is substantially of
the same size as the layer 12. It has been found that the asphalt
based flexible membrane that is commonly used as water- and
weatherproofing typically on roofs, decks and other exterior
roofing surfaces under roofing material is usable in accord with
the present invention to provide soundproofing of interior walls.
Any composition formula for the asphalt based flexible membrane may
be employed, so long as it has enough "mass", "pliability" or
"elasticity" to serve as a sound absorbing and sound deadening
material. If the material is too brittle, it will act like the
remainder of the structure and transmit the sound instead of
absorbing it.
[0014] In a first embodiment, the soundproofing membrane of the
present invention may be supplied in sheet or roll form and may be
applied by homeowners or contractors to ceilings, floors or walls;
either to existing sheet material such as plywood or wallboard or
alternatively, may be applied to sub-floor, studs or ceiling
joists. Although the soundproofing membrane of the present
invention includes at least one surface which is self-adhesive,
this is not a limitation of the present invention since it may be
nailed, stapled or otherwise fastened to an interior surface to be
soundproofed and both major planar surfaces may be
self-adhesive.
[0015] One embodiment of a soundproofing product or static
structure of the present invention designated generally at 30 in
FIG. 3 is shown attached to an interior room wall 32 in new and/or
existing construction. The static soundproofing structure 30
attached to interior wall 32 includes contiguous, sound absorbing
layer 34 and wall layer 36, adhesively joined about substantially
coextensive confronting major faces 38. The sound absorbing layer
34 is preferably comprised of an asphalt based, flexible membrane
having opposing self-adhesive faces, of the type described above in
connection with the description of FIGS. 1, 2. The structural layer
36 is preferably comprised of a gypsum based sheet material having
opposing major faces, such as sheetrock, or other interior wall
laminate. The confronting major surfaces of the flexible sound
absorbing layer 34 and of the sheet material of the wall structural
layer 36 are adhesively joined together at their interface 38.
[0016] In use, various modes or embodiments are contemplated. In a
first embodiment, the sound absorbing and soundproofing barrier
membrane 34 could be applied to the ceiling or wall panel 36, such
as sheetrock, and the assembly in turn adhered, nailed or screwed
to the wall 32. In a retrofit situation, the contractor or
homeowner could apply the membrane 34 over the existing wallboard
32 on the wall or ceiling of the home, and then apply another layer
of wallboard 36 over that. In yet another embodiment, the
preconfigured structure 30 comprising wallboard 36 and
soundproofing layer 34 could be affixed to the interior room wall
32.
[0017] Another embodiment generally designated at 50 in FIG. 4 of a
soundproofing product of the present invention is shown attached to
an interior wall 52 of a room in new and/or existing construction.
The static soundproofing (sound dampening) structure 50 attached to
interior wall 52 is similar to the embodiment 30 of FIG. 3, except
that it is a three-layer product in which the sound absorbing layer
54 is "sandwiched" between contiguous wall layers 56, 58 adhesively
joined about substantially coextensive confronting major faces at
the respective interfaces 53, 55 there between. Structure 50 allows
for the use of fewer nails which are undesirable since the nails
transmit sound. The sound absorbing layer 54 is preferably
comprised of the same asphalt based, flexible membrane having
opposing self-adhesive faces of the type described above in
connection with the description of FIGS. 1, 2. The structural
layers 56, 58 are each preferably comprised of gypsum based sheet
material, such as sheetrock, or other interior wall laminate,
having opposing major faces.
[0018] In use, this embodiment contemplates that the entire
sandwiched structure 50 will be sold as an integral unit. This
embodiment will typically not be used in a retrofit situation
although it is not precluded from being used as such. It is
contemplated that in this embodiment, the homeowner or contractor
would simply apply the sandwiched structure 50 to wall studs or
ceiling joists 52 using nails, screws, adhesive or the like. In a
retrofit situation, the contractor or homeowner could apply the
sandwiched structure 50 over the existing wallboard 52 on the wall
or ceiling of the home.
[0019] The invention also has application in its product and its
method aspects for flooring such as plywood sub floors prior to the
installation of the floor or another piece of plywood to serve as
the base for other flooring materials such as tile, linoleum or
carpet. In addition to eliminating or at least greatly minimizing
the transmission of sound, the present invention also serves to
reduce air infiltration into and out of the room, thereby helping
to conserve energy required to heat and cool a room. The present
invention can also serve as a moisture barrier, i.e., bathroom
floors.
[0020] The present invention is not intended to be limited to a
system or method which must satisfy one or more of any stated or
implied object or feature of the invention and should not be
limited to the preferred, exemplary, or primary embodiment(s)
described herein. Modifications and substitutions by one of
ordinary skill in the art are considered to be within the scope of
the present invention, which is not to be limited except by the
allowed claims and their legal equivalents.
* * * * *