U.S. patent number 3,885,362 [Application Number 05/352,735] was granted by the patent office on 1975-05-27 for modular noise abatement enclosure and joint seal.
Invention is credited to Gordon J. Pollock.
United States Patent |
3,885,362 |
Pollock |
May 27, 1975 |
Modular noise abatement enclosure and joint seal
Abstract
A free-standing modular space enclosure for achieving desired
levels of noise abatement, particularly in manufacturing
facilities, by acoustically isolating separate units of
noise-producing industrial machinery and apparatus, while at the
same time providing ready access to any part or portion of the
isolated equipment or machinery by removal of any adjacent
detachable panel of the noise enclosure. Such access is desirable
and necessary for repair, maintenance, regulation and inspection of
the machinery or apparatus so isolated. The enclosure comprises a
four-sided structure, the walls of which are assembled from a
plurality of modular panels which are acoustically isolated from
each other and from the skeletal framework although detachably
sealed at their common joints or areas of engagement with each
other. In addition to the side walls, the enclosure is provided
with a roof also assembled from a plurality of modular panels and
acoustically isolated from the wall panels and from the skeletal
framework although engaged therewith. Any of the standard modular
panels may be replaced, if desired, with special panels having
specified features or characteristics such as, doors, windows,
feed-through systems, service boxes, and the like.
Inventors: |
Pollock; Gordon J. (Cleveland,
OH) |
Family
ID: |
23386266 |
Appl.
No.: |
05/352,735 |
Filed: |
April 19, 1973 |
Current U.S.
Class: |
52/126.7; 49/310;
52/270; 52/395; 52/474; D25/33; 52/241; 52/283; 52/463 |
Current CPC
Class: |
E04H
1/1238 (20130101); E04B 1/8218 (20130101); E04B
2/7409 (20130101); E04B 2001/8442 (20130101); E04B
2001/8254 (20130101) |
Current International
Class: |
E04H
1/12 (20060101); E04B 2/74 (20060101); E04B
1/82 (20060101); E04B 1/84 (20060101); E04b
001/348 (); E04g 021/10 (); E04b 001/88 () |
Field of
Search: |
;52/589,299,283,395,403,463,474,27,241,262,483,363,270,486,487,126,393,281,122
;49/310,480 ;248/68CB,56 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
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|
|
|
|
|
|
41,023 |
|
Oct 1969 |
|
DK |
|
1,039,034 |
|
Aug 1966 |
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GB |
|
906,661 |
|
Jan 1946 |
|
FR |
|
547,070 |
|
Oct 1957 |
|
CA |
|
29,932 |
|
Jul 1911 |
|
GB |
|
Primary Examiner: Abbott; Frank L.
Assistant Examiner: Braun; Leslie A.
Attorney, Agent or Firm: Isler & Ornstein
Claims
Having thus described my invention, I claim:
1. In a modular noise abatement enclosure, the combination of a
free-standing open skeletal frame having a ground-engaging channel
member with upstanding spaced legs, an upper support rail, posts
interconnecting said channel member and support rail in coextensive
vertically spaced relationship, height-adjusting means provided on
said posts for positioning said upper support rail in a horizontal
plane independently of the positional plane of said ground-engaging
channel member, and a plurality of side wall panels detachably
mounted in co-planar abutting relationship on each side of said
frame to form a continuous enclosure, each of said panels having a
sound-insulating interior face, each of said side wall panels
having a lower edge slidably engaging the legs of said channel
member in sealing engagement and having an upper edge detachably
engaging said rail and suspended thereby to provide the sole
vertical support for said panel and maintain said lower edge out of
direct downward load-bearing engagement with said channel member,
whereby any one of said panels can be bodily displaced and detached
from said frame by relative upward movement thereof to provide
interior access to a selected portion of the enclosure.
2. A combination as defined in claim 1, including a compressible
seal affixed to a vertically-extending edge of each panel for
sealing abutment with a vertically-extending edge of an adjacent
panel.
3. A combination as defined in claim 2, wherein said
vertically-extending edge of each panel comprises a flange having
an inwardly directed offset bend terminating in a reverse open fold
defining a seal-retaining recess, and said compressible seal is
coextensive with said flange and has an edge portion retained in
said recess, said seal extending outwardly and reversely from said
recess around the exterior of said fold on opposite sides thereof
to provide a substantially U-shaped seal contour having one leg of
the U engageable with said vertically extending edge of an adjacent
panel, and retainer means carried by each panel for securing the
opposite leg of the U against displacement.
4. A combination as defined in claim 3, wherein said retainer means
is a resilient clip having an inwardly-directed hook at one edge
thereof, said hook being yieldably displaceable to pass between
said opposite leg of the U and an edge portion of each said panel
to extend into locking relationship with said offset bend portion
of said flange, and said clip having another portion interposed in
sealing engagement between said opposite leg of the U and a portion
of each said panel, whereby said clip locks said seal against
displacement from said flange.
5. A combination as defined in claim 4, wherein said
sound-insulating face is a noise-insulating mat on the interior of
said side wall panels, and means are provided on said resilient
clip for retaining said mat on said panels.
6. A combination as defined in claim 1, wherein said upper support
rail has an upwardly directed leg portion, and said upper edge of
said side wall panels is provided with means for engaging said leg
portion in response to relative downward movement of the panel.
7. A combination as defined in claim 1, wherein said channel member
has a pair of spaced upwardly directed legs, each of said legs
having outwardly flared terminal portions to provide guideways, and
said lower edge of said side wall panels is provided with spaced
portions defining guide surfaces slidably engageable with said
spaced channel legs in response to relative downward movement of
the panel.
8. A combination as defined in claim 7, wherein said upper support
rail has an upwardly directed leg portion, and said upper edge of
said side wall panels is provided with a downwardly directed lip
for engaging said leg portion in response to said downward movement
of the panel.
9. A combination as defined in claim 1, including roof wall panels
carried by said frame for enclosing the roof side thereof.
10. A combination as defined in claim 9, wherein said upper support
rail is provided with a ledge portion and underlying opposed edges
of said roof wall panels in noise-sealing relationship thereto, and
said roof wall panels are disposed in abutting co-planar
relationship.
11. A combination as defined in claim 10, including a compressible
seal affixed to an edge of each roof wall panel for sealing
engagement with the abutting edge of an adjacent roof wall
panel.
12. A combination as defined in claim 1, wherein said height
adjusting means includes a threaded stud connected to said channel
member and projecting upwardly into said post, and a post support
element underlying said post and threadedly engaging said stud for
vertical displacement thereon.
13. A combination as defined in claim 1, wherein at least one of
said side wall panels is provided with means for access
therethrough without bodily detachment thereof.
14. A combination as defined in claim 13, wherein said means for
access is an opening in said side wall panel and a closure movably
connected to said side wall panel for sealing engagement with said
opening.
15. A combination as defined in claim 14, wherein the bottom
portion of said closure is provided with a movably mounted
spring-loaded ground-engaging seal which is normally urged out of
ground-engaging position in response to opening movement of said
closure and is yieldably restored to ground-engaging position in
response to closed position of said closure.
16. A combination as defined in claim 13, wherein said means for
access is an opening in said side wall panel and a utility service
box connected to said side wall panel in overlying relationship to
said opening and in resiliently yieldable sealing engagement with
said opening.
17. A combination as defined in claim 16, wherein said utility
service box comprises a separable housing defining a hollow
receptacle and having openings provided in said housing for
traversal of utility lines therethrough, and a compressible
material retained in said receptacle and normally sealing the
openings therein, said material being yieldably displaceable into
contour sealing engagement with said utility lines in response to
securement of the separable housing portions to each other.
18. A combination as defined in claim 1, including a rigid
perforated backing plate retained on the interior of said side wall
panels in overlying relationship to the exposed surface of said
sound-insulating face.
19. A combination as defined in claim 1, wherein said frame
includes a second support rail above said upper support rail, said
posts interconnecting said channel member and said upper and second
support rails in vertically spaced relationship, said upper support
rail providing an upwardly directed second channel member, and a
second plurality of side wall panels detachably mounted in coplanar
relationship on each side of said frame above said first-named
panels, said second side wall panels having a lower edge slidably
engaging said second channel member in sealing engagement and
having an upper edge removably engaging said second support rail
and suspended thereby.
20. A combination as defined in claim 19, wherein said upper
support rail has an upwardly directed leg portion, said upper edge
of said first-named side wall panels is provided with means for
engaging said leg portion in response to relative downward movement
of the panel, said second channel member being disposed above said
leg portion, said second support rail having a second upwardly
directed leg portion, said second side wall panels having a lower
edge slidably engaging said second channel member is sealing
engagement and having an upper edge provided with means for
removably engaging said second upwardly directed leg portion,
whereby any one of said second side wall panels can be bodily
detached from said frame by relative upward movement thereof
independently of said first-named side wall panels.
21. A combination as defined in claim 1, including a second
plurality of side wall panels spaced inwardly from said first-named
side wall panels and disposed in parallel opposed relationship
thereto, said second side wall panels having a lower edge slidably
engaging said channel member in sealing engagement therewith and
having an upper edge removably engaging said rail and suspended
thereby.
22. A combination as defined in claim 21, including a compressible
seal affixed to a vertically extending edge of each of said second
panels for sealing engagement with an abutting edge of an adjacent
panel.
23. A combination as defined in claim 22, including a shelf support
member mounted between adjacent edges of said first-named and
second side wall panels and having portions for retaining shelf
brackets.
24. A combination as defined in claim 21, including a gypsum panel
supported by and between said first-named and second side wall
panels, and parallel thereto.
25. A combination as defined in claim 21, wherein said support rail
is affixed to the ceiling of a fixed building structure.
Description
BACKGROUND OF THE INVENTION
With the heightened awareness of industry of the undesirable
effects of high noise levels on worker efficiency and morale, as
well as the increased legislative activity pertaining to industry
noise abatement, there is increased emphasis on and need for
compact, inexpensive, easily installed, portable and flexible
noise-abating space enclosures for production machinery and
equipment which exceeds tolerable noise levels. Because there is
need for frequent access to such machinery and equipment for
maintenance, repair and a variety of other reasons, the primary
approach to noise-abating space enclosures for such machinery has
emphased a walk-around area within the space enclosure and a
doorway in a substantially permanent wall structure of the space
enclosure by means of which maintenance and repair personnel have
access to the "room" defined by the enclosure and within which the
machinery or equipment is positioned. By reason of the particular
construction used for such noise-abating space enclosures and the
access arrangement provided, such enclosures necessarily have to be
large enough to provide a walk-around space for service and
maintenance personnel and thus have to be considerably larger than
would be required for noise-abating enclosure of the unit of
machinery or equipment itself. When such space enclosures are
assembled from modular panels, a critical area is the joint between
adjacent panels which not only should provide an effective
acoustical barrier in itself, but should also be designed to
accomodate to irregularities in the assembly of the panels or
possible thermal expansion and contraction. Additionally, these
joints should be durable and should not themselves create a
possible source of noise resulting from metal-to-metal contact.
Despite costly and complicated design efforts, these critical
problems still plague the prior art.
SUMMARY OF THE INVENTION
The invention contemplates a modular panel structure to provide a
noise-abating space enclosure, in which the panels of the roof and
side walls of the structure are not mechanically secured to each
other, but are detachably engaged in an appropriate framework
whereby each individual panel of the enclosure can be readily
removed or lifted out of position independently of all the other
panels so as to provide ready access to that portion of the
enclosed machinery or equipment which is adjacent to the removed
panel. Whatever service, maintenance, repair, regulation or
inspection of the equipment is required, it can be accomplished
directly through the opening provided by the removal of one or more
individual panels. Such an arrangement eliminates the necessity of
providing any interior walk-around space within the noise enclosure
and permits the enclosure to be built extremely close to the
outline of the equipment that it encloses, thus providing a much
smaller, more compact and less costly enclosure than those of the
prior art. The enclosure is free-standing and portable so that it
can be moved quickly and easily if the particular machine or
equipment has to be relocated on the plant floor and similarly, the
enclosure is readily enlarged or reduced in size or modified by the
addition of special features whenever the equipment it encloses is
replaced or modified.
The invention also contemplates an improved compressible joint seal
between adjacent wall panels which will accomodate to
irregularities in the panels or in the assembly thereof and which
is so mounted and secured to the panel structure that it will not
interfere with repeated removal of the detachable panels, but will
not ordinarily be displaced from its operative sealing position
when the panel is restored to its place in the enclosure.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is an isometric view of the supporting framework or skeletal
structure upon which the panels are mounted to provide a
noise-abating space enclosure in accordance with the invention.
FIG. 2 is an isometric view with the panels in place on the frame
of FIG. 1 to provide one form of enclosure.
FIG. 3 is a cross-sectional view, taken as indicated on line 3--3
of FIG. 1 and showing details of a corner post assembly. FIG. 4 is
a cross-sectional view, taken as indicated on line 4--4 of FIG. 3,
showing further details of the corner post assembly.
FIG. 5 is a cross-sectional view, taken as indicated on line 5--5
of FIG. 2 and showing details of the panel structure and joint.
FIG. 6 is a vertical cross-sectional view, taken as indicated on
line 6--6 of FIG. 2 and showing details of the panel structure.
FIG. 7 is a cross-sectional view, taken as indicated on line 7--7
of FIG. 1 to show details of the form of securement of the support
frame at its upper corner.
FIG. 8 is a cross-sectional view, taken as indicated on line 8--8
of FIG. 2 to show details of the roof wall structure.
FIG. 9 is an enlarged cross-sectional view, taken as indicated on
line 9--9 of FIG. 2 to show details of the joint seal between the
wall panels.
FIG. 10 is a view similar to FIG. 9, but showing a modified form of
joint seal between panels.
FIG. 11 is a fragmentary cross-sectional view similar to FIG. 5,
but showing a slightly modified form of panel insulation
arrangement.
FIG. 12 is a horizontal cross-sectional view, taken as indicated on
line 12--12 of FIG. 2 and showing details of a hinged door panel
piece.
FIG. 13 is a fragmentary vertical cross-sectional view, taken as
indicated on line 13--13 of FIG. 2 and showing detils of a door
seal which could be utilized with the door structure shown in FIGS.
2 and 12.
FIG. 13a is a fragmentary view in elevation of the door seal shown
in FIG. 13.
FIG. 14 is a fragmentary cross-sectional view, taken as indicated
on line 14--14 of FIG. 2 and showing details of a service box
feature on one of the enclosure panels.
FIG. 15 is a fragmentary cross-sectional view, taken as indicated
on line 15--15 of FIG. 2 and showing further details of the service
box.
FIG. 16 is an isometric view of one of the rubber blocks employed
in the service box.
FIG. 17 is a fragmentary isometric view of a structure employed to
add a module of height to the space enclosure.
FIG. 18 is a fragmentary cross-sectional view, taken as indicated
on line 18--18 of FIG. 17.
FIG. 19 is an isometric view of a space enclosure embodying the
principles of my invention and adapted for use as partitions or
walls for office enclosures.
FIG. 20 is a fragmentary cross-sectional view, taken as indicated
on line 20--20 of FIG. 19.
FIG. 21 is a view similar to FIG. 20 but showing a modified form of
panel joint.
FIG. 22 is a fragmentary isometric view of the joint shown in FIG.
21.
FIG. 23 is a horizontal cross-sectional view, taken as indicated on
line 23--23 of FIG. 19 to show details of the corner joint
assembly.
FIG. 24 is a fragmentary cross-sectional view, taken as indicated
on line 24--24 of FIG. 19 to show details of the connection of the
portable partition wall to the wall of the fixed building
structure.
FIG. 25 is a vertical cross-sectional view, taken as indicated on
line 25--25 of FIG. 19 to show the connection of the portable wall
structure to the floor and ceiling of the fixed building
structure.
FIG. 26 is a fragmentary cross-sectional view, taken as indicated
on line 26--26 of FIG. 19 showing the joint between a wall panel
and the door jamb .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring more particularly to FIGS. 1-9 of the drawings, there is
shown, as in FIGS. 1 and 2, a noise-abating enclosure, designated
by reference numeral 30, which includes a free-standing support
frame 31 on which are mounted side wall panels 32, corner panels 33
and roof wall panels 34. As will appear more fully hereinafter,
some of the wall panels 32 or 34 are modified to provide special
features or characteristics such as the hinged door 35 and the
service box 36 shown in FIG. 2. However, for purposes of the
present description, these modified panels need not be considered,
as all the side wall panels could be standard panels 32 and all the
roof wall panels could be standard panels 34, if no special
features or accessories are required. In any event, the special
panels or modified panels are of the same size as the standard
panels which they replace and also have the same joint construction
as the standard panels.
For purposes of flexibility in the size of the enclosure, for ease
and convenience of assembly and installation, and for purposes of
minimizing manufacturing cost, the side wall panels 32 and the roof
wall panels 34 are made to a uniform width, for example 24 inches,
and are made in stock lengths in one or two foot increments up to a
convenient maximum length of, for example, 10 feet. It will be
understood that all the panels 32 in the structure would be of a
uniform length or heighth and that all the panels 34 would
similarly be of a uniform length.
The frame 31 includes a plurality of horizontally disposed channel
elements 37 which are arranged in a coplanar quadrangular
relationship at ground or floor level and are connected with each
other in a manner to be described. In FIG. 1, six of such elements
37 are shown, there being one provided on each of the end walls and
two provided on the front wall and on the rear wall of the
enclosure. It will be understood that the number of such elements
that are used or required will depend upon the length of the
elements used and the size of the enclosure which is to be
assembled. As best seen in FIGS. 4 and 6, the channel elements 37
are substantially U-shaped in cross-section and the terminal
portion of the legs 38 of the channel element are bent or flared
upwardly as at 39 to provide an enlarged throat or guideway for
slidable insertion of the panel 32 into the channel element. The
exterior surface of the web of channel element 37 has adhesively
secured thereto any suitable form of vibration damping or
cushioning material in the form of a continuous gasket or pad 40
which engages the floor surface and serves to insulate or isolate
the enclosure from direct contact with the floor and thereby
minimizes vibration and sound transmissions between the floor and
the enclosure.
As best seen in FIGS. 3 and 4, a corner plate 41 is placed into
overlying relationship to adjacent channel elements at their corner
junctures. Each corner plate is provided with a pair of notches or
recesses 42 which extend in a direction normal to each other and
are of a size sufficient to permit the corner plate to slide down
into the channel element 37 over the interior leg 38 of the channel
element. The corner plate 41 is provided with a pair of spaced
downwardly projecting pins 43 which are so located as to enter and
traverse matched openings 44 which are provided for that purpose in
the web of the channel element 37. This mechanical interlock
between the corner portions of the channel elements 37 and the
respective corner plates 41 maintains the channel elements in the
desired right angle relationship to each other at the corner and
prevents them from shifting horizontally relatively to each other.
The pin 43 may conveniently be provided with a flattened lip
portion 45 which is spot welded or otherwise permanently secured to
the web of the channel 37.
The corner plate 41 also is provided with an upwardly projecting
threaded stud 46, which is welded or otherwise permanently affixed
to the corner plate in a position which is inwardly of the inner
legs 38 of the channel elements at the respective corners. The
under surface of an inward portion of the corner plate 41 is
provided with a sound absorbing gasket or pad 47 which is the same
or similar to the previously described pad 40 and is intended for
the same purpose. A vertically extending corner post 48, which may
conveniently be in the form of angle iron or the like, has a seat
element or plate 49 permanently affixed to the lower end thereof
and provided with an aperture or opening 50 which permits the stud
46 to traverse the seat plate 49 when the corner post is slidably
mounted thereon. The seat plate rests upon an underlying nut 51
which threadedly engages the stud. By rotating the nut 51 in one
direction or the other, the vertical position of each of the corner
posts 48 may be adjusted within limits so that the enclosure 30
will be level despite sloping portions or irregularities that may
exist in the floor surface on which the enclosure is set. When the
leveling procedure has been completed by manipulation of the nuts
51 at each of the corners of the structure, a lock nut 52 may be
utilized if desired to bear against the upper surface of the seat
plate 49. It will be noted that for purposes of the corner plate
arrangement above described, a portion of each of the inner legs 38
of the channel elements is cut away, as at 53, to accomodate to the
recesses 42.
If the enclosure is reasonably short in length, the four corner
posts 48 will provide sufficient vertical support for the panels of
the enclosure. If the enclosure is somewhat longer, it may be
desirable to provide additional vertical supports, such as the
intermediate vertical support posts 54 which can be identical in
structure to the corner posts 48. Depending upon the length of the
enclosure, any desired number of such intermediate support posts 54
may be utilized to prevent any sag in the enclosure and to provide
the necessary rigidity to the support frame 31.
When intermediate support posts 54 are used, a floor plate 55
having the upwardly projecting threaded stud 46 is utilized to
adjustably support the lower end of the support post 54 in the same
manner as previously described with reference to the corner post 48
and the corner plate 41. It is not necessary to provide the floor
plate 55 with recesses to accomodate the interior legs 38 of the
channels 37, as was the case with the corner plate 41, although
such recesses may be provided on the floor plate 55 if desired.
However, it is necessary to cut away portions of the channel legs
38, as at 56, to provide clearance for setting the floor plate 55
into the desired overlying relationship to the web of the channel
element. The floor plate 55 may also be provided with the
downwardly projecting ends 43 to traverse the underlying channel
element in the same manner as previously described with reference
to the corner plate. The floor plate 55 also provided with an
isolating pad 47 on the underside thereof in the same manner as
previously described with reference to corner plate 41. It will be
noted that the frame as thus described is free-standing and
portable, as it has no securement to the floor.
As best seen in FIGS. 1 and 7, the upper end of each of the corner
posts 48 has a flanged corner gusset 57 affixed thereto as by
welding or the like. Similarly, the upper end of each of the
intermediate support posts 54 also have a flanged gusset 58 affixed
to the upper ends thereof. The inwardly directed horizontally
extending flanges 59 of the gussets are provided with spaced
apertures 60 which match corresponding openings 61 provided in the
top rails 62 of the frame. Suitable fasteners 63, such as
illustrated bolts, traverse the openings 60 and 61 and are secured
by nuts to rigidly connect the top rails 62 to the respective posts
48 and 54. The top rails 62 are leveled to a horizontal plane by
means of the vertical adjustment of the posts, as previously
described. When it is necessary to use the intermediate support
posts 54, it is also advisable to provide a corresponding upper
cross brace 64 which has gussets 65 affixed to the ends thereof by
means of which the cross brace can be bolted or otherwise connected
to the opposed intermediate posts 54 just below the adjacent top
rail.
The top rail has a cross-section substantially in the form of a
right angle which provides an inwardly directed horizontally
extending ledge portion 66 and an upwardly directed support leg 67
which is bent as at 68 to provide an offset. The end of the support
ledge 66 is provided with a reverse bend 69 to form a recess on the
ledge for accomodating a cushioning or gasket strip 70 for the
purpose of noise isolation. The end of the support leg 57 is
provided with a reverse bend 71 to provide broad surface engagement
with a similar noise isolating strip 70 which is accomodated in the
upper portion of the side wall panels 32. It will be noted that the
top rails 62 are disposed in a plane which is inwardly of the
vertical support posts whereas the channel elements 37 are disposed
in a plane outwardly of the vertical support posts, so that the top
rails are offset inwardly from the channel elements.
The structure of the side wall panels 32 and the roof wall panels
34 is substantially identical. Except for their configuration and
size, the corner panels 33 are also structurally the same as the
other panels. Each of the panels includes a heavy structural skin
or face portion 72 of sheet metal or the like which is bent
inwardly on all four sides thereof to provide a form of open faced
box or receptacle of sufficient depth to receive the required
thickness of noise-insulating mats 73. In the side wall panels 32,
there are two opposed horizontally extending flanges 74 and 75 and
two vertically extending opposed flanges 76 and 77. As best seen in
FIG. 6, the upper flange 74 is provided with a downwardly extending
lip 78 which hooks behind the leg 67 of the top rail 62 when the
side panel is in place. The lower flange 75 is also provided with a
downwardly directed lip 79 which provides a bearing surface or
guide surface for the lower end of the panel when it is moved
downwardly into the channel element 37. Each side wall panel is
thereby held in place by being suspended by the upper flange 74
from the top rail and having its bottom flange 75 slidably received
and retained within the channel element 37. The channel element has
sufficient depth so as to accomodate and retain the bottom of the
side panel within the entire range of vertical adjustment permitted
by the manipulation of the nut 51 on the threaded stud 46 of the
corner plate 41 and floor plate 55.
As best seen in FIG. 5, the vertically extending flange 76 is
provided with an inwardly directed lip 80 which functions as a
retainer for the insulation mat 73. The opposite vertical flange 77
is provided with an inwardly directed offset bend as at 81 and is
bent to provide an open flat fold 82 to receive and retain a
continuous vinyl gasket 83. As shown in FIG. 9, the gasket 83 has a
bulbous formed portion 84, shown in phantom outline, which
compresses or is deformed to accomodate to any variation which
might occur in the sealing joint between adjacent abutting panels.
The gasket 83 is installed by inserting one edge of the gasket into
the open space provided by the flat fold 82 and then wrapping the
rest of the gasket around the outside of the flat fold so that it
seals against the flange 76 of the adjacent side wall panel 32 or
the adjacent corner panel 33, as well as fitting snugly and sealing
against a resilient insulation retainer clip 85 on the opposite
side of the flat fold.
The insulation retainer clip 85 is provided at one edge thereof
with a reverse bend forming an inwardly directed hook 86 which is
yieldably displaced as the clip is pressed into place between the
gasket 83 and the edge of the insulation mat 73 and then returns to
its original configuration to hook under and be retained by the
offset 81 of the flange 77. The opposite edge of the clip 85 is
bent to form a retaining lip 87 for holding the mat 73 in place in
the same manner as the lip 80 of the flange 76. Once the hook 86 is
engaged, it cannot be removed without destroying it, and the
sealing gasket 83 is thereby permanently held in place. All the
panels are uniformly made with the gasketed flange 77 on the same
side of the panel which, in this instance, is illustrated as being
the right side. In this manner, the gasketed flange 77 of one of
the side panels is always in sealing abutment with the vertically
extending flange 76 of the adjacent panel. As shown in FIG. 5, this
same flange structure is also utilized on the corner panels 33. By
reference to FIG. 8, it will be noted that the same flange
structure is also utilized for the abutting edges of the roof wall
panels 34. As shown in FIG. 6, the shorter edges or sides of the
roof panel are provided with flanges 88 having an inwardly directed
lip 89 which serves as a retainer for the insulation mat 73.
After the framework shown in FIG. 1 has been assembled and leveled,
the panels are installed without the use of any tools or fasteners.
The corner panels 33 are set in place first and then the side wall
panels are set in place. Both these panels are installed by
inserting the bottom of the panel slidably into the channel element
37 for a sufficient distance to provide temporary engagement. The
upper flange 74 of the panel is then hooked over the leg 67 of the
top support rails 62 and the panel is then pushed downwardly or
permitted to drop further into the channel element 37 until the
portion 68 engages the sponge neoprene gasket strip 70. After the
sides of the enclosure have been mounted, then the roof wall panels
34 are placed in position by resting the flanges 88 on the sponge
neoprene gasket strip 70 which is provided on the ledge portion 66
of the top support rail. During assembly, the flexible joints
provided by the arrangement of the vinyl gasket 83 will accomodate
to irregularities in the abutment of adjacent panels resulting from
manufacturing defects or dimensional variations, so that an
excellent noise seal is effected.
A lift handle 90 is conveniently provided on each of the side wall
panels 32 for the purpose of quickly and easily obtaining access to
the interior of the enclosure whenever such access is necessary. A
side panel 32 which is two feet wide and seven or eight feet in
height will weigh approximately 50-55 pounds. An adult person can
grasp the lifting handle 90 and easily raise any panel 32
sufficiently to lift its upper flange 74 out of its hooked
engagement with the support leg 67 and then remove the panel from
its engagement with the channel element. After access to the
enclosed piece of machinery or equipment has been obtained and the
necessary repair or maintenance mission has been accomplished, the
lift handle 90 aids in easily returning the panel to position on
the enclosure in the manner previously described. It will be
understood that such lifting handles 90 could also be provided on
one or more of the roof wall panels 34 if the enclosed machinery or
equipment routinely will require access from overhead.
There are occasions when the noise insulation mats 73 may become
damaged or oil-soaked and require replacement. When this occurs,
the particular panel involved is detached from the enclosure and
the insulation mat is removed, either by deforming it sufficiently
so it will slip out of the panel, or by deforming the retainer clip
85 sufficiently to remove it and thereby permit the mat to be
lifted out. A new insulation mat is then installed by placing one
edge of the mat under the lip 80 and inserting a new retainer strip
85.
The form of joint seal that I have described above is the preferred
form. However, other forms of joint seals or joint constructions
could be utilized with an enclosure embodying the features of my
invention. In FIG. 10, I have shown an example of a modified form
of joint seal. In this form, the opposed vertical flanges 91 of the
panels are symmetrically identical and are rebent to provide a
thickened or enlarged portion 92. A resilient T-bar 93 is secured
at appropriate places to the frame 31 and has outwardly directed
spaced spring arms 94 which yieldably accomodate the abutting
portions 92 of the panel flanges and frictionally retain the panels
in connected sealed relationship. A cushioning pad 70 is adhesively
secured to the inner face of the T-bar to reduce noise
transmissions. If desired, the reverse bend portions of the flanges
91 can be further bent convergently, as at 95 to provide seating
surfaces for the flanged edges 96 of a perforated steel back plate
97 which can be used to overlie the insulation mat 73 to protect it
from damage or injury under adverse operating conditions.
In FIG. 11, there is shown a slightly modified form of perforated
steel back plate 98 and the manner in which it can be secured to
the panel structure for the same purpose as was previously recited
with respect to the perforated steel back plate 97. The back plate
98 is shown as having a flange or edge 99 which is parallel to and
offset from the main body of the back plate. This edge is slid
underneath the lip 80 of the vertical panel flange 76. The opposite
edge 99 on the back plate is extended to provide an integral
retainer clip 100 which serves the same function as the retainer
clip 85 previously described and is installed in the same manner
into locking engagement with the flange 77 of the panel.
In FIG. 2 of the drawings, I have shown one of the standard side
wall panels 32 modified to provide a hinged door 35. The details of
this hinged door structure are shown in FIGS. 12, 13 and 13a of the
drawings. As best seen in FIG. 12, the vertical flanges of the
modified door panel 101 are the same as previously described with
reference to the side wall panels 32. The upper flange 74 and the
lower flange 75 of the panel 101 may also be identical to that
previously described with reference to the standard panel 32 and
the mounting thereof in the enclosure would be as previously
described. The body of the panel 101 is formed and recessed to
provide the door jambs 102 and the opening 103. The door 35 itself
is formed in any suitable manner from sheet metal or the like and
has mounted on the interior face thereof an insulation mat 73 and a
protective perforated steel back plate 104. A suitable hinge 105 is
secured to one of the door jambs and to one edge of the door. An
operating and locking handle 106 is provided for opening and
closing movement of the door. The door would then be operated in a
conventional manner and the modified door panel 101 would be
mounted on or detached from the frame 31 in the same manner as
previously described with reference to the standard panels 32.
Under certain conditions, it is not permissible for the door 35 to
have any sort of threshold, as it is necessary that ingress and
egress through the door should not involve any change in elevation
above floor level. Under such circumstances, the channel element 37
which would normally extend below the bottom edge of the door 35
and which would receive and retain the lower flange 75 of the
modified panel, has to be eliminated together with the coextensive
portion of the flange 75 of the panel. However, those portions of
the flange 75 which extend to either side of the door opening are
still retained on the panel and are received in the corresponding
portions of the channel element 37. Inasmuch as this arrangement
destroys the previously described seal between the panel and the
frame and the floor at the bottom of the door opening, I have shown
an alternative sealing arrangement for the door 35 in FIGS. 13 and
13a of the drawing. To maintain a noise abatement seal at the
bottom of the closed door 35 under those circumstances where the
door is required to extend substantially to floor level, I have
provided a spring-loaded hinged plate 107 which is secured to the
interior surface of the door 35 adjacent to the bottom edge thereof
and which is normally urged to the upward phantom line position
shown in FIG. 13. The plate 107 has a sealing gasket 108 affixed
thereto in floor engaging position. The plate 107 may be
substantially as wide as the door opening 103, but the width of the
gasket 108 may be slightly greater so that the ends of the gasket
will abut the door jamb when the door is in its fully closed
position. Alternatively, a projection or lug may be provided on the
door jamb to engage the plate 107 when the door is in its fully
closed position. In either event, when the door is opened, the
spring-loaded plate will be freed from restraint and will swing
from the solid line position shown in FIG. 13 to the phantom line
position, thus permitting the door to be open without any
appreciable wear on the gasket, as would result if the gasket were
permitted to scrape the floor during the door opening. When the
door is closed, the plate remains in its upward, non-floor engaging
position until abutment of the gasket or the plate occurs which
causes the plate assembly to swing downward and return to its solid
line sealing position.
In FIG. 2, I have also shown one of the standard side wall panels
32 modified to provide a service box accessory 36. Such a service
box is utilized to permit cables and pipes to traverse the panel
without diminishing the noise abatement characteristics of the
enclosure. In FIGS. 14, 15 and 16 of the drawings, I have shown
details of the service box arrangement. The service box consists of
an upper half 109 and a lower half 110, each half providing a
container for an equal quantity of individual sponge rubber blocks
111, one of which is shown in perspective in FIG. 16. One face of
each of the blocks is provided with a plurality of closely spaced
cuts or slits 112. The rubber blocks 111 which are placed in the
lower half 110 are so disposed that these slit faces will abut the
corresponding slit faces of the rubber blocks which are in the
upper half 109 of the service box. As many sets or pairs of upper
and lower blocks are used as are necessary for the number of
individual cables or pipes which will extend through the service
box. Appropriate openings are provided in the face of the panel 32
for the passage of the cables and pipes. The lower half 110 of the
service box is then mounted in proper position on the exterior of
the panel 32 by means of the fasteners 113. The pipes and cables
are then laid in place on the rubber blocks of the lower half of
the service box. The upper half 109 and its rubber blocks are then
placed over the lower half and is drawn into abutment therewith by
means of the projecting ears 114 and fasteners 115. The upper half
of the service box can then be secured to the panel 32 by means of
the fasteners 113 extending through the flanges 116 which are
provided on each half of the service box. As the pairs of rubber
blocks are drawn together around the service lines, the slitted
portions are deformed and compressed and displaced to form a tight,
conforming seal between each pair of blocks and the service line
which traverses them. By this arrangement, noise leaks are
minimized without interfering with the connection of service lines
to the machinery or equipment within the enclosure.
When the height of the enclosure exceeds a certain magnitude, the
size of the side wall panels 32 becomes so great as to make the
panels unwieldy and too heavy for simple access removal and
replacement. Such a condition also results in the side panels
having a long unsupported vertical span which is undesirable both
from the standpoint of structural rigidity and the standpoint of
noise abatement. To overcome this problem, there is shown in FIGS.
17 and 18 of the drawings a modified form of structure which is
utilized when the enclosure has to be of an abnormal height. In all
basic respects the panels and the frame structure is identical to
that previously described with reference to FIGS. 1-9 of the
drawings. However, to permit the use of shorter and less cumbersome
side wall panels 32 and corner panels 33, an intermediate
horizontal support rail 117 is affixed to the vertical posts 48 and
54, as by fasteners 118. The upper horizontally extending leg 119
of the rail 117 provides an underlying support or channel elements
37 which are affixed to the leg 119 as by welding or other suitable
means. These channel elements provide the retainer channel for the
upper group of panels 32 and 33. The lower leg of the support rail
117 is formed into an upperly directed hook 120 which serves the
same function as the support leg 67 of the top support rail 62 in
supporting and engaging the upper flange 74 of the lower series of
panels 32 and 33. In other respects, the frame 31 is as previously
described and the panels 32 are mounted on the frame and detached
therefrom in the same manner as previously discussed.
FIGS. 19 through 26 of the drawings represent adaptations of the
principles of my invention, previously described, to wall
partitions of modular arrangement which can be utilized as full or
partial space enclosures in offices and similar commercial
installations, particularly in floor-to-ceiling partitions.
FIG. 19 illustrates a representative floor-to-ceiling office
enclosure assembled from a plurality of panels 32a which, except
for slight modifications, are very similar in structure to the
panels 32 previously described with reference to the noise
abatement enclosure. As best seen in FIG. 20, the panels 32a
include the metal face member or skin 72 having the vertical
flanges 76 and 77 and include insulation mats 73. It will be noted
that the joint seal between the panels utilizes the vinyl gasket 83
to provide a compressible butt joint comparable to that previously
described. A plurality of the panels 32a are utilized and, as
illustrated in FIG. 19, modified panels having special
characteristics can also be utilized for the purpose of providing
special features such as the hinged door 35. For purposes of the
partition or office enclosure, a dual set of panels 32a is
utilized, these panels being spaced horizontally from each other to
provide both an exterior row of panels and an interior row of
panels which give the enclosure a finished appearance interiorly
thereof, which ordinarily is not necessary in connection with the
noise abatement enclosure. A gypsum board filler 121 can be
utilized in the median space between opposed panels 32a if
additional sound proofing is desired.
As indicated in FIGS. 21 and 22, the joint between adjacent panels
can be modified by the insertion of a notched shelf-support member
122 on which shelf-support brackets (not shown) can be secured if
desired to provide for shelving either interiorly or exteriorly of
the enclosure.
As shown in FIG. 23, a cap member 123 which is of general
rectangular tubular construction and is provided with a vinyl
gasket seal at one face thereof, is used at the corner intersection
of the panel 32a to conceal the joint and provide a finished
appearance to the structure. The cap member 123 can also be used to
finish off the end of a partition wall when, for some reason, it
does not terminate in abutment with the fixed building structure
but terminates as a free-standing end. When the end of the
partition wall terminates at and is to be connected to a wall of
the fixed building structure, the arrangement shown in FIG. 24 is
used. This consists of a channel member 124 which is affixed to the
wall 125 of the building structure and telescopically and slidably
engages an opposed vertically extending channel member 126 which is
connected to the end of the partition wall or panel. This
arrangement accomodates to variations in spacing between the end of
the partition wall and the fixed wall, within limits, and also
accomodates to any out of plumb condition of the fixed wall that
may exist.
As shown in FIG. 25, the bottom edge of each panel 32a is extended
to provide a channel-engaging leg 127 so that spaced legs 127 are
slidably and telescopically received in a floor channel member 128
which merely rests upon the floor surface 129 and is provided with
a floor-engaging sponge neoprene gasket strip 70 to isolate the
sound or vibration transmittals between the floor and the
enclosure. The legs 127 are sufficiently long so that adjustments
can be made to accommodate to variations and irregularities in the
floor-to-ceiling height while still maintaining an effective seal
at the floor level. The channel member 128 is of sufficient width
and height to serve as a baseboard compartment for the installation
of electrical wiring and fittings.
A panel support member 130 is secured to the ceiling 131 of the
fixed building structure, using a gasket strip 70 to isolate noise
vibrations. The member 130 is provided with spaced arms 132 which
are rebent as at 133 to provide upwardly directed support ledges
134 for the upper edges of the panels 32a. The back surface of each
panel is stiffened or reinforced by a series of horizontally
extending channel members 135 which are welded or otherwise fixedly
secured to the back face of the skin 72 of the panel. The
insulation mats 73 are disposed intermediate these reinforcing
channels. The previously mentioned downwardly extending spaced legs
127 are extensions of the lowermost reinforcing channel member 135,
whereas the uppermost of these reinforcing members has an upwardly
and inwardly extending formed leg portion 136 which is adapted to
overlie one of the ledges 134 so as to suspend each of the panels
32a from the ceiling support member 130. Thus, the dual set of
panels 32a forming the partition wall is suspended from the ceiling
support member 130 at its upper edge and is nested into the floor
channel member 128 at its lower edge to provide a sealed wall
partition structure which has superior light-proof and sound-proof
characteristics. In order to minimize the direct load which would
otherwise be imposed on the ceiling by the suspended panels, the
support member 130 is utilized primarily to provide a seal, and a
vertical strut 138 engages the member 130 in load-bearing
engagement with the floor to take the panel load off the
ceiling.
FIG. 26 illustrates the joint between the modified door containing
panel 32a and the adjacent panel 32a. It will be noted that the
vertical edges of the door jamb 137 represent the previously
described joint seal arrangement of the wall structure using dual
sets of panels 32a. Accordingly, the door jamb 137 is so formed as
to provide an identical joint structure through that which would
exist between adjacent pairs of panels 32a.
It is to be understood that the forms of my invention herein shown
and described, are to be taken as preferred examples of the same,
and that various changes in the shape, size and arrangement of
parts may be resorted to, without departing from the spirit of my
invention, or the scope of the subjoined claims.
* * * * *