U.S. patent number 3,656,576 [Application Number 05/134,157] was granted by the patent office on 1972-04-18 for noise shield panels and method of fabrication.
Invention is credited to Gunter Gubela.
United States Patent |
3,656,576 |
Gubela |
April 18, 1972 |
NOISE SHIELD PANELS AND METHOD OF FABRICATION
Abstract
A hollow, rectangular plastic casing and a sheathed sound
absorbing material batt forming a sound absorbing panel; as a panel
casing noise source facing front wall, an echelon of four forwardly
inclined integral step-like faces, each with three off-set series
of longitudinally spaced outwardly-flanged apertures, and a bottom
straight margin with a single, like aperture series; a casing back
wall with alternating raised and depressed regions; the batt spaced
from the back by fibrous blocks or deeper back depressions; end
closures and opposed vertical flats at the lateral ends of the
front and back walls; and a longitudinal land and complementarily
shaped groove in the top and bottom casing walls, whereby like
panels are insertable with land and groove engagements and with
panel ends engaged between the opposed flanges of respective spaced
H-beam uprights optionally. A panel edge-surrounding impregnated
sealing band, forming a seal concealed in the tongue-and-groove
engagement of adjacent panels. A noise fence comprising spaced
H-beams thus filled with interposed panels and capped by inverted
U-channels. Casing fabrication in one piece by blow-molding from
heated extruded thermoplastic tubular stock; or by vacuum forming,
injection molding, centrifugal or rotational casing as front and
back halves to be partially telescoped and welded or cemented
together.
Inventors: |
Gubela; Gunter (5 Koln Kalk (5
Cologne-Kulk), DT) |
Family
ID: |
11144097 |
Appl.
No.: |
05/134,157 |
Filed: |
April 15, 1971 |
Foreign Application Priority Data
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Nov 19, 1970 [IT] |
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13039 A/70 |
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Current U.S.
Class: |
181/210 |
Current CPC
Class: |
E01F
8/007 (20130101) |
Current International
Class: |
E01F
8/00 (20060101); E04h 017/00 (); B64f 001/26 ();
E04b 001/82 () |
Field of
Search: |
;181/33R,33G,33GA,33GB,33GC,33HE,30 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
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64,423 |
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Jun 1955 |
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FR |
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1,142,698 |
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Feb 1969 |
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GB |
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Primary Examiner: Ward, Jr.; Robert S.
Claims
I claim:
1. A noise shield panel, especially adapted for construction of a
noise shield fence for screening of highways and like noise
sources, comprised of:
a synthetic plastic casing
and, within the casing, a sound-absorbing fibrous material batt;
the front wall of the casing, intended to be disposed toward the
noise source, in substantial part being comprised of several
superposed, forwardly inclined wall elements
successively integrally connected by respective approximately
horizontal wall elements,
resulting in a saw-tooth-like, wall local cross-section;
said inclined wall elements each having a multiplicity of sound
energy admitting apertures therethrough.
2. A noise shield panel as described in claim 1, wherein:
said casing has
an elongated rectangular form in frontal aspect, and roughly
rectangular form in side aspect,
with a thickness dimension small as compared to height and
width;
said batt extending over the major part of the casing height and
width.
3. A noise shield panel as described in claim 1, wherein: the
forwardly inclined elements are inclined from the vertical by an
angle of from about 3.degree. to about 30.degree..
4. A noise shield panel as described in claim 2, wherein: said
panel front wall includes four said inclined wall elements.
5. A noise shield panel as described in claim 3, wherein: said
apertures are surrounded by respective short outward flanges
integral with the inclined wall elements.
6. A noise shield panel as described in claim 1, wherein:
in each of said inclined wall elements,
said apertures are arrayed equi-spaced in rows,
with the apertures of adjacent rows offset from each other.
7. A noise shield panel as described in claim 6, wherein:
the casing front wall further includes
a vertical wall element provided with at least one row of sound
energy admitting apertures therethrough,
said vertical wall element located below the lowermost inclined
wall element, and thereto joined by a further approximately
horizontal element.
8. A noise shield panel as described in claim 2, wherein:
the sound absorbing material is a form-stable glass fiber batt of
rectangular cross section enclosed by a moisture shield, such as a
synthetic plastic film envelope or a spray coating of a bituminous
resin.
9. A noise shield panel as described in claim 2, wherein:
the sound absorbing glass fiber batt has a rectangular cross
section
and is
disposed against inside edges of the saw tooth section region of
the wall,
and spaced from the back wall of the casing,
by spacer blocks of sound absorbing material interposed at both
ends of the casing between the batt and said back wall.
10. A noise shield panel as described in claim 9, wherein:
the said front and back walls, at two opposite end regions of the
panel, have flat marginal external surfaces parallel to each other
over the entire end marginal extent of the panel,
whereby the said end regions are adapted to engage in respective
inter-flange slots of correspondingly spaced H-section beam
uprights.
11. A noise shield panel as described in claim 10, wherein:
for introduction of the sound absorbing batt,
at least one of the two opposite casing end walls is provided as a
flap connected in hinge-like fashion with an adjacent edge of one
of said back and front walls.
12. A noise shield panel as described in claim 2, wherein:
the casing has a back wall with alternating elevations and
depressions running transversely of the casing length.
13. A noise shield panel as described in claim 2, wherein:
said batt has a rectangular cross section;
said back wall is stiffened by a checkerboard-like pattern of
integrally molded square inward depressions,
with at least four of said depressions located near the periphery
of the casing and similarly depressed inward deeper than the
others, and contacting the back of the said batt, thereby to
support it against inside edges of the saw tooth-like section
region of said front wall.
14. A noise shield panel as described in claim 2, wherein:
one edge wall of the casing has a land and
the opposite edge wall parallel thereto has a correspondingly
located and shaped groove,
whereby like panels similarly oriented may be placed edgewise one
upon another with a tongue-and-groove type engagement of lands and
grooves.
15. A noise shield panel as described in claim 2, wherein:
the synthetic plastic casing is comprised of two half-shell
members,
embodying respectively said front and back walls, and respective
peripheral flanges forming side, top and bottom end wall
portions,
the flange of one member telescoped into the flange of the other,
and overlapped portions of said flanges secured as a seam to form
the hollow casing.
16. A noise shield panel as described in claim 15, wherein:
the flanges of the two half-shells are secured as a seam running
around all four narrow sides of the casing;
the overlapped seamed flanges being bonded to one another by
cementing or welding.
17. A noise shield panel as described in claim 15, wherein:
the said half-shells of the casing are vacuum formed, injection
molded, or centrifugally cast.
18. A noise shield panel as described in claim 2, wherein:
a sealing band runs around all four narrow edge walls of the
casing;
said band comprised of a bituminous-impregnated elastic band.
19. A noise shield panel as described in claim 2, wherein:
the synthetic plastic casing is a blow-molded body.
20. A noise shield panel as described in claim 2, wherein:
the forwardly inclined elements are inclined from the vertical by
an angle of from about 3.degree. to about 30.degree. ;
the casing front wall further includes a vertical wall element
located below the lowermost inclined wall element, and thereto
joined by a further approximately horizontal element;
said vertical wall element provided with at least one row of sound
energy admitting apertures therethrough;
said apertures in each of said inclined wall elements are arrayed
equi-spaced in rows,
with apertures of adjacent rows offset from each other; the said
front and back walls, at two opposite end regions of the panel,
have flat marginal external surfaces parallel to each other over
the entire end marginal extent of the panel,
whereby the said end regions are adapted to engage in respective
inter-flange slots of correspondingly spaced H-section beam
uprights;
the sound absorbing material is a form-stable glass fiber batt of
rectangular cross section
disposed against inside edges of the saw tooth section region of
the front wall,
and spaced from the back wall of the casing.
21. A noise shield panel as described in claim 20, wherein:
the sound absorbing glass fiber batt is enclosed by a moisture
shield such as a synthetic plastic film envelope or a spray coating
of bituminous type resin.
22. A noise shield panel as described in claim 20, wherein:
the casing back wall has alternating elevations and depressions
running transversely of the panel length; and
said batt is spaced from the back by spacer blocks of sound
absorbing material interposed at
both ends of the casing between the glass fiber batt and the said
back wall.
23. A noise shield panel as described in claim 20, wherein:
said back wall is stiffened by a checkerboard-like pattern of
integrally molded square inward depressions,
with at least four of said depressions located near the periphery
of the casing and similarly depressed inward deeper than the
others,
and contacting the back of the said fiber batt, thereby to support
it against inside edges of the sawtooth-like section region of said
front wall.
24. A noise shield panel as described in claim 20, wherein:
one edge wall of the casing has a land and
the opposite edge wall parallel thereto has a correspondingly
located and shaped groove,
whereby like panels may be placed similarly oriented edgewise one
upon another with a tongue-and-groove type engagement of lands and
grooves.
25. A noise shield panel as described in claim 2, wherein:
the forwardly inclined elements are inclined from the vertical by
an angle of from about 3.degree. to about 30.degree.;
the casing front wall further includes
a vertical wall element located below the lowermost inclined wall
element, and thereto joined by a further approximately horizontal
element;
said vertical wall element provided with at least one row of sound
energy admitting apertures therethrough;
said apertures in each of said inclined wall elements are arrayed
equi-spaced in rows,
with the apertures of adjacent rows offset from each other; said
apertures are surrounded by respective short collar-like round
outward flanges integral with the wall elements;
the said front and back walls, at two opposite end regions of the
panel, have flat marginal external surfaces parallel to each other
over the entire end marginal extent of the panel,
whereby the said end regions are adapted to engage in respective
inter-flange slots of correspondingly spaced H-section beam
uprights;
the sound absorbing material is a form-stable glass fiber batt of
rectangular cross section
disposed against inside edges of the saw tooth section region of
the front wall,
and spaced from the back wall of the casing.
26. A noise screening fence constructed of noise shield panels as
described in claim 20 and
a plurality of H-beam uprights embedded in the ground at a spacing
from one another corresponding to the length of said panels as
measured between the ends having said flat surfaces;
a plurality of said panels being disposed one upon another in
vertical alignment between respectively adjacent uprights with
opposite panel ends engaged in the inter-flange slots of the
uprights;
and with an inverted channel beam spanning the top ends of adjacent
uprights
forming an upper edge of the noise screening fence.
27. A noise screening fence as described in claim 26, including,
between two adjacent uprights,
a door constructed of the described panels.
28. For fabrication of a noise shield panel as described in claim
19, a method comprising the steps of:
blowing a heated section of thermoplastic synthetic tube in a blow
mold having an internal shape corresponding to the configuration of
the desired finished panel
with the apertures of the front wall blown in a flanged form
initially closed by a cap-like wall across the flange outer
end;
removing the cap-like closures from the flange ends, by sawing or
grinding off, to free the apertures;
and introducing the fibrous batt into the interior of the casing.
Description
Definitions: For convenience of description and brevity in the
claims, the side of a structure or panel intended to face a source
of noise or sound to be screened is herein considered as and termed
the front or forward side or face, and the opposite side, the rear
or back side or face; while the narrow top bottom and end faces or
walls will at times be referred to as "edges" of the panels.
The present invention is concerned with a noise shield panel,
especially useful in the construction of a shielding fence, for
screening of noise sources; and more particularly, such a panel
comprised of a sound absorbing batt enclosed in a plastic casing,
which in its front side is provided with a multiplicity of
acoustical energy admitting openings; to a noise screening
structure embodying the panels; and further to a method for
fabrication of such panels.
Many and various attempts have already been made to eliminate or
abate the noise coming from highways and also at aircraft service
areas at airports, or at engine test stands.
Hitherto these attempts and constructions have not produced
satisfactory results. Particularly there have been proposed the
disposition of concrete blocks or slabs arranged as in a
lattice-like form, but such concrete elements are not only costly
in fabrication, but also unsatisfactory in performance. Also there
are known noise-absorbing materials, such as foamed synthetic
plastics or pumice stone concrete; and walls built of such
materials have already shown relatively good results in their sound
shielding or noise abating effect.
The hereinafter described noise shield or screening panels are
adapted for construction of noise screening or shielding fencing
erected along highways and airports and in shops and work places
for improvement of working conditions, at noisy industrial
facilities and installations, or like noisy places where high
intensity noise generation occurs which it is desirable to absorb
or attenuate.
It is a general object of the present invention to provide a noise
shielding panel useful for construction of a noise screen fence of
any desired length and height, which in its noise absorption effect
is better than comparable prior art panels for this purpose, and
which nonetheless can be easily fabricated.
For the attainment of this object, there is first provided a noise
screening panel structure comprised of a plastic casing enclosing a
batt of sound absorptive fibrous material, such that a noise shield
is easily constructed along a screen or fence line, straight or
curved as desired, and to any necessary practical height, by
erecting a succession of steel H-section beams as uprights at
spacings corresponding to the desired panel lengths, say at about
one meter spacing, and then simply filling in each screen section
defined between the successive uprights with a corresponding
vertically aligned series of such panels inserted from the top and
with ends engaged in the opposed vertical slots provided by the
more or less parallel flanges on respectively adjacent sides of the
beams, and then advantageously capping the top with inverted
channel beams secured to the uprights, preferably with dependent
flanges external of the beams and forming skirts dependent slightly
below the top margins of the uppermost panels. Moreover, the panels
and manner of support are applicable to other uses as in total
enclosures of noise sources.
In the panel itself, the end portions are shaped for reception in
such inter-flange slots; and the top and bottom narrow walls of the
panel have respectively longitudinal groove and broad rib or land
formations of complementary shapes, such that, on insertion of
successive similarily oriented panels in a given fence vertical
section, a tongue-and-groove type engagement is achieved by the
land of one and the groove of the other panel. This engagement
itself is effective both to provide an acoustical labyrinth or seal
as well as some degree of aligning function, or to afford a recess
region concealing contact-sealing strips externally applied on the
respective panels.
Further, the front face wall of the panel is provided over its
major area with a plurality of successively joined, forwardly
inclined, oblique longitudinal faces in an echelon arrangement,
exhibiting a saw tooth vertical cross-section, in which are
provided a multiplicity of sound wave accepting openings presenting
a close extensive arrangement of open areas across the
substantially entire front face for receiving the acoustical energy
of the noise, with uniform absorption throughout the panel
structure. In a preferred form of the invention, each of such
openings is surrounded by a short integral flange or collar-like
formation, resulting in effect in respective tubular openings which
may be round, oval, or polygonal. Such tubular openings are
effective not only in directing the incoming sound relative to the
rest of the panel structure, but also to provide reinforcements for
the wall section at the areas otherwise weakened by the presence of
those openings.
Additionally the flanged character of the opening conduces to the
exclusion of liquid water as from rain or other natural
precipitation. Both this angularly corrugated front face
configuration, and alternating depressions and raised portions in
the back opposed wall are also effective for overall structural
rigidification of the wide panel areas, therefore also increasing
strength against wind loadings which may arise; but further in the
combination with the sound absorbing material batt, they are
effective to attain a higher efficiency for sound or noise
absorption purposes, particularly with a spaced disposition of the
batt from the front and back casing walls as hereinafter
detailed.
Thus the casing serves not merely as a container for the fibrous
sound absorption material partially filling its internal volume,
but also it has a cooperative effect with that material in
achieving higher noise abating efficiency.
Moreover, in the panels as hereinafter disclosed, the back wall,
which is usually exposed to the view of the general public outside
of the "fenced in" noisy region, has such form that it not only
achieves certain mechanical or structural purposes and acoustical
functions, but also in the erected fence results in an appearance
somewhat more akin to a vertical paling fence, or a lattice work,
which has an eye appeal and esthetic effect considerably greater
than would otherwise result with a broad flat panel area.
The overall or general design of the panel structure is such that
it is susceptible in particular embodiments to advantageous low
cost fabrication by various common techniques for manufacturing
plastic articles. Thus by one embodiment, the casing may be
fabricated essentially as one piece, from extruded hollow stock
heated and then blow molded to an appropriate final shape; into
which, with appropriate spacing means present, the batt of sound
absorbing material is then introduced from one or the other end,
with the ends then simply closed by hinged flap-like end wall
structures, also integrally molded or suitably secured thereon
after the molding of the main hollow body section.
By another form which the same basic design may take, the casing
may be produced as two molded half-shells, by any of various known
techniques such as injection molding, vacuum forming, centrifugal
or rotational casting. After emplacement of the fibrous batt, the
two facing half-shells are brought together in telescoped relation
of their margins; and then joined at the marginal overlaps by
welding or by cementing. The latter embodiment in fabrication
procedure has the advantage, that to the extent of the minimum
usable and maximum overlap available in the seams, half-shells
produced from the same molds or tooling may be used to provide a
variety of product panels of different thickness, therefore
different absorption material content. This is advantageous not
only from the view point of tooling costs, but further where the
half-shells are to be made and stores in inventory for subsequent
assembly into finished panels as needed, a minimum inventory, both
in the total number of shells and as well in variety of shells, is
required to meet potential demands for a variety of panel thickness
sizes. In a given manufacturing operation, this then means that
less warehousing or storage space is required as well as a lower
inventory in order to provide quick delivery of order demands which
may be made.
Further a band of somewhat elastic material, impregnated with
bituminous material, may be carried around the larger
circumference, i.e., the top, bottom and side edges, of the panel;
which is a simple expedient for achieving several advantageous
mechanical and acoustical sealing functions as hereinafter
appearing.
A further object of the present invention is to provide a noise
screen or sound screen panel of a type comprising a plastic housing
having a front wall perforated for sound or noise energy acceptance
and containing a sound absorbing fibrous material and having
improved absorption efficiency.
Another object is to provide a noise shield panel which is adapted
to fabrication in a low cost and a simple manner by common plastic
fabrication techniques.
Another object is the provision of a noise shield panel of improved
form capable of erection in and support in a relatively simple
sound screening fence structure.
A still further object is the provision of a noise shield panel
having improved mechanical and physical characteristics to
withstand outdoor weathering environments.
Another object is to provide an overall noise screen fence which is
simple, of relatively low cost and flexible in installation.
Another object is the provision of a simple inexpensive method of
fabricating the panels. Other objects and advantages will appear
from the following description and the drawings wherein:
FIG. 1 is a perspective view of a portion of a noise screening
fence embodying the present invention;
FIG. 2 is an enlarged fragmentary perspective view in which three
panels of a section of the fence appear;
FIG. 3 is still further enlarged and perspective view of a panel of
the invention showing the front and top sides and also a vertical
section taken at the line 3--3 in FIG. 4;
FIG. 4 is a perspective fragmentary view showing the back and one
end of the panel of FIG. 3;
FIG. 5 is a vertical transverse section through a panel of modified
structures, the section taken as indicated by the line 5--5 on FIG.
6; and
FIG. 6 is a fragmentary rear view of the panel of FIG. 5, wherein a
back pattern is represented rather schematically.
In FIG. 1 is shown, in more or less generalized form, a noise
screen fence embodying the present invention comprised of steel
uprights 10, so-called H- or I-beam sections either driven into, or
embedded in appropriate concrete bases or anchoring footings in the
ground at spaced locations along the screen or fence line; the
space between successive uprights being filled from above by a
vertical aligned set or series of superimposed like generally
rectangular sound absorbing panels 11 successively received with
opposite ends slid into the effective vertical slots 15 provided by
the opposed parallel flange halves on respective sides of the webs
of the uprights, and a protecting and stiffening capping 12 of
inverted U- or trough-shaped steel channels secured on or over the
tops of the uprights.
The spacing of the uprights is slightly greater than the panel
length to allow easy insertion, despite slight non-parallelism.
Each panel, for example, may be on the order of 1 m long and 30 cm
high.
With a lintel provided by say a channel section 14 disposed with
flanges upward between two uprights, a door 13 is provided by
hinging on one upright a group of panels similarly supported in a
frame of channel irons. If desired, an upwardly facing channel may
be secured between uprights at the bottom of each fence section.
The structure may follow a curved fence or screen line by rotating
the uprights successively slightly from web parallelism up to the
ability of the flange halves (or "slots") of the successive rotated
uprights to accept the panel ends.
The enlarged fragmentary view of FIG. 2 shows more clearly a
portion of a fence section delimited by two successive uprights 10,
with three of the panels 11 having their end portions engaged in
the respective vertical opposed slots 15 of the uprights; a pair of
which slots for adjacent screen sections are afforded back-to-back
on each H-shaped upright. The top edge of the panel, by a central
longitudinal ridge or land 16, is engaged with a correspondingly
shaped or mating groove 17 in the bottom of the like panel
thereabove. The positions of the land and groove obviously could be
reversed in the casing component of the panel.
FIGS. 3 and 4 show details of a panel 11 of this invention as
comprising a hollow plastic shell or casing including a front side
or wall with a corrugated or echelon-shaped portion above a narrow
vertical bottom margin face 20, providing a plurality, here four,
of narrow longitudinal wall elements or faces 21, forwardly
inclined 3.degree. to 30.degree. from the vertical and connected to
each other and to the bottom face by more or less horizontal wall
elements or joining portions 22. In the vertical bottom face there
is a horizontal single series (through a plurality could be used)
of longitudinally spaced, like round apertures 23, each having a
surrounding horizontally outwardly extending short collar or
tubular flange; while in each inclined face there are three like
horizontal series 24, 25, 26 of similar apertures with the
apertures of the series successively offset laterally. As appears
in FIG. 3, a local saw-toothed vertical section (i.e., in the
region in from the ends) results in the front wall, with internal
back edges or ridges 22a running longitudinally of the panel for
the width of the echelon formation.
In the back wall of the casing, depressed areas 27, extending
vertically over the panel back wall height, define therebetween in
effect alternating broad lands or raised portions 28; and the front
and back walls in the embodiment of FIGS. 3 and 4 are integrally
connected by the top and bottom side walls 29, 30, which have
formed therein the correspondingly placed complementary shaped
flat-topped land 16 and flat-bottomed groove 17, here extending
over the full panel length. The sides of the land and groove are
similarly inclined, tapered, so that when one panel is set upon the
other, the interfitting tongue-and-groove type engagement assures
in effect an acoustical seal as well an aligning mechanical
engagement of the panels in what may be loosely termed a coplanar
relation.
Also at the ends, from top to bottom of the panel, the front and
back walls have parallel vertical outside surfaces as inset flats
31, 32 respectively; the horizontal widths of flats are about equal
to the depths of the inter-flange slots 15 of the uprights, with
the panel thickness as measured between these flat outer surfaces
31, 32, corresponding to the slot width (i.e. the nominal flange
spacing).
A form-stable rectangular batt of fibrous sound-absorbing material
such as glass or mineral fiber, either encased in a protecting
envelope such as a loose plastic film bag 35 or coated with a
spray-on synthetic resin, extends horizontally over substantially
the length of the panel and vertically from the interior land
resulting at the bottom groove 17 substantially to the inside
bottom of the top wall 29; thus filling only about the front of the
casing interior. The looseness of such a thin bag itself promotes
sound absorption. The sack 35 may be polyethylene or other suitable
thin film; and may be tubular film end-sealed after introduction of
the batt.
To the extent that the glass fiber batt 34 is not very hygroscopic,
it is not absolutely necessary that it be completely enveloped by a
film covering, but for helping to maintain the batt form, it is yet
advantageously spray-coated with a suitable synthetic resin as
described, to a thickness which does not interfere with sound
absorption.
A batt 34 of glass fiber is already generally protected against
absorption of moisture; for the fibers themselves are also coated
with a phenolic resin. Thus the panel filling is quite difficulty
destroyed by fire because the synthetic resin coating becomes
ineffective only after reaching a temperature of 380.degree. C.
By vertical spacer blocks 36 interposed near the ends and at one or
more intermediate locations and likewise of fibrous sound-absorbing
material, the batt 34 is held spaced from the back wall and against
the inward longitudinal edges 22a formed on the inside of the
casing front wall; these blocks 36 being either gripped between the
batt 34 and the back wall or cemented to the latter.
The opposite end faces or edges of the panel are closed by housing
end walls such as 38 (see FIG. 4), corresponding in outline to the
vertical transverse cross section at the end portions of the casing
and each preferably formed or molded as a flap structure integrally
hinged along one vertical edge to the vertical end edge of the
front wall. These flaps then are automatically held closed by the
uprights after insertion of the panels.
The casing may be made of a synthetic plastic such as polyethylene,
especially low density polyethylene. In the form of FIGS. 3 and 4,
preferably it is fabricated as a blow-molded structure or element
by starting with a piece of thermoplastic tubular stock heated and
received in an approprately shaped blowing mold.
In the panel structure modification of FIGS. 5 and 6, wherein
corresponding elements or structural features are designated by
similar reference numerals, the general structure is similar to
that already described, except that the casing is made in two
pieces; and that the back wall, as schematically indicated in FIG.
6, has a checker board like pattern of vertically and horizontally
spaced and staggered rows and columns of like square-shaped
elevations 40 and box-like depressions, 41, from the flat bottom of
which latter the back of the batt 34 is spaced, here by certain
ones 41a, of the square depressions projecting further inwardly to
engage the batt rather than by use of the spacer blocks previously
described for FIGS. 3 and 4. At least four of the deeper box-like
depressions 41a are provided in symmetrical locations near the
panel periphery, that is, near the corners, though others may be
additionally used. This pattern, as in the previously described
rear wall and sawtooth corrugated front wall configuration provides
not only spacings relative to the batt for purposes to be
described, but also structural stiffening of the walls, hence of
the panel as a whole.
Here the casing is made in the front half and rear half-shells 42,
43 with flange-like portions telescoped into overlapped relations
in the regions of the panel top wall land 16, the the bottom wall
groove 17, and the corresponding vertical regions on the lateral
end walls; the two halves being welded or cemented together in a
peripheral seam or joint 44 running continuously around the top,
sides, and bottom.
The continuous peripheral flange 43a formed by the top, the bottom
and the end wall portions of the back half-shell at its open side,
is shown telescopingly received within the corresponding flange 42a
at the open back of the front half-shell, in the fashion of a
paper-board box and its cover, but of course this relation may be
reversed. In either case, the possible extent of the overlap
permits of a certain selection or variation of product panel
thickness obtainable from a given set of molds and from a
previously manufactured stock of such half-shells; so that panel
products with different thicknesses of the batt 34 may be easily
produced; different upright sections as required being used in the
fence.
The back shape of FIG. 5-6 may be utilized in a one-piece panel
casing as described for FIGS. 3-4; and conversely the back wall
form of FIGS. 3-4 may be used in a two-piece casing described for
FIGS. 5-6 with, of course, the spacing blocks 36 then used.
In FIGS. 5-6, the various apertures in the noise-source-facing
front wall are shown as simple unflanged apertures as at 23a and
26a. These apertures of either panel form may be round, elongated
or polygonal, with or without flanges of corresponding shape; and
the direction of the flange axes may range from horizontal to
perpendicular to the inclined faces. The flanges apertures, 23, 24,
25, 26, may be molded each with an initial cap thereacross, as by
blow molding of the casing; and thereafter these caps may be
sheared, sawed or ground off of the short tubes in effect present
at each aperture. By this design, it is practically impossible for
rain or other natural precipitation to pass through the
openings.
FIGS. 5-6 show a feature useable also in the FIG. 3 form, namely,
externally on the peripheral joint region an elastic sealing band
45 comprised of say a band of Moltoprene or other suitable elastic
material impregnated with a bituminous substance contributing to
noise sealing; the band on the land of an inferior panel and in the
groove of a superior panel then sealing to each other as well as
adhering to their respective panels in a location concealed by the
nesting of these formations.
These seal bands, adherent to the circumference of the individual
panels and coming into contact in the concealed recess region
between the lands and grooves of super-imposed panels, effect a
contact seal in the concealed location. This not only helps hold
the panels to one another an anti-rattling expedent and effects an
acoustical seal, but also at the ends to some degree helps achieve
a better acoustical seal between the panels and the webs of the
upright-forming H-beams in a noise screen fence in which such
panels finds advantageous use.
Further those bands maintain that acoustical seal as well as a
mechanical seal, despite a fair degree of thermal expansion and
contraction of the panels in the assembled fence. This obviously
contributes to the overall efficiency and performance of such a
fence or screen as a whole.
It is observed that the spacing and offset of the openings is such
as to provide a "dense field" of such openings, and a uniform sound
absorption over the exposed front face of the panel.
Moreover, the flanging of the openings is effective to confer
strength on the flat areas perforated by such openings, at the very
regions where the apertures as such weaken the overall rigidifying
effect of the general front and back configurations adverted to,
strengthening the panel as a whole against the force of wind
loadings which may occur.
With these panel forms, sound waves, propagating from a noise
source horizontally or obliquely upward to a panel, can penetrate
well into these apertures or tubes present in such multiplicity in
the front panel wall and thus reach the panel interior.
The oblique faces 21, especially with the described tubular form of
the openings, in effect bend the sound waves to enter the panel
interior at an angle; and this itself causes some dissipation of
sound energy, so that there is not quite so much to be interiorly
absorbed and converted into heat.
The sound enters through the openings 23, 24, 25, 26 into the
hollow panel where it is partially absorbed with about 50 percent
reduction in noise level on initially encountering and passing
through the sound absorbing material batt 34. The part penetrating
the batt to reach the hollow space between the batt and the back
wall is in great part reflected from the inner back wall surface
back again to the batt where it is further absorbed, so that
finally little is returned to the inner side of the front wall.
Hence, entirely apart from a still further reflection from the
front wall back to the batt, any interiorly reflecting sound
reaching the front wall and passing back out through the
above-described flanged openings is extremely attenuated and is no
longer disturbing.
The irregularity of the internal back wall surface, i.e., the
non-coplanar character of its various areas, results in irregular
or diffuse reflection, aiding absorption.
The casing thus serves not only as a container for the fibrous
sound absorbent material, but cooperates with the latter in a
combination attaining a higher sound absorbing efficiency.
Obviously both panel forms have respective advantages in ease of
fabrication of the housing as well as in completion of the final
assembly.
It may be noted that, apart from the functional features of the
patterning of the back wall, its vertical grooving in the panel
form of FIGS. 3-4 confers on the noise screen a fence-like aspect;
and also the back pattern of FIGS. 5-6 produces in the noise screen
a rather interesting appearance as contrasted to what would result
from the use of plain flat-backed panels.
The following example is explanatory of the performance of such
noise screen erected along the margin of a freeway.
In front of the screen, the sound level of the noise from passenger
automobiles was found to be 91 to 94 decibels, dB (A) as measured
with a sound meter in accordance with DIN 45633, with evaluation or
calibration curve A in accordance with this standard. Such a
measurement may be used as an approximate measure for loudness and
oppressiveness of noise. At a point seven meters behind the screen,
the noise level was measured at only 63 dB (A); at 20 m distance
from the screen at 62 dB (A). Thus the difference in the sound
level at 20 m behind the screen amounted to a drop of considerably
more than 10 dB (A). But each 10 dB (A) more or less in sound
intensity means a doubling or halving of the perceived loudness.
Since by a screen of the invention, the noise level was attenuated
by more than 10 dB (A), this represented a reduction by more than
half in the noise perception.
A sound or noise screen in accordance with the invention is a
practical combination of steel, synthetic plastic elements and
sound absorbing material.
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