Patent Application
20080236943
This invention relates to interior building materials and methods, and more particularly, to a novel soundproofing system and method.
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.
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.
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.”
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.
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:
Referring now to
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
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.
One embodiment of a soundproofing product or static structure of the present invention designated generally at 30 in
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.
Another embodiment generally designated at 50 in
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.
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.
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.
