WO2013049895A1 - Structure de panneaux acoustiques - Google Patents
Structure de panneaux acoustiques Download PDFInfo
- Publication number
- WO2013049895A1 WO2013049895A1 PCT/AU2012/001213 AU2012001213W WO2013049895A1 WO 2013049895 A1 WO2013049895 A1 WO 2013049895A1 AU 2012001213 W AU2012001213 W AU 2012001213W WO 2013049895 A1 WO2013049895 A1 WO 2013049895A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- foam
- iayer
- face
- layer
- recesses
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Ceased
Links
Classifications
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/62—Insulation or other protection; Elements or use of specified material therefor
- E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
- E04B1/82—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to sound only
- E04B1/84—Sound-absorbing elements
- E04B1/86—Sound-absorbing elements slab-shaped
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
- E04C2/26—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
- E04C2/284—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating
- E04C2/296—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating composed of insulating material and non-metallic or unspecified sheet-material
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/62—Insulation or other protection; Elements or use of specified material therefor
- E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
- E04B1/82—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to sound only
- E04B1/84—Sound-absorbing elements
- E04B2001/8457—Solid slabs or blocks
- E04B2001/8461—Solid slabs or blocks layered
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/62—Insulation or other protection; Elements or use of specified material therefor
- E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
- E04B1/82—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to sound only
- E04B1/84—Sound-absorbing elements
- E04B2001/8457—Solid slabs or blocks
- E04B2001/8476—Solid slabs or blocks with acoustical cavities, with or without acoustical filling
Definitions
- the present invention relates to acoustic panel structures, particularly for use in building structures, but also of more general application.
- the initial thermal insulating material was typically expanded polystyrene foam or some form of rigid polyurethane. These insulating materials are light weight and very stiff structurally.
- the foam layer provides good thermal insulation.
- the present invention provides a composite panel in which a set of recesses is provided within the foam layer, so that the acoustic attenuation of the panel is increased, particularly at lower frequencies.
- the present invention provides a composite panel comprising a first face layer, a foam layer, and a second face layer, wherein the foam layer includes a set of recesses extending from the first face layer inwardly towards the second face layer, but only extending part of the distance through the foam layer, the foam layer including a second set of recesses extending from the second face layer inwardly towards the first face layer, wherein the first and second sets of recesses interleave each other, and wherein the effect of the recesses is to increase the attenuation of the panel for at least relatively low frequency sounds.
- the present invention provides, in the construction of a composite panel, formed from at least a first face layer, a second face layer, and a foam layer between the first and second face layer, the use of a foam layer which includes multiple recesses extending from the first face layer within but not extending fully through the foam layer.
- the present invention provides A method of constructing a composite panel, including at least the steps of providing a first and second face layer, providing a foam layer which includes multiple recesses extending operatively from the first face layer within but not extending fully through the foam layer, and adhering the foam layer between the first and second face layers, so as to form a composite panel.
- the present invention provides a composite panel comprising a first face layer, a foam layer, and a second face layer, wherein the foam layer includes a set of recesses extending from the first face layer inwardly towards the second face layer, but only extending part of the distance through the foam layer, and wherein the effect of the recesses is to increase the attenuation of the panel for at least relatively low frequency sounds.
- An acoustic insulating material ideally should be dense and have damped elasticity.
- the insulating cores used in prior art systems were light and stiff, the exact opposite to the ideal requirement for acoustic attenuation.
- the cell structure within such rigid foams is believed to provide a series of light rigid membranes, which resonate very efficiently with low frequency sounds.
- the inventors determined that in order to advance the acoustic performance, it was important to improve the flexural rigidity of the centre core. The provision of suitable grooves or similar recesses in the foam layer has been demonstrated to improve the acoustic performance of the panels.
- Figure 1 is a graph showing sound attenuation by a rigid foam core
- Figure 2 is a graph showing a comparison between sound attenuation by rockwool and rigid foam
- Figure 3A is a graph showing sound attenuation for a panel without recesses
- Figure 3A is a graph showing sound attenuation for a similar panel with recesses
- Figure 4 is a cross sectional view of one profile
- Figure 5 is a cross sectional view of a second profile
- Figure 6 is a cross sectional view of a third profile
- Figure 7 is a cross sectional view of a fourth profile
- Figure 8 is a cross sectional view of a fifth profile
- Figure 9 is a is a cross sectional view of a sixth profile
- Figure 10 is a is a cross sectional view of a seventh profile
- Figure 1 1 is a is a cross sectional view of a eighth profile
- Figure 12 is a is a cross sectional view of a ninth profile
- Figure 13 is a is a cross sectional view of a tenth profile
- Figure 14 is an eleventh profile.
- the present invention will be described with reference to particular illustrative examples. It will be appreciated that the examples are intended to be illustrative, and not limitative of the invention. It will be further understood that the present invention is capable of implementation in relation to a wide range of materials and applications, beyond those described in detail below. It is applicable to a wide range of foam materials, and can be implemented in many different ways, as will be explained further below. In general terms, the implementations described relate to a simple sandwich panel construction, in which a foam material is between two relatively rigid outer membranes or sheets.
- the foam material may be of any suitable material, and whilst the invention will be described mainly in the context of expanded polystyrene, the structures described may be used for expanded foam materials of any suitable type, for example expanded polystyrene, extruded polystyrene, polyurethane, phenolic foam, bio-polymer foams, PIR (polyisocyanurates), composites, bio-composites or other polymers.
- the invention has particular advantages for light, rigid foams.
- the membrane, substrate or sheeting may be formed of any suitable material, being suitable for the intended application. It may be for example paper faced gypsum sheeting, magnesium cement sheeting, fibrous cement, cement based products, wood, plywood, metal (including corrugated roofing), plastics and other materials. Depending upon the application, different materials, and/or different thicknesses, may be used for the two faces of the panel. Whilst in general the panels will have planar faces, in suitable applications textured or contoured material, for example corrugated metal or a suitable decorative facing, may be used.
- the present invention could be implemented within a composite, multilayer panel, with additional layers, coatings and functions beyond those described.
- the present invention is based upon an improved understanding of the deficiencies of relatively rigid foam materials, such as polystyrene, in acoustic applications.
- relatively rigid foam materials such as polystyrene
- the lightweight, rigid structure of an expanded polystyrene foam acts as a very effective resonator for relatively low frequency sounds, for example falling between 200 and 1200 Hz.
- the foam sections of implementations of the present invention are designed so as to reduce the ability for sound to propagate directly along the cell boundaries within the foam structure, by providing recesses within the foam structure. Additionally, such recesses act to reduce the rigidity of the foam structure. In preferred forms, as will be explained further below, the recesses alter the mechanical structure of the foam, so that it is less rigid, and in some cases has hinge like structures within the foam. Further, the removal of some material is believed to act to reduce the rigidity of the foam structure as a whole, which is turn acts to reduce the efficiency of sound transport within the foam. As a consequence, the attenuation of sound across the foam, and hence across the panels as a whole, is greatly improved, particularly in the low frequency portion of the sound signals.
- Figure 1 shows vibration transmission through a collection of rigid foam cores. The results shown are an average, provided to assist in understanding. It can be seen that there is no vibration insulation occurring until about the 1250 Hz 1/3 octave band frequency, from then on into the higher frequencies there is a steady increase. The foam core actually amplifies the vibration at the 315 Hz 1/3 octave band frequency. Different rigid insulation samples exhibited amplification at 250 to 500 Hz 1/3 octave bands.
- Figure 2 compares the averaged results for the rigid foam cores to the insulation that can be achieved by a glasswool insulation batt of approximately 15 kg per cubic metre density. In the lower frequencies (that is below 500 Hz) the more flexible glasswool insulation is 20 to 30db superior to the rigid polystyrene cores. In the higher frequencies (that is, above 1000Hz) the improvement is typically 26dB. Glasswool is not rigid and exhibits a high degree of flexibility.
- Figure 3A is a graph illustrating the outcomes of an acoustic test conducted using a panel with 12mm INEX board (a magnesium cement board available commercially from the applicant) and a solid 126 mm thick polystyrene layer. The test was designed to determine the airborne sound transmission loss of the panel without any sealing of the joints. This provided an Rw value of 34, with a frequency specific attenuation as shown in figure 3A.
- INEX board a magnesium cement board available commercially from the applicant
- Figure 3B is a similar graph to figure 3A.
- the panel was 12mm
- the present invention may be implemented using a wide variety of different approaches to removing material and thereby altering the mechanical structure of the foam material.
- the foam material includes a geometric pattern of grooves or cut outs of the foam material. Channels were trialled on one side and also both sides of the styrene foam central core. The results of these systems gave some degree of improvement, but it was desired to provide a greater extent of improvement. The decision was made to use a system of overlapping slits or recesses as a means of improving the flexural rigidity.
- the graphs indicate that the acoustic performance of some existing systems may be significantly improved by using such modified foam cores, which is a very significant improvement. This opens up new areas of use of these composite panels in the construction of buildings.
- Insulated roof panels have also suffered the problems of the 'polystyrene signature' not only in terms of airborne sound transmission, but also relating to the transmission of noise from rain on the roof.
- Airborne sound insulation for a roof structure is important where that building may be under the flight path of a major city airport.
- the generation of rain noise on a metal roof deck is a problem that affects theatres, and concert venues, classrooms, offices and even homes. This is a limitation in the use of conventional composite panels for roofing, which the implementations of the present invention are able to significantly improve.
- slits bridges the acoustic performance between the rigid core and a flexible glasswool core.
- Different methods of improving the flexibility of the rigid insulation core may be used.
- the optimum shape, spacing, depth, and overlap may vary for different applications and materials, and the suitability for particular systems and applications can be optimised by comparative attenuation testing.
- the present invention encompasses a manufactured product, which is provided for use in a finished form, materials which are trimmed, shaped or finished on site, and structures where the composite is formed on site, by applying the foam material to a substrate and then finishing with another layer.
- the panels may include edging material, flanges or rails to facilitate fixing or joining, and other such features are as required in the particular application, or which assist in the practical use of of the panels. It is the layered construction with which the present invention is concerned, and other features may be added or varied as required.
- Figures 4 to 14 illustrate possible profiles, incorporating shaped recesses or grooves extending through both faces of a generally planar sheet of foam material.
- sheet material 1 1 , 12 are provided, with a core of a foam material, for example expanded polystyrene.
- a foam material for example expanded polystyrene.
- the sheet material is a paper faced gypsum material, and that the thicknesses or each face are the same.
- the thicknesses may be different, a wide variety of sheet materials may be used, and that indeed the sheet material may be different on each side if desired.
- the foam core 14 of the composite panel 10 is illustrated having a thickness, labelled as 13, which for present purposes we will call X.
- the value of X will depend upon the intended application, for example, a floor panel is likely to be thinner than a wall panel.
- Sets of grooves 20, 21 extend through the foam layer. For the purposes of simplicity, only one groove in each face is labelled, although it will be understood that all grooves extending from that side are referred to collectively.
- Grooves 20, 21 extend for a considerable depth into the surface of the foam core 14. It is preferred that their depths are such that they overlap - that it, that both extend so that their depths are co-extensive within the foam. It is preferred that their depths are more or less the same, however, implementations with different depths are possible. It is preferred that there is an overlap between the grooves on opposite faces, more preferably in the range of about 20 to about 85% of the thickness of the foam, most preferably about one third of the thickness of the foam core. In a most preferred form, each groove has a depth of about 2/3 of the thickness of the core.
- the width and spacing may be optimised in a particular application, however, a groove width of about 3.0 mm, and centre spacing of 33 mm, have been found effective.
- the size and depth of the slits represents a balance between acoustic performance and structural capability. Acoustically, the deeper and wider the slits, and the more closely spaced, the better the attenuation. However, as more material is removed, the structural capacity of the foam and hence the overall composite tends to be reduced.
- cut outs in the styrene material operates to improve the flexibility of the polystyrene core.
- the optimum shape, spacing, depth, and overlap may vary for different applications and materials, and the suitability for particular systems and applications can be optimised by comparative attenuation testing. It will be appreciated that care needs to be taken to understand the required mechanical properties of the finished composite panel when designing or selecting the modified foam profile.
- the removal of material will be expected to reduce the rigidity of the panel, whether this is significant in particular cases needs to be taken into account.
- the shape and configuration of the removed material may also have an impact on the structural characteristics of the overall composite panel. The more material which is removed, in principle, the higher degree of loss of rigidity in the foam and hence the higher the loss of rigidity in the overall composite panel would be expected. Appropriate shaping and structuring can optimise the mechanical performance of the modified foam structure.
- the exact shape and geometry are, to an extent, limited by the practicalities of manufacture.
- the grooves would generally be applied using a hot wire approach, as is well known in the art. This provides limits to how narrow and how sharp the grooves can be. It is possible that a moulding approach may be possible. It is envisaged that sheets or tiles of grooved foam would be manufactured, and then secured between the sheet material using adhesives or other known approaches.
- the foam material is in one implementation formed of expanded polystyrene (EPS).
- EPS comes in a range of class grades relating to the material's average density. The selection of appropriate class of grade for the purpose of the panel construction can vary depending upon the environmental factors and standard requirements for the location in which the panel is to be erected. Ideally, the higher density class grades should be employed, i.e. having an average density of 19-28 kg/m 3 . Boards formed of EPS can be sourced from Poly-Tek Australia Pty Ltd. An ideal thickness of the EPS material for attenuation applications has been found to be approximately 126mm, providing an overall panel thickness of 150mm for insertion into a standard 180UB column.
- the polystyrene and board layers may be joined by an adhesive fit for purpose and suitable for long term durability of the panel.
- Normal construction approaches for composite panels may be used.
- panels are formed by applying an adhesive between the MgO board and the polystyrene, so as to adhere the polystyrene between the sheet materials.
- suitable adhesive is dependent upon the styrene material and the sheet material, and the appropriate manufacturer should be consulted to ensure that the adhesive will be suitable. This is a factor of not only the materials, but the intended application and environmental conditions.
- the adhesive cover the entire face of the core material, to ensure complete bonding to the sheet material.
- pressure should be applied using a suitable clamp or other system, in accordance with the adhesive manufacturer's instructions, to ensure that a good bond is achieved.
- the adhesive may be applied via a roller or the like, manually or using an automated system.
- polyurethane adhesives have proved suitable, as they provide effective wetting of the surfaces, interact well with the substrate, and provide effective adhesion.
- One suitable adhesive is Daltobond YG10004, available commercially from Huntsman Polyurethanes Australia Pty Ltd.
- the adhesive cover the entire face of the core material, to ensure complete bonding to the sheet material.
- pressure should be applied using a suitable clamp or other system, in accordance with the adhesive manufacturer's instructions, to ensure that a good bond is achieved.
- the adhesive may be applied via a roller or the like, manually or using an automated system.
- Figure 5 illustrates another profile, with grooves 22, 23 being of a similar rectangular profile, but narrower in width.
- Figure 6 illustrates another profile, with triangular cut-outs from each face, offset. This arrangement provides a clear hinge like form 26 between the grooves 24, 25 in each face, improving the flexural rigidity of the foam.
- Figure 7 is a version with grooves 27, 28 having a trapezoidal profile, in this case with only a small overlap, but still with a hinge like structure 29 created.
- Figure 8 has triangular grooves 30, 31 , which do no overlap. A more pronounced version is shown with the grooves 34, 35 in figure 10.
- Figure 9 shows grooves 32, 33 which are trapezoidal in form and do not overlap, while figure 10 has grooves 36, 37 which are more shallow again. It is not essential that the grooves be perpendicular to the faces 1 1 , 12.
- Figure 12 illustrates an implementation with angled grooves 40, 41 in each surface, which are still overlapped. It can be seen that there is no direct path through the foam from one face to the other in this implementation.
- Figure 13 illustrates a similar implementation, with grooves 42, 43 being narrower in width.
- Figure 14 illustrates in detail one implementation, which was used for the tests in figure 3B.
- the MgO sheets 13, 15 are used, and the polystyrene layer 30 includes large cut out triangular portions 31 , 32 from each face.
- the grooves in one face may have different depths to those in the other. They may have different shapes, or even mix shapes within each face. It is possible to implement an arrangement with an array of recesses or indentations which are nor linear but form an array within each surface. Similarly, the grooves could be curved. The efficacy of each selected geometry should be subjected to attenuation tests prior to adoption for practical use.
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- Engineering & Computer Science (AREA)
- Architecture (AREA)
- Physics & Mathematics (AREA)
- Acoustics & Sound (AREA)
- Civil Engineering (AREA)
- Structural Engineering (AREA)
- Electromagnetism (AREA)
- Laminated Bodies (AREA)
- Building Environments (AREA)
Abstract
L'invention concerne un panneau acoustique, en particulier à des fins d'utilisation en bord de route. Le panneau est constitué d'une plaque d'oxyde de magnésium de chaque côté, avec un panneau de polystyrène entre celles-ci. Dans un mode de réalisation préféré, le polystyrène comprend des évidements découpés permettant d'améliorer l'affaiblissement acoustique basse fréquence.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| AU2011904120 | 2011-10-06 | ||
| AU2011904120A AU2011904120A0 (en) | 2011-10-06 | Acoustic Panel Structures |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| WO2013049895A1 true WO2013049895A1 (fr) | 2013-04-11 |
Family
ID=48043128
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| PCT/AU2012/001213 Ceased WO2013049895A1 (fr) | 2011-10-06 | 2012-10-08 | Structure de panneaux acoustiques |
Country Status (1)
| Country | Link |
|---|---|
| WO (1) | WO2013049895A1 (fr) |
Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO2015120502A1 (fr) * | 2014-02-12 | 2015-08-20 | Arkistruct Ltd. | Système de construction de panneaux préfabriqués |
| CN110056096A (zh) * | 2019-04-03 | 2019-07-26 | 宿州云宏建设安装有限公司 | 一种蜂窝式不锈钢隔音板 |
| US20220010549A1 (en) * | 2020-07-09 | 2022-01-13 | James G. Thompson | Noise Barriers and Methods of Their Manufacture |
Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| DE2231387A1 (de) * | 1972-06-27 | 1974-01-10 | Alex Walser | Mehrschaliger innenwandaufbau mit schalldaemmung |
| EP0304352B1 (fr) * | 1987-07-20 | 1992-06-03 | La Rhenane S.A. | Panneau isolant à faible module d'élasticité et procédé de doublage utilisant un tel panneau |
| EP0965701A1 (fr) * | 1998-06-19 | 1999-12-22 | Dow Deutschland Inc. | Panneau d' isolation acoustique |
| US6007890A (en) * | 1993-11-19 | 1999-12-28 | The Dow Chemical Company | Acoustic insulating panels or elements |
-
2012
- 2012-10-08 WO PCT/AU2012/001213 patent/WO2013049895A1/fr not_active Ceased
Patent Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| DE2231387A1 (de) * | 1972-06-27 | 1974-01-10 | Alex Walser | Mehrschaliger innenwandaufbau mit schalldaemmung |
| EP0304352B1 (fr) * | 1987-07-20 | 1992-06-03 | La Rhenane S.A. | Panneau isolant à faible module d'élasticité et procédé de doublage utilisant un tel panneau |
| US6007890A (en) * | 1993-11-19 | 1999-12-28 | The Dow Chemical Company | Acoustic insulating panels or elements |
| EP0965701A1 (fr) * | 1998-06-19 | 1999-12-22 | Dow Deutschland Inc. | Panneau d' isolation acoustique |
Cited By (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO2015120502A1 (fr) * | 2014-02-12 | 2015-08-20 | Arkistruct Ltd. | Système de construction de panneaux préfabriqués |
| AU2014383001A2 (en) * | 2014-02-12 | 2019-02-28 | Arkistruct Ltd. | A prefabricated panel building system |
| CN110056096A (zh) * | 2019-04-03 | 2019-07-26 | 宿州云宏建设安装有限公司 | 一种蜂窝式不锈钢隔音板 |
| US20220010549A1 (en) * | 2020-07-09 | 2022-01-13 | James G. Thompson | Noise Barriers and Methods of Their Manufacture |
| US12442182B2 (en) * | 2020-07-09 | 2025-10-14 | James G. Thompson | Noise barriers and methods of their manufacture |
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