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(11) | EP 1 662 060 A2 |
| (12) | EUROPEAN PATENT APPLICATION |
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| (54) | A soundproofing block |
| (57) A soundproofing block (4) for building comprising two side units (8) extending along
a prevailing direction (X) and facing one another so as to be superimposed relative
to a cross direction (Y). The block (4) further comprises a central unit (12), interposed
between the side units (8), staggered relative to the side units (8) so as to exhibit
projecting portions (18,20) relative to said side units (8). The central unit (12)
and the side units (8) are made of a single soundproofing material consisting of a
mix of concrete, fibres and rubber so as to form a homogeneous block of soundproofing
material.
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[0002] It is known in the art, in particular in the building field, to construct walls with soundproofing blocks suitable for limiting sound transmission; such blocks, however, are not capable of achieving a suitable sound insulation and are expensive to manufacture.
[0003] The need of a soundproofing block which would achieve a suitable sound insulation and which should be inexpensive to manufacture is therefore felt.
[0004] The object of the present invention is to provide a soundproofing block capable of solving the problems mentioned above with reference to the prior art.
[0006] Further features and the advantages of the soundproofing block according to the present invention will appear more clearly from the following description of preferred non-limiting embodiments thereof, wherein:
[0007] figure 1 shows a perspective view of a soundproofing block according to the present invention;
[0008] figure 2 shows a perspective view of a plurality of soundproofing blocks of figure 1, in an assembly configuration;
[0009] figure 3 shows a front view of the soundproofing block of figure 1 from the side of arrow III of figure 1;
[0010] figure 4 shows a side view of the soundproofing block of figure 1 from the side of arrow IV of figure 1;
[0012] Elements or parts of elements in common between the embodiments described below are referred to with the same reference numerals.
[0013] With reference to the annexed figures, reference numeral 4 globally denotes a soundproofing block, suitable for building applications and the like.
[0014] According to one embodiment, block 4 comprises three units properly shaped and said connected to one another, and extends along a prevailing direction X.
[0015] In particular, block 4 comprises two side units 8 and one central unit 12, interposed between said side units 8, relative to a cross direction Y perpendicular to said prevailing direction X.
[0016] Preferably, the side units 8 are equal to one another in their dimensions and shape and are parallel to one another and to said prevailing direction X.
[0017] The prevailing X and cross Y directions define a support plane S for said block 4, that is, a plane parallel to a laying surface of the block itself.
[0018] According to a preferred embodiment, the two side units 8 are equal to one another in their dimensions and shape, both being shaped as a parallelepiped, with a base parallel to said support plane S and a height parallel to a longitudinal direction Z, perpendicular to said support plane S and to the prevailing and cross directions X and Y.
[0019] Preferably, said side units 8 are aligned to one another relative to the prevailing and longitudinal directions X and Z, so as to be superimposable along the cross direction Y. The cross direction Y defines a thickness of the block units.
[0020] The side units 8 extend from an upper end 13 to a lower end 14, along the longitudinal direction Z, as well as from a front end 15 to a rear end 16, along the prevailing direction X.
[0021] According to one embodiment, the central unit 12w exhibits the same dimensions as the side units 8 relative to the prevailing and longitudinal directions X and Z.
[0022] The block exhibits a centre line plane W perpendicular to the support plane S; preferably, the centre line plane W is also the symmetry plane for the block.
[0023] The central unit 12 is advantageously arranged staggered relative to the side units 8, along the prevailing and longitudinal directions X and Z, so as to exhibit projecting portions relative to the side units 8.
[0024] In particular, the projecting portions comprise a first projecting portion 18 and a second projecting portion 20.
[0025] The first projecting portion 18 protrudes relative to the side units 8 along the longitudinal direction Z, for example on the side of the upper end 13 of the side units 8, by a length M. On the side of the lower end 14, the central unit 12, along the longitudinal direction Z, determines with the side units 8 a first recess 24, having a length M' preferably equal to said length M.
[0026] Advantageously, the first recess 24 is counter-shaped relative to the first projecting portion 18 so as to allow a shape coupling between the first projecting portion 18 and the first recess 24.
[0027] The second projecting portion 20 protrudes relative to the side units 8 along direction X, for example on the side of the front ends 15 of the side units 8, by a length P. On the side of the rear end 16, the central unit 12, along direction X, determines with the side units 8 a second recess 26, having a length P' preferably equal to said length P.
[0028] Advantageously, the second recess 26 is counter-shaped relative to the second projecting portion 20 so as to allow a shape coupling between the second projecting portion 20 and the second recess 26.
[0029] According to a preferred embodiment, said first projecting portion 18 comprises a pair of upper longitudinal chamfers 28, inclined by an angle a relative to a plane parallel to the centre line plane W, that is, passing by the prevailing and longitudinal directions X, Z, and symmetrically arranged relative to said plane W so that, relative to a section plane perpendicular to said centre line plane W, that is, passing by the longitudinal and cross directions Z and Y, the first projecting portion 18 exhibits a trapezoidal section, in particular an isosceles trapezium section.
[0031] Preferably, said first recess 24 comprises a pair of lower longitudinal chamfers 30, inclined by an angle a' relative to a plane parallel to the centre line plane W and symmetrically arranged relative to said plane. Preferably, said lower longitudinal chamfers 30 are parallel to the upper longitudinal chamfers 28, that is, angle a is equal to angle a', so that on the whole, the first recess 24 is counter-shaped relative to the first projecting portion 18.
[0032] According to a preferred embodiment, said second projecting portion 20 comprises a pair of front side chamfers 32, inclined by an angle b relative to a plane parallel to the centre line plane W, that is, passing by the cross and longitudinal directions Y and Z, and symmetrically arranged relative to said centre line plane W so that, relative to a section plane parallel to said support plane S, the second projecting portion 20 exhibits a trapezoidal section, in particular an isosceles trapezium section.
[0034] Preferably, also said second recess 26 comprises a pair of rear side chamfers 34, inclined by an angle b' relative to the symmetry plane W, symmetrically arranged relative to the symmetry plane W.
[0035] Preferably, said rear side chamfers 34 are parallel to the front side chamfers 32 of the second projecting portion 20, that is, angle b' is equal to angle b, so that on the whole, the second recess 26 is counter-shaped relative to the second projecting portion 20.
[0036] Such blocks 4 are therefore stackable on one another relative to both the prevailing direction X and to the longitudinal direction Z. In particular, thanks to the counter-shaping of the projecting portions 18,20 relative to the respective first and second recesses 24,26 it is possible to stack up a plurality of blocks to form a wall, inserting each second projecting portion 20 of a block into a second recess 26 of an adjacent block along the prevailing direction X, as well as inserting each first projecting portion 18 of a block with the first recess 24 of an adjacent block along the longitudinal direction Z.
[0037] Advantageously, at said shape couplings, suitable constraining means are inserted between the blocks, preferably liquid concrete or adhesive for masonry, so as to ensure the coupling stability.
[0038] Advantageously, the soundproofing material that makes up the blocks according to the present invention is a mix substantially comprising concrete, fibres and rubber.
[0040] The fibres are high resistance glass fibres, having average length of about 18-20 mm. Preferably, said glass fibres are fibres marketed with the trade name Anti-CrakTM by `Saint-Gobain'. Said fibres are contained in a percentage by weight of about 5%.
[0041] The rubber advantageously consists of tyre scrap grains, preferably having an average diameter comprised between 2 and 4 mm.
[0043] The process for obtaining a soundproofing block according to the present invention shall now be described.
[0044] Such process comprises the step of forming a mix based on concrete, fibres and tyre scrap grains.
[0045] The mix is then mixed with water in a mixer. The resulting mix is gathered in a hopper and delivered to a block-shaped die, that is, the mix is cast in a die shaped as the blocks according to the invention.
[0046] The mix is compacted by shaking, that is, imparting vibrations to the die. Preferably, the mix is pressed so as to consolidate the mix into the die. The mix is withdrawn and the block is dried for about 3-5 hours.
[0047] Advantageously, in the making of the mix, the glass fibres, substantially soft, twist about the rubber grains, thus forming highly resistant reticular structures.
[0048] As it can be understood from the description, the soundproofing block according to the invention allows overcoming the disadvantages of the prior art soundproofing blocks.
[0049] Unusually, the soundproofing block exhibits a high soundproofing power. In particular, this high soundproofing power is due to both the particular geometry of the block and to the material of the block.
[0050] In fact, the staggered position of the units of the blocks, as well as the presence of internal inclined walls have the effect of creating irregular surfaces that reflect the sound waves, preventing the transmission of the same through walls made up of such blocks.
[0051] Moreover, the soundproofing block according to the present invention is inexpensive to manufacture.
[0052] In fact, the block is manufactured with recycled material, in particular rubber from second-hand tyres, and the manufacture of the same is carried out through a single casting of liquid material in a counter-shaped die relative to said soundproofing block.
[0053] Moreover, thanks to the fact that the block is entirely made of soundproofing material, the soundproofing power thereof is particularly high. In fact, unlike the blocks of the prior art, the sound waves do not meet masonry portions or tiles containing cores of soundproofing material therein.
[0054] Such portions form sound bridges and cause resonance that in the block of the present invention, entirely made of soundproofing material, are eliminated.
[0055] Moreover, the blocks according to the present invention are entirely made of soundproofing material having a high specific weight, higher than the specific weight of the masonry or of the ceramic forming the tiles normally used. Thus, by increasing the mass of the blocks, the relative soundproofing power increases accordingly.
1. A soundproofing block (4) for building, comprising two side units (8) extending along
a prevailing direction (X), substantially equal to each other, and facing each other
so as to be superimposed relative to a cross direction (Y), perpendicular to said
prevailing direction (X), and a central unit (12), interposed between said side units
(8), said central unit (12) being substantially equal and arranged staggered relative
to the side units (8) along said prevailing direction (X) and along a longitudinal
direction (Z) perpendicular to the prevailing direction (X) and to the cross direction
(Y), so as to exhibit projecting portions (18,20) relative to said side units (8)
wherein said central unit (12) and said side units (8) are made of a single soundproofing
material consisting of a concrete mix, rubber and fibres, so as to form a homogeneous
block entirely made of a soundproofing material.
2. A soundproofing block (4) according to claim 1, wherein the projecting portions (18,20)
comprise a first projecting portion (18) that protrudes by a length (M) relative to
the side units (8) along the longitudinal direction (Z), at an upper end (13) of the
side units (8) .
3. A soundproofing block (4) according to claim 2, wherein said first projecting portion
(18), on the side of a lower end (14) opposite said upper end (13), determines with
the side units (8) a first recess (24) of length (M') relative to the longitudinal
direction (Z).
4. A soundproofing block (4) according to claim 3, wherein said length (M) is equal to
said length (M').
5. A soundproofing block (4) according to claim 3 or 4, wherein said first recess (24)
is substantially counter-shaped relative to said first projecting portion (18) so
as to allow a shape coupling with the first projecting portion (18).
6. A soundproofing block (4) according to any one of claims 2 to 5, wherein said first
projecting portion (18) comprises a pair of upper longitudinal chamfers (28), inclined
by an angle (a) relative to a plane passing by said prevailing (X) and longitudinal
(Z) directions.
7. A soundproofing block (4) according to claim 6, wherein said angle (a) is equal to
45 degrees.
8. A soundproofing block (4) according to any one of claims 3 to 7, wherein said first
recess (24) comprises a pair of lower longitudinal chamfers (30), inclined by an angle
(a') relative to a plane passing by said prevailing (X) and longitudinal (Z) directions.
9. A soundproofing block (4) according to claim 8, wherein said angle (a) is equal to
said angle (a') so that the first recess (24) is counter-shaped relative to the first
projecting portion (18).
10. A soundproofing block (4) according to any one of the previous claims, wherein said
projecting portions (18,20) comprise a second projecting portion (20) that protrudes
by a length (P) relative to the side units (8) along the prevailing direction (X),
at a front end (15) of the side units (8).
11. A soundproofing block (4) according to claim 10, wherein said second projecting portion
(20), on the side of a rear end (16) opposite said front end (15), determines with
the side units (8) a second recess (26) of length (P') relative to the prevailing
direction (X).
12. A soundproofing block (4) according to claim 11, wherein said length (P) is equal
to said length (P').
13. A soundproofing block (4) according to claim 11 or 12, wherein said second recess
(26) is substantially counter-shaped relative to said second projecting portion (20)
so as to allow a shape coupling with the second projecting portion (20).
14. A soundproofing block (4) according to any one of claims 10 to 13, wherein said second
projecting portion (20) comprises a pair of front side chamfers (32), inclined by
an angle (b) relative to a plane passing by said longitudinal (Z) and cross (Y) directions.
15. A soundproofing block (4) according to claim 14, wherein said angle (b) is equal to
45 degrees.
16. A soundproofing block (4) according to any one of claims 11 to 15, wherein said second
recess (26) comprises a pair of rear side chamfers (34), inclined by an angle (b')
relative to a plane passing by said longitudinal (Z) and cross (Y) directions.
17. A soundproofing block (4) according to claim 16, wherein said angle (b) is equal to
angle (b') so that the second recess (26) is counter-shaped relative to the second
projecting portion (20).
18. A soundproofing block (4) according to any one of the previous claims, made of a mix
wherein the percentage by weight of concrete does not exceed the value of 7-8%.
19. A soundproofing block (4) according to any one of the previous claims, made of a mix
wherein the fibres are high resistance glass fibres having an average length of about
18-20 mm.
20. A soundproofing block (4) according to claim 19, wherein said fibres are contained
in a percentage by weight of about 5%.
21. A soundproofing block (4) according to any one of the previous claims, made of a mix
wherein the rubber consists of tyre scrap grains.
22. A soundproofing block (4) according to claim 21, wherein said grains have an average
diameter comprised between 2 and 4 mm.
23. A soundproofing block (4) according to claim 21 or 22, wherein said grains are contained
in a percentage by weight of about 90%.
24. A wall comprising a plurality of soundproofing blocks (4) according to any one of
claims 1 to 23, wherein said blocks (4) are couples joint-wise to each other, so as
to associate each projecting portion (18,20) of a block (4) to a corresponding recess
(24,26) of an adjacent block, said blocks (4) being constrained by constraining means.
25. A wall according to claim 24, wherein said constraining means comprise liquid concrete
or adhesive for masonry.
26. A wall according to claim 24 or 25, wherein said wall is associated to a panel so
as to determine an interspace between the wall and the panel, said interspace being
suitable for seating raceways for pipes, wires and the like.
27. A process for manufacturing a soundproofing block according to any one of claims 1
to 23, comprising the steps of:
- forming a mix based on concrete, fibres and tyre scrap grains,
- mixing the mix with water in a mixer,
- casting in a counter-shaped die relative to said soundproofing block.
28. A process according to claim 27, comprising the steps of:
- compacting the mix by shaking
- pressing the mix into the die
- withdrawing
- drying.