Abstract:
A shapeable framing element for the construction of panels comprising mounting means to affix said shapeable framing element to a substrate, said mounting means being divided into a plurality of mounting tabs defining a plurality of channels, thereby allowing said framing element to be shaped into curvilinear forms prior to being mounted upon said substrate. A shapeable element for attaching objects to a substrate. A method for constructing a panel enclosing a desired geometric volume upon a substrate

Description:
[0001]    This application claims the benefit of priority to U.S. Provisional Patent Application Ser. No. 61/162,034, which was filed on Mar. 20, 2009, and which is incorporated herein by reference. 
     
    
     TECHNICAL FIELD 
       [0002]    The present invention relates to shapeable framing elements for the construction of room sound proofing panels, especially those constructed of sound proofing material covered with fabric. 
       BACKGROUND OF THE INVENTION 
       [0003]    Acoustical sound proofing systems are used to reduce noise levels in rooms and other interior spaces where there is a need for noise reduction or improved sound quality. Examples include class rooms, media rooms, board rooms, band or chorus practice rooms, and the like. It is advantageous for such systems also to be aesthetically pleasing, as they are often exposed to the room occupants. Systems such as the Whisper Walls® System (Whisper Walls, Aurora, Colo.) provide soundproofing panels covered with a variety of fabrics. The panels are constructed of framing elements which anchor to a surface, such as a wall, in a manner which defines a framed volume, typically a rectangular solid. Insulation, typically fiberglass, fills the framed volume; and fabric is tucked into the framing elements so that it completely covers the framed volume and its filling of insulation. The framing elements can include jaws which grip the fabric covering and hold it tautly in place. 
         [0004]    Existing framing elements for acoustical sound proofing systems are comprised of relatively rigid materials such as nylon. The rigid nature of the framing elements limits the framed volume to straight sided forms such as cubes and triangular and polygonal solids. Existing framing elements are therefore incapable of being shaped to form sound proofing panels of curvilinear forms such as circle, ovals, and serpentine solids. Without the availability of curvilinear forms, it is impossible to construct soundproofing panels in varied and artistic forms, or to construct decorative assemblies of sound proofing panels in a wide assortment of shapes. 
       SUMMARY OF THE INVENTION 
       [0005]    The present invention provides a shapeable framing element which permits the construction of fabric covered room sound proofing panels in curvilinear forms, yet which provides sufficiently strong anchorage and fabric gripping capabilities to yield sound proofing panels which are stable and durable. The shapeable framing element allows the user to design sound proofing panels, and assemblies of panels, in an unlimited variety of artistic forms, including flowers, sunbursts, and musical notes. The shapeable framing elements can also be used to construct rectilinear sound proofing panels similar to those currently known in the art. The present invention also provides methods for fabricating shapeable framing elements and for utilizing them in the construction of sound proofing systems of an unlimited variety of forms. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0006]    Other advantages of the present invention will be readily appreciated as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein: 
           [0007]      FIG. 1  shows a front elevational view of a shapeable framing element. 
           [0008]      FIG. 2  shows a left elevational view of a shapeable framing element. 
           [0009]      FIG. 3  shows a rear elevational view of a shapeable framing element. 
           [0010]      FIG. 4  shows a top side view of a shapeable framing element. 
           [0011]      FIG. 5  shows a bottom side view of a shapeable framing element. 
           [0012]      FIG. 6  shows a front elevational view of a shapeable framing element flexed into an arctuate form. 
           [0013]      FIG. 7  shows a cross section of a sound proofing panel constructed with a single shapeable framing element. 
           [0014]      FIG. 8  shows a plan view of two mounted shapeable framing elements. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0015]    A shapeable framing element  10  according to the present invention includes a rearward side  12  which faces the wall or other substrate on which the element is mounted; a forward side  14 , an upper side  16 , and a lower side  18 , though the terms upper and lower are not intended to be limiting. The invention comprises three portions: a rearward mounting portion  20 , a forward gripping portion  22 ; and a connecting portion  24  located between the mounting portion  20  and gripping portion  22 . The mounting portion is divided into a plurality of mounting tabs  26  which define a plurality of channels  28  therebetween. In the preferred embodiment at least one mounting tab includes at least one aperture  30  for the insertion of at least one fastener  32  as will be discussed below. The gripping portion includes an upper jaw  34  and a lower jaw  36  in close apposition to each other. In the preferred embodiment, the jaws include interlocking ridges as depicted in  FIG. 2 . Upper jaw  34  and lower jaw  36  define a gripping space  38  in which fabric is inserted as will be discussed below. In the preferred embodiment, upper jaw  34  includes an upper lip  40 , which is an extension of the forward aspect of upper jaw  34  that curves toward the upper side  16  of shapeable framing element  10 . Similarly, lower jaw  36  includes a lower lip  42 , which is an extension of the forward aspect of lower jaw  36  that curves toward the lower side  18  of shapeable framing element  10 . The connecting portion  24  includes an upper wall  44  which is an extension of upper jaw  34 ; and a lower wall  46 , which is an extension of lower jaw  36 . The upper wall  44  and lower wall  46  can be in close apposition for their entire lengths. In the preferred embodiment, however, the lower wall  46  includes a right angle bend toward the lower side  18  and the upper wall  44  includes a right angle bend toward the upper side  16 , thereby defining, in combination with the attachment portion, a chamber  48  which is rectangular in cross section as shown in  FIG. 2 . Alternatively, the lower wall  46  and upper wall  44  can be bent or curved in various directions to define chambers of various shapes. 
         [0016]    A shapeable framing element is defined as a framing element which can be flexed into curvilinear shapes prior to mounting on a substrate. The present invention, a shapeable framing element, is great improvement over the rigid framing elements known in the art. The shapeable framing element  10  can be flexed prior to mounting so that it frames an area of any desired shape, including curvilinear shapes, even complete ovals and circles. Multiple shapeable framing elements  10 , shaped into diverse forms, can be used in combinations frame areas of complex shape, such as the shape of a flower or a sunburst. The shapeable framing element  10  can also, of course, be utilized in its unflexed, linear form in combinations that produce the rectilinear shapes already known in the art. 
         [0017]    The shapeability of the present invention arises mainly from the channels  28  which divide the mounting portion  20  into individual mounting tabs  26 . In the preferred embodiment, the channels  28  also extend into the connecting portion  24 , leaving only the gripping portion  24  undivided. The division of the mounting portion  20  and optionally of the connecting portion  24  allow the shapeable framing element  10  to flex, much as the division of the human spine into vertebrae allows the human back to flex. In framing elements known in the art, the mounting portion and connecting portions comprise a single, continuous, relatively rigid unit. 
         [0018]    In the preferred embodiment, shapeable framing element  10  is preferably made of nylon but can alternatively be made of any material known in the art that provides sufficient strength, durability, and elasticity, including such plastics as fiberglass, polyethylene, and polyfluorocarbons; of rubber; of metals such as steel alloys; and of wood. The shapeable framing element  10  can be fabricated in any length and cut to lengths suitable for storage, shipping, or for a specific framing job. A preferred method of fabrication is to provide a rigid Whisper Wall® framing element and cut channels into its mounting and connecting portions with a buzz saw. In the preferred embodiment, channels  28  are cut with a width of ⅛ inch and the mounting tabs  26  have a width of ½ inch. The mounting tabs  26  and channels  28  all have a length of 1 inch. However, it is understood by those skilled in the art that any channel and mounting tab dimensions may be used without departing from the principles of the invention, as long as the resulting product provides a shapeable framing element with desirable shapeability and strength. In the preferred embodiment, the forward edge of the gripping portion  22  projects forward ½ inch relative to the rearward side of shapeable framing element  10 . The distance that the gripping portion  22  projects forward, however, will be vary according to the desired depth of the framed volume, as will be seen below. 
         [0019]    Alternatively, shapeable framing element  10  can be molded as a single unit, with mounting tabs  26  and channels  28  formed in the molding process. Shapeable framing element  10  can also be assembled from individual components. For example, separate mounting, connecting, and gripping components can be assembled to serve the functions of mounting portion  20 , connecting portion  24 , and gripping portion  22 , respectively. With this option, the shapeable framing element  10  can be constructed of components of diverse materials, with each component optimized for its specific function. 
         [0020]    A method for constructing a soundproofing panel of any desired shape is shown in  FIG. 7 .  FIG. 7  is a cross sectional view of a single shapeable framing element flexed into an arc, which is why two sections of the shapeable framing element appear. The outline of the shape of the panel (not shown) is inscribed on a wall  50  or other substrate. A fabric strip  52  of the desired material and design, preferably 2 inches in width, is attached to the wall  50  or other substrate, using any suitable adhesive known in the art, following the inscribed outline. Shapeable framing element  10  is then flexed to follow the outline of the fabric strip  52  and placed with the rearward side  12  in contact with fabric strip  52 . Shapeable framing element  10  is then mounted securely onto fabric strip  52  and underlying wall  50 . Preferably mounting is accomplished by inserting at least one fastener  32 , such as a screw, through at least one mounting tab  26  and driving the screw through fabric strip  52  and into underlying wall  50 . Alternatively, mounting can be accomplished with nails, bolts, rivets, or any other fastener known in the art; or it can be accomplished by stapling at least one mounting tab  26  fabric strip  52  and the underlying substrate; or it can be accomplished by cementing at least one mounting tab  26  to fabric strip  52 . 
         [0021]    After shapeable framing element  10  is securely mounted, the exterior edge  54  of fabric strip  52  is tucked between the upper jaw  34  and lower jaw  36  of gripping portion  22  so that fabric strip  52  is stretched taut. The exterior edge  54  of fabric strip  52  is defined as the edge which projects over the upper side  16  of shapeable framing element  10 . The mounting process continues until a desired framed volume  56  is defined by one or more shapeable framing elements  10 . 
         [0022]    Next, framed volume  56  is filled with soundproofing material  58 . Preferably, the soundproofing material is made of fiberglass, but it can alternatively be made of any soundproofing material known in the art, such as rock wool, celled foams, and baffles of rubber, plastic, or cardboard. The maximum depth of the soundproofing material  58  typically matches the distance to which the gripping portion  22  projects beyond the rearward side  12  of shapeable framing element  10 . With this configuration, the soundproofing material  58  is flush with the fabric covering  60  to be discussed below. This produces panel with smooth, flat appearance. Alternatively, the sound proofing material  58  can project beyond the gripping portion  22 . This will produce a “puffy” effect when fabric covering  60  is installed, adding to the artistic possibilities provided by the invention. Note that fillings other than sound proofing materials may be utilized, for example thermal insulation. Panels constructed with shapeable framing elements may alternatively be used to enclose loudspeakers. The framed volume  56  may alternatively be left unfilled, if a purely decorative panel is desired. 
         [0023]    Finally, fabric covering  60 , preferably of the same pattern and material as fabric strip  52 , is tucked between the upper jaw  34  and lower jaw  36  of gripping portion  22  so that fabric it is stretched taut. The free ends of fabric strip  52  and fabric covering  60  may protrude into chamber  48  as depicted in  FIG. 7 , or they may reside entirely within upper jaw  34  and lower jaw  36  of gripping portion  22 . The result is a soundproofing panel in which appears to the viewer to be a seamless panel of fabric, as the shapeable framing elements are completely hidden underneath fabric strip  52  and fabric piece  60 . 
         [0024]    Conjoined assemblies of sound proofing panels can also be constructed through the use of the present invention. In this manner, complex artistic works can be produced. The method is as described above for individual panels, but the at least two shapeable framing elements are mounted in a side to side joining as in  FIG. 8  or in a butt end or other joined configuration (not shown). In  FIG. 8 , a first shapeable framing element  70  is joined to a second shapeable framing element  72  in a side to side join, where the first shapeable framing element  70  defines a portion of a framed volume representing the central body of a flower  74  and the second shapeable framing element  72  defines a portion of a framed volume representing a petal of the same flower  76 . 
         [0025]    Obviously, many modifications and variations of the present invention are possible in light of the above teachings. It is, therefore, to be understood that within the scope of the appended claims wherein reference numerals are merely for convenience and are not to be in any way limiting, the invention may be practiced otherwise than as specifically described.