Soundproof door for use in reduction of sound transmitted from one side of the door to the other side

A soundproof door having a multiple-layered core to form a concrete inner portion of the soundproof door, the multiple-layered core due to particularly constituted by having a soft-soundproofing core interleaved in between two spaced hard-soundproofing cores to form as a whole as a sandwich structure are excellent in sound isolation for soundproof door, and the soundproof door at least has an STC of 30, determined in accordance with ASTM E413-10 and E90-09, to minimize the transmission of sound from one side of the soundproof door to the other side.

BACKGROUND OF THE PRESENT INVENTION

1. Field of the Invention

The present invention relates to a soundproof door, and more particularly, to an improved soundproof door having an STC number greater than of STC 30 determined in accordance with ASTM E413-10 and E90-09.

2. Description of Related Art

A soundproof door is a door which has been designed or retrofitted to cut out as much external noise as possible.

However, most soundproof doors currently used in prior art are wooden doors or synthesized plastic doors, those doors are poor in sound isolation or acoustic insulation.

SUMMARY OF THE INVENTION

The major purpose of the present invention is to provide an improved soundproof door for use in reduction of sound transmitted from one side of the door to the other side, which improvement includes the soundproof door has a multiple-layered core to form a concrete inner portion of the soundproof door, the multiple-layered core particularly constituted by having a soft-soundproofing core interleaved in between two spaced hard-soundproofing cores to form as a whole as a sandwich structure are excellent in sound isolation for soundproof door, and the soundproof door at least has an STC of 30 determined in accordance with ASTM E413-10 and E90-09, so that the soundproof door may minimize the transmission of sound from one side of the soundproof door to the other side.

The structural composition of the soundproof door comprises two door skins one formed as a front door skin and the other formed as a rear door skin for the soundproof door respectively; a quadrilateral frame constituted by a top rail member, a bottom rail member, a left stile member and a right stile member to seal the perimeter of the door skins; and a multiple-layered core having function of sound isolation to form a concrete inner portion of the door, wherein the multiple-layered core comprises two spaced hard-soundproofing cores and a soft-soundproofing core interleaved in between the spaced hard-soundproofing cores to constitute with a sandwich structure.

The above-mentioned soundproof door may further comprises one or more reinforced members in parallel set up alongside one or more sides of the soft-soundproofing core, and both the soft-soundproofing core and each the reinforced member are interleaved in between the two spaced hard-soundproofing cores to constitute with a sandwich structure.

Another structural composition of the soundproof door comprises two door skins one formed as a front door skin and the other formed as a rear door skin for the soundproof door respectively; a quadrilateral frame constituted by a top rail member, a bottom rail member, a left stile member and a right stile member to seal the perimeter of the door skins; one or more reinforced members in parallel set up alongside one or more inner sides of the quadrilateral frame; and a multiple-layered core having function of sound isolation to form a concrete inner portion of the door, wherein the multiple-layered core comprises two spaced hard-soundproofing cores and a soft-soundproofing core interleaved in between the spaced hard-soundproofing cores to constitute with a sandwich structure.

The hard-soundproofing core may be made of either a single-layered soundproofing core or a multiple-layered soundproofing core constituted by two or more the single-layered soundproofing cores.

The hard-soundproofing core is made of wood plate, iron plate, calcium silicate board, gypsum board, magnesium oxide board, silicon magnesium board, glass fiber composite board or ceramic composite board.

The soft-soundproofing core is made of rock wool fiber board, ceramic fiber wool board, phenolic foaming board, glass fiber board, closed cell polyurethane foaming board, opened cell polyurethane foaming board, expandable polystyrene foaming board or expandable polyethylene foaming board.

The reinforced member is made of hard PVC board, PVC composite extrusion board, PS board, ABS board, hardwood board, high density particle board or LVL board.

DETAILED DESCRIPTION OF THE INVENTION

As shown in fromFIG. 1toFIG. 3, a soundproof door10disclosed in this present invention has a total thickness T1ranged from 30 mm to 70 mm and comprises two door skins11and12formed as a front door skin and a rear door skin for the soundproof door10respectively, a quadrilateral frame20constituted by a top rail member21, a bottom rail member22, a left stile member23and a right stile member24to seal the perimeter of door skins11and12of the soundproof door10, and a multiple-layered core30to form a concrete inner portion of the soundproof door10.

As shown in fromFIG. 7toFIG. 9, another embodiment of the soundproof door15of the present invention still has a total thickness T1ranged from 30 mm to 70 mm and comprises the door skins11and12of the soundproof door15, the quadrilateral frame20to seal the perimeter of door skins11and12, one or more reinforced members70in parallel set up alongside one or more inner sides of the quadrilateral frame20of the soundproof door15, and the multiple-layered core30to form a concrete inner portion of the soundproof door15.

Particularly, the multiple-layered core30of the soundproof door10or15of the present invention has function of sound isolation to minimize the transmission of sound from one side of the soundproof door10or15to the other side.

The door skin11or12has a thickness of 1-5 mm and is made of fiber reinforced plastic (FRP) sheet, SMC sheet, BMC sheet, wood plate, iron plate, PVC sheet, PS sheet, ABS sheet or laminated veneer lumber (LVL) sheet. Wherein the SMC sheet is made of fiber reinforced plastic (FRP) by sheet molding compound method, and the BMC sheet is made of fiber reinforced plastic (FRP) by Bulk Molding Compound method.

Further, the door skin11or12can be shaped either as a flat door skin of which door surface is a flat surface or as a panel door skin of which door surface as depicted inFIG. 10has decorative panel patterns formed on the door surface. The door skin11or12may have a smooth surface without wood grain or with imitating wood grain. The door skin11or12may have a rough back surface for increasing the binding force when they are bond together with the quadrilateral frame20and the multiple-layered core30, or further with the reinforced member70.

The quadrilateral frame20including the top rail member21, the bottom rail member22, the left stile member23and the right stile member24is made of hard PVC board, foamed PVC board, PVC composite extrusion board, hardwood board, high density particle board, laminated veneer lumber (LVL) board, stainless steel plate, galvanized and coated steel plate or calcium silicate plate.

The multiple-layered core30at least comprises two spaced hard-soundproofing cores40and a soft-soundproofing core50interleaved in between the two spaced hard-soundproofing cores40to constitute with a sandwich structure.

As shown in fromFIG. 4toFIG. 6, another practical embodiment of the multiple-layered core30comprises the two spaced hard-soundproofing cores40, the soft-soundproofing core50and one or more reinforced members60in parallel set up alongside one or more sides, preferably each side, of the soft-soundproofing core50thereof, and in particular both the soft-soundproofing core50as well as the reinforced member60are interleaved in between the two spaced hard-soundproofing cores40to constitute with a sandwich structure.

The hard-soundproofing core40has a thickness of 3-12 mm and is made of either a single-layered soundproofing core or a multiple-layered soundproofing core constituted by two or more the single-layered soundproofing cores.

The hard-soundproofing core40has an excellent soundproofing ability to preferably block sound with high frequency over 500 Hz and is made of wood plate, iron plate, calcium silicate board, gypsum board, magnesium oxide board, silicon magnesium board, glass fiber composite board or ceramic composite board.

The soft-soundproofing core50has an excellent soundproofing ability to preferably block sound with low frequency beneath 500 Hz and is made of rock wool fiber board, ceramic fiber wool board, phenolic foaming board, glass fiber board, closed cell polyurethane foaming board, opened cell polyurethane foaming board, expandable polystyrene (EPS) foaming board or expandable polyethylene (EPE) foaming board.

The reinforced member60or70has an excellent rigidity and is made of hard PVC board, PVC composite extrusion board, PS board, ABS board, hardwood board, high density particle board or LVL board.

As shown inFIG. 10, a soundproof door assembly100of the present invention for use as a building structure is further disclosed to improve sound isolation qualities. The structural component of the soundproof door assembly100comprises the above-mentioned soundproof door10(or15), a doorframe80used to support the soundproof door10(or15) and one or more door hinges90used to control the soundproof door10(or15) capably to swing relative to the doorframe80.

The doorframe80is a quadrilateral door frame constituted by four components including a header81, a doorsill82, a strike jamb83and a hinge jamb84, and each component is an integral structure made of thermoplastic material by extruding forming technique, wooden material or metal material.

Each component of the doorframe80is made from hard polyvinyl chloride (PVC) board, foamed PVC board, PVC composite extrusion board, hardwood plate, stainless steel plate, aluminum alloy plate, galvanized and coated steel plate, or calcium silicate plate, and preferably made from hard polyvinyl chloride (PVC) board, foamed PVC board or PVC composite extrusion board.

Referred to fromFIG. 10toFIG. 12, the soundproof door10(or15) of the present invention is a moving part, and the doorframe80of the present invention which is positioned proximate the soundproof door10(or15) is a stationary frame. Each door hinge90has two long straps, one strap is fastened to the right stile member24(or, alternatively, fasten to the left stile member23) of the soundproof door10(or15) and the other is fastened to the adjacent hinge jamb84of the doorframe80.

And, a doorknob93with a latch bolt93acan be installed to the soundproof door10(or15) through a generally conventional assembling technique so that the doorknob93may drive the soundproof door10(or15) operated in either open or close stage.

The soundproof door assembly100of the present invention shows a longitudinally cross-sectional structure as shown inFIG. 11. And, the header81of the doorframe80is provided with a structural arrangement containing a depressed section81aand a horizontal doorstop81b, wherein the depressed section81ais formed to accept the soundproof door10(or15) if closed, and the horizontal doorstop81bis formed to adjoin to the depressed section81ato prevent the soundproof door10(or15) from swinging through when closed.

As shown inFIG. 10andFIG. 11, at the junction where the horizontal doorstop81bis adjoining to the depressed section81aof the header81, an inserted slot81cis formed along the junction.

Accordingly, a first soft packing strip95ahaving a griping-mounting piece96ais installed onto the header81by way of having its griping-mounting piece96awholly inserted into the inserted slot81c, and the first soft packing strip95is then positioned into the right place on the outer side of the horizontal doorstop81bof the header81.

Further referred toFIG. 11, the doorsill82of the doorframe80has a depression section82ain order to accept the soundproof door10(or15) if closed and a protruding ridge82bformed as a door stop next to the depressed section82ain order to prevent the soundproof door10(or15) from swinging through when closed.

On the surface of the protruding ridge82b, an inserted slot82cis formed thereon. Accordingly, a second soft packing strip95bhaving a griping-mounting piece96bis installed onto the doorsill82by way of having its griping-mounting piece96bwholly inserted into the inserted slot82c, and the second soft packing strip95bis then positioned into the right place on the protruding ridge82bof the doorsill82.

As shown inFIG. 11, a rain shielding plate86made of aluminum alloy or thermoplastic material by extruding forming technique is optionally installed and covered onto the depressed section82aof the doorsill82for preventing water from seeping into the doorsill82of the doorframe80under stress of weather.

Likewise, the soundproof door assembly100of the present invention shows a horizontally cross-sectional structure as shown inFIG. 12. The strike jamb83of the doorframe80therefore has a depressed section83aand a longitudinal doorstop83b, wherein the depressed section83ais not only provided for a strike plate94affixed thereto to match with the latch bolt93aof the doorknob93together as a conventional door lock, but also formed to accept the soundproof door10(or15) if closed, and the longitudinal doorstop83bis formed to adjoin to the depressed section83ato prevent the soundproof door10(or15) from swinging through when closed.

As shown inFIG. 10andFIG. 12, at the junction where the longitudinal doorstop83bis adjoining to the depressed section83aof the strike jamb83, an inserted slot83cis formed along the junction.

Accordingly, a third soft packing strip95chaving a griping-mounting piece96cis installed onto the strike jamb83by way of having its griping-mounting piece96cwholly inserted into the inserted slot83c, and the third soft packing strip95cis then positioned into the right place on the outer side of the longitudinal doorstop83bof the strike jamb83.

Further referred toFIG. 12, the hinge jamb84of the doorframe80has a depressed section84aand a longitudinal doorstop84b, wherein the depressed section84ais not only provided for one strap of the door hinges90affixed thereto, but also formed to accept the soundproof door10(or15) if closed.

At the junction where the longitudinal doorstop84bis adjoining to the depressed section84a, an inserted slot84cis formed along the junction.

Accordingly, a fourth soft packing strip95dhaving a griping-mounting piece96dis installed onto the hinge jamb84by way of having its griping-mounting piece96dwholly inserted into the inserted slot84c, and the fourth soft packing strip95dis then positioned into the right place on the outer side of the longitudinal doorstop84bof the hinge jamb84.

The soundproof door assembly100of the present invention due to having an assembling arrangement as shown in fromFIG. 10toFIG. 12may achieve a superior sound isolation quality, since there are no clearances existed in between the soundproof door10(or15) and the doorframe80.

The aforesaid soundproof door10or15of the present invention has function of sound isolation, and the doorframe80as well as those soft packing strip95a,95b,95cand95dare also excellent in functions of sound isolation. Accordingly, the soundproof door10(or15) if closed to the doorframe80will at same time tightly press and touch to the first soft packing strip95ainstalled on the header81, the second soft packing strip95binstalled on the doorsill82, the third soft packing strip95cinstalled on the strike jamb83and the fourth soft packing strip95dinstalled on the hinge jamb84of the doorframe80. Therefore, the soundproof door assembly100of the present invention may effectively minimize the transmission of sound from one side of the soundproof door10of15to the other side.

The following examples are recited to demonstrate that the soundproof door10(or15) or the soundproof door assembly100of the present invention if measured and evaluated for sound transmission class (STC) test has a STC number greater than STC30for door (or door assembly), preferably greater than STC33for door (or door assembly) or even greater than STC38for door (or door assembly), to minimize the transmission of sound at frequency of 500 Hz from one side of the soundproof door10(or15) to the other side.

Sound Transmission Class (STC) Test:

The Sound Transmission Class (STC) is the most common sound reduction measurement in use, which is determined in accordance with both ASTM E413-10 (Classification for Rating Sound Insulation) and ASTM E90-90 (Standard Test Method for Laboratory Measurement of Airborne Sound Transmission Loss of Building Partitions and Elements).

Higher STC is generally better to reduction of sound vibration as it travels from one side of a door to the other.

A soundproof door having a total thickness T1of 45 mm is assembled according to the structural composition shown asFIGS. 4-6.

The door skins11and12have a thickness of 2 mm and are made of SMC sheet, the quadrilateral frame20have a thickness of 41 mm and is made of laminated veneer lumber (LVL) board, and the multiple-layered core30comprises the spaced hard-soundproofing cores40each having a thickness of 8 mm and made of silicon magnesium board to block sound with high frequency over 500 Hz, the soft-soundproofing core50having a thickness of 25 mm and made of rock wool fiber board to block sound with high frequency beneath 500 Hz, and four reinforced members60each having a thickness of 25 mm and in parallel set up alongside each side of the soft-soundproofing core50.

After STC test is determined in accordance with ASTM E413-10 and E90-09, the result is that the soundproof door of the Example 1 has an STC of 38 (or STC 38) for door.

A soundproof door assembled as the same specification as that of soundproof door of Example 1, in addition to the soft-soundproofing core50made of phenolic foaming board used to replace the rock wool fiber board used in Example 1.

After STC test is determined in accordance with ASTM E413-10 and E90-09, the result is that the soundproof door of the Example 2 has an STC 33 for door.

A soundproof door of Example 1 is mounted to a stationary doorframe positioned proximate the soundproof door via three door hinges and then assembled together as a soundproof door assembly having an assembling arrangement shown asFIGS. 10-12. The stationary doorframe is a quadrilateral door frame made of PVC composite extrusion board, and the quadrilateral door frame has been mounted a loop of soft packing strip used to tightly contact onto the door skin of the soundproof door if closed.

After STC test is determined in accordance with ASTM E413-10 and E90-09, the result is that the soundproof door assembly of the Example 3 has an STC 40 for door.