Patent Publication Number: US-9428905-B2

Title: Sound panel and method for assembly of sound panel

Description:
REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation of U.S. application Ser. No. 14/050,046, filed Oct. 9, 2013, which is hereby specifically incorporated by reference herein in its entirety. 
    
    
     TECHNICAL FIELD AND BACKGROUND 
     This disclosure relates to sound panels, for example, acoustic panels and bass traps. Sound panels are acoustic energy absorbers which are designed to dampen different frequencies of sound energy with the goal of attaining a certain level and range of different frequencies within a room or area. The sound panels function by turning sound energy into heat through friction. 
     SUMMARY 
     Disclosed is a sound panel including a frame, the frame having a front end and a back end; an absorption member, the absorption member having a front end and a back end; a first board, the first board having an inner surface and an outer surface, the inner surface of the first board facing the front end of the frame and the front end of the absorption member, the first board fastened to one of the front end of the frame or the front end of the absorption member; and a second board, the second board having an inner surface and an outer surface, the inner surface of the second board facing the back end of the frame and the back end of the absorption member, the second board fastened to one of the back end of the frame or the back end of the absorption member. 
     Also disclosed is a sound panel including an outer fabric, the outer fabric having a top surface and a bottom surface; a frame, the frame having a top surface and a bottom surface, the bottom surface of the frame facing the top surface of the outer fabric, the outer fabric fastened to the frame; and an absorption member positioned between the top surface of the outer fabric and the bottom surface of the frame. 
     Also disclosed is a method for constructing a sound panel including obtaining a frame and an absorption member, the frame having a front end and a back end, and the absorption member having a front end and a back end; placing the frame on the absorption member; fastening a first board to one of the front end of the frame or the front end of the absorption member, an inner surface of the first board facing the front end of the frame and the front end of the absorption member; and fastening a second board to one of the back end of the frame or the back end of the absorption member, an inner surface of the second board facing the back end of the frame and the back end of the absorption member. 
     Various implementations described in the present disclosure may include additional systems, methods, features, and advantages, which may not necessarily be expressly disclosed herein but will be apparent to one of ordinary skill in the art upon examination of the following detailed description and accompanying drawings. It is intended that all such systems, methods, features, and advantages be included within the present disclosure and protected by the accompanying claims. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The features and components of the following figures are illustrated to emphasize the general principles of the present disclosure. Corresponding features and components throughout the figures may be designated by matching reference characters for the sake of consistency and clarity. 
         FIG. 1  is a perspective view of fabric laid out on a flat surface in accord with one embodiment of the current disclosure. 
         FIG. 2  is a perspective view of a membrane in accord with one embedment of the current disclosure. 
         FIG. 3  is a perspective view of the membrane of  FIG. 2  placed on top of the fabric of  FIG. 1 . 
         FIG. 4  is a perspective view of an absorption member next to assembly of  FIG. 3 . 
         FIG. 5  is a perspective view of the absorption member placed on top of the assembly of  FIG. 3 . 
         FIG. 6  is a bottom view of a frame next to the assembly of  FIG. 5 . 
         FIG. 7  is a perspective view of the frame of  FIG. 6  placed on top of the assembly of  FIG. 7   
         FIG. 8  is a perspective view of  FIG. 7  that also includes fabric overlaying the frame. 
         FIG. 9  is a perspective view of the assembly of  FIG. 8  with the frame inverted from the position of the frame in  FIG. 8 . 
         FIG. 10  is a side perspective view of the assembly of  FIG. 9  on fabric material with boards fastened around the exterior portions of the assembly of  FIG. 9 . 
         FIG. 11  is a perspective view of the assembly of  FIG. 10  with the fabric material being wrapped around the frame of the assembly of  FIG. 10 . 
         FIG. 12  is a perspective view of the top side of a sound panel in accord with one embodiment of the current disclosure. 
         FIG. 13  is a perspective view of the bottom side of a sound panel in accord with the embodiment shown in  FIG. 12 . 
     
    
    
     DETAILED DESCRIPTION 
     Within this application a sound panel and associated methods, systems, devices, and various apparatus are disclosed. The sound panel includes at least outer fabric, one absorption member, and one frame. It would be understood by one of skill in the art that the disclosed sound panel is described in but a few exemplary embodiments among many. No particular terminology or description should be considered limiting on the disclosure or the scope of any claims issuing therefrom. 
     One embodiment of a sound panel  100  is disclosed and described in  FIGS. 12-13 . In order to construct the sound panel  100 , a multitude of methods may be used. In the current embodiment, one method of construction is illustrated in  FIGS. 1-11 . 
       FIG. 1  shows outer fabric  110  placed on a flat surface; however, the outer fabric  100  is not required to be initially placed on a flat surface. As seen in  FIG. 1 , the outer fabric  110  includes a back end  113 , a front end  117 , a top surface  111 , and a bottom surface  121  (not shown). Also, the outer fabric  110  includes a left end  115 , a right end  119 , and corners  112 ,  114 ,  116 , and  118 . Directional references such as “up,” “down,” “top,” “left,” “right,” “front,” “back,” and “corners,” among others are intended to refer to the orientation as shown and described in figure (or figures) the components and directions are referencing. The shape of the outer fabric  110  is not required to be rectangular, and can be any other shape, such as a triangle, diamond, polygon, circle, among others. In the current embodiment, the outer fabric  110  is made of thin breathable fabric, but other materials and types of fabrics may be used. Moreover, in alternative embodiments, outer fabric  110  is not required. 
       FIG. 2  shows membrane  210  from a perspective view. In the current embodiment, the membrane  210  includes a back end  213 , a front end  217 , a top surface  211 , and a bottom surface  221  (not shown). Also, the membrane  210  includes a left end  215 , a right end  219 , and corners  212 ,  214 ,  216 , and  218 . The shape of the membrane  210  is not required to be rectangular, and can be any other shape, such as a triangle, diamond, polygon, circle, among others. In the current embodiment, the membrane  210  is made of 0.5 pounds of mass loaded vinyl, but any type of flexible material and different weights of such material, may be used. Moreover, in alternative embodiments, membrane  210  is not required. The membrane  210  limits frequencies over 400 hz. Without the membrane  210 , there would be a broader frequency absorption than with the use of the absorption member  310  alone. 
       FIG. 3  displays the bottom surface  221  of the membrane  210  being placed on the top surface  111  of the outer fabric  110 . In the current embodiment, the top surface  211  of the membrane  210  faces upward, and the membrane  210  is placed in the middle of the outer fabric  110 ; however, such a configuration is not required. Additionally, in  FIG. 3 , the size, or distances from the back end  213  to the front end  217  and the left end  215  to the right end  219  of the membrane are shorter than the distances from the back end  113  to the front end  117  and the left end  115  to the right end  119  of the outer fabric  110 . However, such a configuration is not required and the membrane  210  may be larger than or equal in size to the outer fabric  110 . 
     In  FIG. 4 , an absorption member  310  is provided. In the current embodiment, the absorption member  310  includes a back end  313 , a front end  317 , a top surface  311  (not shown), and a bottom surface  321 . Also, the absorption member  310  includes a left end  315 , a right end  319 , and corners  312 ,  314 ,  316 , and  318 . The distances from the back end  313  to the front end  317  and the left end  315  to the right end  319  of the absorption member are approximately equal to the distances from the back end  213  to the front end  217  and the left end  215  to the right end  219  of the membrane  210 . However, such a configuration is not required and the absorption member  310  may be different in size to the membrane  210 . The shape of the absorption member  310  is not required to be rectangular, and can be any other shape, such as a triangle, diamond, polygon, circle, among others. In the current embodiment, the absorption member  310  is made of fiberglass, but other materials may be used. In the current embodiment, the fiberglass is four inches thick, and the density is 1.6 lbs./cubic foot. However, the thickness and density of the absorption member  310  can be varied and adjusted to capture different ranges of frequencies. In alternative embodiments, the thickness of the absorption member  310  may include a range of thicknesses, such as two inches, four inches, or six inches, among other. In one aspect, the thickness is from 2 to 24 inch thick fiberglass. Likewise, in alternative embodiments the density of the absorption member  310  may include a range of densities, such as 0.5 lbs./cubic foot, 1 lbs./cubic foot, 3 lbs./cubic foot, or 6 lbs./cubic foot, among others. In one aspect, the absorption member is constructed from about 1.6 lbs./cubic foot to 10 lbs./cubic foot density. It is well understood in the industry that when thicker absorption members  310  are used, the range of frequencies that are captured increases. Also, in the current embodiment, the thickness of the absorption member  310  may be adjusted before or after assembly is complete. 
       FIG. 5  displays the bottom surface  321  of the absorption member  310  placed on the top surface  211  of the membrane  210 . In the current embodiment, the top surface  311  of the absorption member  310  faces upward, and both the membrane  210  and absorption member  310  are placed in the middle of the outer fabric  110 ; however, such a configuration is not required. Additionally, in  FIG. 3 , the distances from the back end  313  to the front end  317  and the left end  315  to the right end  319  of the absorption member  310  are shorter than the distances from the back end  113  to the front end  117  and the left end  115  to the right end  119  of the outer fabric  110 . However, such a configuration is not required and the absorption member  310  may be larger than or equal in size to the outer fabric  110 . 
     In  FIG. 6  a frame  410  is provided. In the current embodiment, the frame  410  includes a back end  413 , a front end  417 , a top surface  411  (not shown), and a bottom surface  421 . Also, the frame  410  includes a left end  415 , a right end  419 , and corners  412 ,  414 ,  416 , and  418 . The shape of the frame  410  in the current embodiment is a rectangle with sectional strip of wood (the component where the bottom surface  421  is indicated—although the bottom surface  421  includes the entire bottom surface of all of the peripheral components of the frame  410  ( 412 ,  413 ,  414 ,  415 ,  416 ,  417 ,  418 , and  419 )). The frame  410  is not required to include the sectional strip of wood, nor is the frame  410  required be rectangular, and any other shape, such as a triangle, diamond, polygon, circle, among others, may be used. An advantage that the frame  410  contributes is to providing a built-in air gap to the sound panel  100 , thereby enhancing the performance of the sound panel  100 . In the current embodiment, the frame  410  is made of thin wood; however, other materials and thicknesses of materials may be used. Additionally, in other embodiments, frame  410  may not be required. The peripheral components of the frame  410  ( 412 ,  413 ,  414 ,  415 ,  416 ,  417 ,  418 , and  419 )) also let in lower frequencies. 
       FIG. 7  shows the bottom surface  421  of frame  410  placed on the top surface  311  of the absorption member  310 . In the current embodiment, the top surface  311  of the absorption member  310  faces upward, and the membrane  210 , absorption member  310 , and frame  410  are placed in the middle of the outer fabric  110 ; however, such a configuration is not required. In this embodiment, the size, or the distances from the back end  413  to the front end  417  and the left end  415  to the right end  419  of the frame  410  are approximately equal to the size, or distances from the back end  313  to the front end  317  and the left end  315  to the right end  319  of the absorption member  310 . However, such a configuration is not required and the frame  410  may be different in size to the absorption member  310 . The sound panel  100  may be placed between a wall or other divider. In other aspects the sound panel  100  may be affixed to a wall or divider in a permanent manner or non-permanent manner. The sound panel  100  may be placed in a manner where there is space between the the sound panel  100  and the wall or divider. Ultimately, the space between the absorption member  310  and the surface of the wall or divider will affect, and usually increase, low end performance. 
     As shown in  FIG. 8 , inner fabric  510  is placed over frame  410 . In the current embodiment, the inner fabric  510  includes a back end  513 , a front end  517 , a top surface  511 , and a bottom surface  521  (not shown). Also, the inner fabric  510  includes a left end  515 , a right end  519 , and corners  512 ,  514 ,  516 , and  518 . In the current embodiment, the inner fabric  510  is made to be approximately the same size as the frame  410  and is fastened to the frame  410 . The inner fabric  510  may be fastened to the frame  410  by the use of staples, nails, screws, ties, glue, or clips, among other fasteners. However, the inner fabric  510  is not required to be the same size as the frame  410  nor is it required to be the same shape. Additionally, the inner fabric  510  does not have to be fastened to the frame. In the current embodiment, the inner frame is made of muslin fabric; however, other materials and types of fabrics may be used. Moreover, in alternative embodiments, the inner fabric  510  is not required. The inner fabric  510  provides a density function for lower frequencies. 
       FIG. 9  shows that the frame  410  and inner fabric  510  unit has been inverted on the absorption member  310 . In  FIG. 9  it is shown that the top surfaces  411  and  511  of the frame  410  and inner fabric  510 , respectively, are now facing the top surface  311  of the absorption member  310 , as opposed to the configuration in  FIG. 8 . 
     In  FIG. 10 , boards  610 ,  620 ,  630  (not shown), and  640  (not shown) are fastened to the exterior frame, which includes the outer portions of back ends ( 213 ,  313 ,  413 , and  513 ), front ends ( 217 ,  317 ,  417 , and  517 ), left ends ( 215 ,  315 ,  415 , and  515 ), right ends ( 219 ,  319 ,  419 , and  519 ), and corners ( 212 ,  214 ,  216 ,  218 ,  312 ,  314 ,  316 ,  318 ,  412 ,  414 ,  416 ,  418 ,  512 ,  514 ,  516 , and  518 ). However, boards  610 ,  620 ,  630  (not shown), and  640  (not shown) are not required to cover or be fastened to all of the exterior frame (previously described). In the current embodiment, the boards  610 ,  620 ,  630  (not shown), and  640  (not shown) are made to be approximately the same height as the combination of the membrane  210 , absorption member  310 , frame  410 , and inner fabric  510 . A specific height is not required and other heights may be used. Additionally, the boards  610 ,  620 ,  630  (not shown), and  640  (not shown) are fastened to the exterior frame (previously described), which may be done by the use of staples, nails, screws, glue, ties, or clips, among other fasteners. The boards  610 ,  620 ,  630  (not shown), and  640  (not shown) lets in lower frequencies. However, boards  610 ,  620 ,  630  (not shown), and  640  (not shown) do not have to be fastened to the exterior frame (previously described). In the current embodiment, the boards  610 ,  620 ,  630  (not shown), and  640  (not shown) are made of fiberboard that is 1/16 inch thick; however, other materials and thicknesses may be used. Moreover, in alternative embodiments, the boards  610 ,  620 ,  630  (not shown), and  640  (not shown) are not required. 
     In  FIG. 11 , it is shown that portions of the outer fabric  110  are folded upon the sides of the combination of the membrane  210 , absorption member  310 , frame  410 , inner fabric  510 , and boards  610 ,  620 ,  630  (not shown), and  640  (not shown). In the current embodiment, the back end  113  is folded upon the back ends  213 ,  313 ,  413 ,  513 , and board  640  (not shown), the front end  117  is folded upon the front ends  217 ,  317 ,  417 ,  517 , and board  620 , the left end  115  is folded upon the left ends  215 ,  315 ,  415 ,  515 , and board  610 , the right end  119  is folded upon the right ends  219 ,  319 ,  419 ,  519 , and board  630  (not shown), and the corners  112 ,  114 ,  116 , and  118  are folded upon their respective corners  212 ,  214 ,  216 ,  218 ,  312 ,  314 ,  316 ,  318 ,  412 ,  414 ,  416 ,  418 ,  512 ,  514 ,  516 , and  518 . After the portions of the outer fabric  110 , described above, are folded upon the sides (as described above), the portions of the outer fabric  110  are fastened to the combined sides (previously described), which may be done by the use of staples, nails, screws, glue, ties, or clips, among other fasteners. However, the portions of the outer fabric  110  do not have to be fastened to the combined sides (previously described), and in alternative embodiments, the outer fabric  110  may not be folded upon the combined sides (previously described). 
       FIGS. 12 and 13  show a constructed sound panel  100 , in the current embodiment, from different perspective views. 
     As previously mentioned, one possible method of construction for sound panel  100  is shown in  FIGS. 1-11 . However, such a method of construction is not required, as some elements are not required and the order of operations may be modified and adjusted. By way of example,  FIG. 1  shows the outer fabric  110  placed on a flat surface to begin construction. Next, as shown in  FIGS. 2-3 , membrane  210  is placed on the top surface  111  of the outer fabric  110 . Absorption member  310  may then be placed on the top surface  211  of membrane  210 , as shown in  FIGS. 4-5 . As shown in  FIGS. 6-7 , frame  410  is placed on the top surface  311  of the absorption member  310 , so the bottom surface  421  of frame  410  is facing the top surface  311 . In  FIG. 8 , inner fabric  510  is placed and fastened on the top surface  411  of the frame  410 . Next, as shown in  FIG. 9 , the frame  410  is inverted with respect to the absorption member  310 ; as such, top surface  411  of frame  410  is facing the top surface  311  of absorption member  310 . In  FIG. 10 , boards  610 ,  620 ,  630  (not shown), and  640  (not shown) are placed and fastened on the exterior frame (as previously described). Finally, as shown in  FIG. 11 , portions of the outer fabric  110  are folded upon and fastened to the combined sides (previously described). Once the steps of  FIGS. 1-11  are completed, the sound panel  100 , of the current embodiment, as shown  FIGS. 12 and 13 , is constructed. 
     One should note that conditional language, such as, among others, “can,” “could,” “might,” or “may,” unless specifically stated otherwise, or otherwise understood within the context as used, is generally intended to convey that certain embodiments include, while other embodiments do not include, certain features, elements and/or steps. Thus, such conditional language is not generally intended to imply that features, elements and/or steps are in any way required for one or more particular embodiments or that one or more particular embodiments necessarily include logic for deciding, with or without user input or prompting, whether these features, elements and/or steps are included or are to be performed in any particular embodiment. 
     It should be emphasized that the above-described embodiments are merely possible examples of implementations, merely set forth for a clear understanding of the principles of the present disclosure. Any process descriptions or blocks in flow diagrams should be understood as representing modules, segments, or portions of code which include one or more executable instructions for implementing specific logical functions or steps in the process, and alternate implementations are included in which functions may not be included or executed at all, may be executed out of order from that shown or discussed, including substantially concurrently or in reverse order, depending on the functionality involved, as would be understood by those reasonably skilled in the art of the present disclosure. Many variations and modifications may be made to the above-described embodiment(s) without departing substantially from the spirit and principles of the present disclosure. Further, the scope of the present disclosure is intended to cover any and all combinations and sub-combinations of all elements, features, and aspects discussed above. All such modifications and variations are intended to be included herein within the scope of the present disclosure, and all possible claims to individual aspects or combinations of elements or steps are intended to be supported by the present disclosure.