Soundproof ventilation panel and its manufacturing method

Abstract

An acoustic ventilation panel is provided. The panel includes a core assembly having a plurality of horizontal channels, a pair of cartridges having a hollow center and flanking the core assembly, and a pair of hollow sides located on the pair of cartridges. Each of the cartridges has a proximally facing side having a plurality of air channel side openings and a distally facing side having a plurality of sound resonator side openings. A vertically oriented ventilation groove is formed through a front side of a first one of the cartridges, and a vertically oriented ventilation groove is formed through a rear side of a second one of the cartridges. The ventilation groove, hollow center, air channel side openings, and horizontal channels together partially define a Z-shaped air channel. The sound resonator side openings and hollow sides partially define a plurality of resonators.

Description

[Technical field]

[0001] [CROSS REFERENCE TO RELATED APPLICATIONS] This application claims priority to and the benefit of U.S. Provisional Patent Application 63 / 220827, entitled "SOUND ISOLATING VENTILATION PANELS AND METHODS FOR MANUFACTURING SAME," filed July 12, 2021, which is incorporated by reference in its entirety for all purposes. For U.S. purposes, this application claims the benefit under 35 U.S.C. § 119 of U.S. Provisional Patent Application 63 / 220827, entitled "SOUND ISOLATING VENTILATION PANELS AND METHODS FOR MANUFACTURING SAME," filed July 12, 2021.

[0002] This invention relates generally to sound-attenuating ventilation panels, such as doors, and methods of making same. [Background technology]

[0003] In commercial and institutional buildings, it is standard for all interior spaces to have a dedicated fresh air supply and return / exhaust. This air may also be conditioned (heated / cooled, humidity controlled). Depending on the building, floor plan, and mechanical system, outside air enters the building and passes through ventilation equipment and ducts, as well as occupied spaces and interior ventilation openings, before being exhausted to the outside. Most commercial buildings use mechanical fans to move air through the system and building, but some employ natural forces such as thermal buoyancy and wind pressure. Common air transfer openings between rooms in a building include door undercuts (the gap between the bottom of the door and the floor), grilles, and transfer ducts. Airflow capacity depends on the cross-sectional area, the shape of the flow path, and any obstructions in the flow path. Through a given ventilation opening or duct, air pressure differential and airflow rate are directly related (airflow is proportional to the square root of the pressure difference). Ventilation system engineers design systems to supply air to each space, taking into account floor area and occupancy, at minimum limits specified by standards organizations.

[0004] For a given size panel (such as a door) that divides a space and provides a means of air transfer, it is generally desirable to maximize the capacity for airflow to increase the application of the panel to spaces requiring higher airflow rates.

[0005] When sound is incident on a panel, components of energy are reflected, absorbed, and transmitted by the panel. Sound transmission is quantified by the transmission coefficient, tao, which is the ratio of the transmitted energy to the total incident sound energy, as well as the transmission loss, which is the decibel reduction in sound level across the panel. For a given panel, both quantities vary across the frequency spectrum.

[0006] Considering a sound source on one side of a single homogeneous panel, the transmission loss of sound through the panel is determined primarily by the mass of the panel per unit area and increases with frequency at 6 dB / octave. In Figure 1 (from Noise Reduction, edited by L.L. Beranek, McGraw-Hill, New York, 1960), Region II shows the mass-controlled band. At frequencies below Region I, the mass-controlled band, panel resonances cause large variations in transmission loss.

[0007] Additionally, the stiffness of the panel affects transmission loss, and bending waves propagate in the plane of the panel with a wavelength that depends on the bulk modulus and density of the panel. For sound incident on a panel at an angle other than 90 degrees, when the angle of incidence and wavelength combine to produce a fraction of a wavelength along the panel equal to the bending wavelength of the panel, a type of resonance occurs, known as "coincidence." The coincidence effect causes more sound to be transmitted, and the "critical frequency" f c From the axial direction upwards, the grazing incident wavelengths start to influence bending waves in the panel, as shown in region III.

[0008] The primary strategy for increasing the sound transmission loss of a single homogeneous panel (increasing its sound insulation) is to increase its mass and thus shift the transmission loss upwards in the mass-controlled band. Two further strategies can increase the transmission loss: by reducing the stiffness, i.e., moving the critical frequency and the decrease in coincidence effect upwards along the frequency axis, and by adding internal damping, i.e., reducing the magnitude of the panel resonances and the decrease in coincidence in transmission loss.

[0009] Two panels separated by an air gap present another option for increasing sound insulation. At the lower end of the frequency spectrum, the air gap acts as a spring, acoustically coupling the panels together to act as a single panel. At frequencies above where the separation distance is equal to 1 / 4 wavelength, the air gap acts to separate the two panels and the transmission loss increases at 18 dB / octave. A reduction in sound transmission due to the coincidence effect is also present in each of the two panels. The transmission loss can be further increased by adding acoustic material between the two panels. This further separates the two panels by damping the waves traveling between the panels and reducing standing waves.

[0010] Airborne sound can be absorbed by dissipative or reactive means. Dissipative sound absorbers, such as open-cell porous materials, resist the organized molecular motion of sound energy and convert it into heat. Reactive sound absorbers employ mechanical or acoustic resonance to increase particle velocity across tuned frequency bands, presenting the opportunity for sound energy in these frequency bands to be absorbed (converted to heat) through the combined use of dissipative materials, or essentially through air absorption. The term "baffle" generally refers to constructions that absorb sound by dissipative or reactive means (e.g., interior ceiling tiles) and constructions that block sound (e.g., highway sound barriers).

[0011] The embodiment described in U.S. Patent 10,612,239 entitled "PANEL AND PANEL STRUCTURE FOR VENTILATION AND BOTH REACTIVE AND DISSIPATIVE SOUND DAMPENING" allows passive air transfer between rooms via Z-shaped air channels through the grooves on the front / back and the hollow center. Sound transmission across the panel and through the air channels is dissipated by sound absorbing baffles in the hollow center and resonators on the perimeter of the grooves.

[0012] The embodiments previously disclosed in US Patent No. 10612239 present challenges related to manufacturability (and therefore cost) and sound transmission performance. Challenges include: - A large number of components are required between the upper sheet (skin) and the lower sheet (skin). - Uses internal components that must be joined (using dowels or floating tenons) at the frame before being laminated to the top / bottom sheets (skins). - Using components that must be loosely positioned during assembly, without direct contact or adjustment with other internal components. - Requires machining of the ventilation grooves after assembly and does not provide a means to restrict dirt and shavings from entering the panel air flow passages during machining. - Use components that prevent the assembly from moving backwards and require ventilation grooves to be machined into specific sides, which must be tracked after assembly. - Requires thick top / bottom skins to provide adequate structure to groove edges. - Limited use with fair soundproofing performance only. - Limited use due to capacity for fair airflow only. - There is little opportunity to apply a surface finish to the internal surfaces visible through the inlet and outlet ventilation channels. - Heavy door skin makes it heavier than a typical hollow interior door, which impacts transportation and installation. - Breakage / crack damage due to stress concentration at the opening / neck of the rectangular resonator.

[0013] Improved panels that address at least some of these challenges are desirable. Summary of the Invention

[0014] The present invention has various aspects, including, but not limited to, acoustic ventilation panels, methods of making acoustic ventilation panels, and cartridge and core components useful in acoustic ventilation panels.

[0015] In one aspect, an acoustic ventilation panel is provided. The panel includes a core assembly including a plurality of horizontal channels, a pair of cartridges having a hollow center and flanking the core assembly, and a pair of hollow sides located on the pair of cartridges. Each of the cartridges includes a proximally facing side having a plurality of air channel side openings and a distally facing side having a plurality of sound resonator side openings. A vertically oriented ventilation groove is formed through a front side of a first one of the cartridges, and a vertically oriented ventilation groove is formed through a rear side of a second one of the cartridges. The ventilation groove, hollow center, air channel side openings, and horizontal channels together partially define a Z-shaped air channel. The sound resonator side openings and hollow sides partially define a plurality of resonators.

[0016] The frame may include an upper rail, a lower rail, and two stiles, where the pair of cartridges may be disposed between the upper rail and the lower rail, where the upper rail, the lower rail, the two stiles, and the distally-facing side may partially define a hollow side.

[0017] The frame may include a front skin and a back skin, where the frame, the core assembly, and the pair of cartridges may be supportively disposed between the front skin and the back skin. A vertically oriented ventilation groove formed through the front surface of a first one of the cartridges may be formed through the front skin, and a vertically oriented ventilation groove formed through the back surface of a second one of the cartridges may be formed through the back skin.

[0018] Each of the cartridges may have a horizontal plane of symmetry and a vertical plane of symmetry.

[0019] Each of the plurality of air flow passage side openings may be aligned with a corresponding one of the plurality of horizontal flow passages.

[0020] The air passage openings may be identical and equally spaced apart, and the sound resonator openings may be identical and equally spaced apart.

[0021] The plurality of air passage side openings may be larger than the plurality of sound resonator side openings, and may be fewer in number.

[0022] The plurality of air flow passage side openings may be arranged in series in a straight line, and the plurality of sound resonator side openings may be arranged in series in a straight line.

[0023] Each space between the air passage openings may be at least 1 inch.

[0024] Each of the cartridges may extend to at least 80%, or at least 90% of the height of the panel.

[0025] The horizontal channels may be formed at least in part from folded cardboard.

[0026] The interior surface of the horizontal channel may include an acoustic absorbing lining of a porous dissipative material such as open cell foam, mineral wool or fiberglass.

[0027] The core assembly may occupy substantially all of the space between the pair of cartridges.

[0028] The core assembly may include between 6 and 24 adjacently arranged horizontal channels.

[0029] The walls between adjacent horizontal channels may include a plurality of openings to increase the exposed surface area of ​​the acoustic lining.

[0030] The hollow sides may include a porous dissipative sound absorbing material.

[0031] Another aspect provides a method of manufacturing an acoustic ventilation panel, the method comprising: a. providing a frame having an upper rail, a lower rail, and two stiles; b. providing a core assembly having a plurality of horizontal channels; c. providing a pair of cartridges having a hollow center, the cartridges positioned between an upper rail and a lower rail, on opposite sides of the core assembly, each cartridge having a proximally facing side having a plurality of air passage openings aligned with the plurality of horizontal passages, and a distally facing side having a plurality of sound resonator openings; d. providing a front skin and a rear skin, whereby the space between the sound resonator side opening and the frame, the distally facing side surface, and the front skin and rear skin define a resonator; e. forming a vertically oriented ventilation groove through the front skin and the front surface of a first one of the cartridges, and forming a vertically oriented ventilation groove through the rear skin and the rear surface of a second one of the cartridges, whereby the ventilation groove, hollow center, air flow path side openings and horizontal flow path together define a Z-shaped air flow path.

[0032] Step c. may further include inserting an insert into each of the cartridges, the insert having a blocking portion and a receiving portion, the blocking portion substantially blocking the air flow path side opening and the sound resonator side opening from the receiving portion configured to receive dust and debris generated by step e., regardless of whether the vertically oriented ventilation groove is formed on the front or back of the cartridge, and after step e., the insert is removed from the cartridge through the vertically oriented ventilation groove.

[0033] Prior to step c., the proximal and distal facing sides may be manufactured by (i) cutting a rectangular block having the length of the cartridge, (ii) stacking the cut blocks, and (iii) drilling air passage side openings or sound resonator side openings through the stacked blocks.

[0034] Prior to step c., the proximal and distal facing sides may be manufactured by (i) drilling slots sized to the air passage side openings or sound resonator side openings through an elongated rectangular block having the length of the cartridge, (ii) cutting the joinery contour into the drilled elongated rectangular block, and (iii) ripping the contoured and drilled elongated block into individual proximal or distal facing sides.

[0035] Prior to step c., the proximal and distal facing sides may be manufactured by (i) preparing two sheets each having the length of the cartridge, sandwiching ribs spaced between the sheets, and matching the rib spacing to the dimensions of the air flow passage opening or sound resonator opening, and (ii) cutting the sheets into strips for the proximal or distal facing sides.

[0036] Prior to step c., the cartridge may be manufactured by (i) adhering a proximally facing side, a distally facing side, and two supports together to form a cartridge, (ii) stacking multiple cartridges from step (i), and (iii) pressing the stacked cartridges vertically and / or horizontally.

[0037] Another aspect provides a cartridge for an acoustic ventilation panel, the cartridge comprising: A hollow center, The front and The back side opposite the front side, a proximally facing side having a plurality of air flow passage openings; a distally facing side having a plurality of sound resonator openings; and vertically oriented ventilation channels formed through the front or rear surface.

[0038] The cartridge may have a horizontal plane of symmetry and a vertical plane of symmetry.

[0039] The air passage openings may be identical and equally spaced apart, and the sound resonator openings may be identical and equally spaced apart.

[0040] The plurality of air passage side openings may be larger than the plurality of sound resonator side openings, and may be fewer in number.

[0041] The plurality of air flow passage side openings may be arranged in series in a straight line, and the plurality of sound resonator side openings may be arranged in series in a straight line.

[0042] Each space between the air passage openings may be at least 1 inch.

[0043] Another aspect provides a core component for an acoustic ventilation panel, the core component comprising a single corrugated sheet folded to define two channels having rectangular cross sections.

[0044] The sheet may include a plurality of linearly arranged slots in a midsection of the sheet and a corresponding plurality of tabs at ends of the sheet for engaging the slots to facilitate forming at least one of the flow channels.

[0045] The two channels may be of equal size.

[0046] It is emphasized that the invention relates to all combinations of the above features with each other and / or with other features described elsewhere in this specification and / or illustrated in the drawings, even if recited in different claims, different paragraphs and / or different sentences.

[0047] In addition to the exemplary aspects and embodiments described above, further aspects and embodiments will become apparent by reference to the drawings and by study of the following detailed description.

[0048] The accompanying drawings illustrate non-limiting exemplary embodiments of the present invention. [Brief description of the drawings]

[0049] [Figure 1] 1 is a chart showing theoretical transmission loss of a homogeneous infinite panel. [Figure 2A] FIG. 2 is a front view of a panel according to an embodiment with the top skin removed to show the internal components. [Figure 2B] FIG. 2B is a front view of a panel according to the embodiment shown in FIG. 2A. [Figure 2C] FIG. 2B is a longitudinal cross-sectional view taken along plane AA in FIG. 2A. [Figure 2D] FIG. 2C is a close-up view of detail B of FIG. 2B. [Figure 3A] FIG. 2B is a partial front view of a panel according to the embodiment shown in FIG. 2A. [Figure 3B] FIG. 3B is a horizontal cross-sectional view taken along plane CC in FIG. 3A. [Figure 3C] FIG. 3C is a close-up view of detail D of FIG. 3B. [Figure 4A] FIG. 2 is a front view of a panel according to an embodiment. [Figure 4B] FIG. 4B is a longitudinal section along plane EE of FIG. 4A. [Figure 4C] FIG. 4C is a close-up view of detail F of FIG. 4B. [Figure 5A] FIG. 4B is a partial front view of a panel according to the embodiment shown in FIG. 4A. [Figure 5B] FIG. 5B is a horizontal cross-sectional view taken along plane GG in FIG. 5A. [Figure 5C] FIG. 5C is a close-up view of detail H of FIG. 5B. [Figure 6A] FIG. 2B is a perspective view of the air flow path side of the cartridge of the panel according to the embodiment shown in FIG. 2A. [Figure 6B]2B is a perspective view of the cartridge side of the panel according to the embodiment shown in FIG. 2A. FIG. [Figure 7A] 1 is a horizontal cross-sectional view of a cartridge according to an embodiment of the present invention. [Figure 7B] 1 is a horizontal cross-sectional view of a cartridge according to an embodiment of the present invention. [Figure 7C] 1 is a horizontal cross-sectional view of a cartridge according to an embodiment of the present invention. [Figure 7D] 1 is a horizontal cross-sectional view of a cartridge according to an embodiment of the present invention. [Figure 8A] FIG. 2B is a partial side view of the cartridge proximal-facing side of the panel according to the embodiment shown in FIG. 2A. [Figure 8B] 2B is a horizontal cross-sectional view of the cartridge proximal-facing side of the panel according to the embodiment shown in FIG. 2A. [Figure 9A] FIG. 2B is a partial side view of the cartridge distal-facing side of the panel according to the embodiment shown in FIG. 2A. [Figure 9B] 2B is a horizontal cross-sectional view of the cartridge distal-facing side of the panel according to the embodiment shown in FIG. 2A. [Figure 10A] FIG. 2B is a partial front view of the support of the cartridge of the panel according to the embodiment shown in FIG. 2A. [Figure 10B] 2B is a horizontal cross-sectional view of the support of the cartridge of the panel according to the embodiment shown in FIG. 2A. [Figure 11A] 13A-13D illustrate a rabbet cutting step that forms the proximally and distally facing sides as part of a method of manufacturing a panel according to an embodiment. [Figure 11B] 13A-13D illustrate a slotting step to form proximally and distally facing sides as part of a method of manufacturing a panel according to an embodiment. [Figure 11C] 13A-13D illustrate a slotting step to form the proximal and distal facing sides of the cartridge as part of a method of manufacturing a panel according to an embodiment. [Figure 11D]13A-13C illustrate a joinery contouring step for forming the proximal and distal facing sides of a cartridge as part of a method for manufacturing a panel according to an embodiment. [Figure 11E] 13A-13D illustrate a cleaving step to form proximally and distally facing sides of a cartridge as part of a method of manufacturing a panel according to an embodiment. [Figure 11F] 13A-13D illustrate a slotting step to form the proximal and distal facing sides of the cartridge as part of a method of manufacturing a panel according to an embodiment. [Figure 11G] 13A-13C illustrate a joinery contouring step for forming the proximal and distal facing sides of a cartridge as part of a method for manufacturing a panel according to an embodiment. [Figure 11H] 13A-13D illustrate a cleaving step to form proximally and distally facing sides of a cartridge as part of a method of manufacturing a panel according to an embodiment. [Figure 12A] 13A-13C are perspective views of sheets laid down to form the proximal and distal facing sides of a cartridge as part of a method of manufacturing a panel according to an embodiment. [Figure 12B] FIG. 12B is a side view of the laid down sheet shown in FIG. 12A. [Figure 12C] 13A-13C are side views of sheets laid down to form the proximal and distal facing sides of a cartridge as part of a method of manufacturing a panel according to an embodiment. [Figure 13A] 13A-13D illustrate a pressing step for assembling a tongue and groove cartridge as part of a method for manufacturing a panel according to an embodiment. [Figure 13B] 13A-13C illustrate a pressing step for assembling a tongue and groove cartridge as part of a method for manufacturing a panel according to an embodiment. [Figure 13C] 13A-13C illustrate a pressing step for assembling a tongue and groove cartridge as part of a method for manufacturing a panel according to an embodiment. [Figure 13D]13A-13D illustrate a pressing step for assembling a drawer locking joint cartridge as part of a method for manufacturing a panel according to an embodiment. [Figure 13E] 13A-13D illustrate a pressing step for assembling a drawer locking joint cartridge as part of a method for manufacturing a panel according to an embodiment. [Figure 14A] FIG. 2B is a perspective view of a dual flow path core element of a panel according to the embodiment shown in FIG. 2A. [Figure 14B] FIG. 14B is a side view of the dual channel core element shown in FIG. 14A. [Figure 14C] FIG. 14B is a plan view of the dual channel core element blank shown in FIG. 14A. [Figure 15A] FIG. 14B is a perspective view of the dual flow path core element shown in FIG. 14A with an acoustic absorbing lining. [Figure 15B] FIG. 15B is a side view of the dual channel core element shown in FIG. 15A. [Figure 16] FIG. 13 is a side view of multiple single-channel core elements of a panel according to an embodiment. [Figure 17] FIG. 2 is a perspective view of a core assembly of a panel according to an embodiment. [Figure 18A] FIG. 2 is a partial side view of a core assembly of a panel according to an embodiment. [Figure 18B] FIG. 2 is a partial side view of a core assembly of a panel according to an embodiment. [Figure 18C] FIG. 2 is a partial side view of a core assembly of a panel according to an embodiment. [Figure 19A] 1 is a photograph showing construction of a core assembly of a panel according to an embodiment. [Figure 19B] 1 is a photograph showing construction of a core assembly of a panel according to an embodiment. [Figure 20] 3 is a photograph of a blank for a core element of a panel according to an embodiment. [Figure 21A] 1 is a perspective view of a dust blocking insert according to an embodiment of the present invention; [Figure 21B] 21B is a horizontal cross-sectional view of the dust blocking insert shown in FIG. 21A inside the cartridge of the panel according to the embodiment shown in FIG. 2A. [Figure 21C] 21B is a photograph of a horizontal cross section of the dust blocking insert shown in FIG. 21A inside the cartridge of a panel according to the embodiment shown in FIG. 2A. [Figure 22A] 2C is a photograph showing steps for removal of the dust blocking insert shown in FIG. 21A inside the cartridge of the panel according to the embodiment shown in FIG. 2A. [Figure 22B] 2C is a photograph showing steps for removal of the dust blocking insert shown in FIG. 21A inside the cartridge of the panel according to the embodiment shown in FIG. 2A. [Figure 22C] 2C is a photograph showing steps for removal of the dust blocking insert shown in FIG. 21A inside the cartridge of the panel according to the embodiment shown in FIG. 2A. [Figure 22D] 2C is a photograph showing steps for removal of the dust blocking insert shown in FIG. 21A inside the cartridge of the panel according to the embodiment shown in FIG. 2A. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0050] Throughout the following description, specific details are set forth in order to provide a more thorough understanding of the invention. However, the invention may be practiced without these specific details. In other instances, well-known elements have not been shown or described in detail to avoid unnecessarily obscuring the invention. Accordingly, the specification and drawings are to be regarded in an illustrative rather than a restrictive sense.

[0051] 2A-2D, 3A-3C, 6A, 6B, 14A-14C, 15A, 15B, 21B, 21C and 22A-22D show a soundproof ventilation panel 100 and its components according to an embodiment.

[0052] panel As shown in Figure 2A, the panel 100 has a rectangular frame 102 consisting of horizontal top and bottom rails 104 and vertical side stiles 106. The frame 102 surrounds a core assembly 120 which occupies the center of the frame 102. The core assembly 120 is flanked on either side by a pair of cartridges 140. A resonator 160 defines the space between the cartridge 140 and the stiles 106. A hardware block 162 occupies the space between the cartridge 140 and the stiles 106 as well as the resonator 160.

[0053] FIG 2A shows the panel 100 with the front skin 108 and back skin 110 omitted. FIGs 2A-3C show the panel 100 with the front skin 108 and back skin 110 sandwiching the frame 102, the core assembly 120 and the cartridge 140. FIGs 4A-5C show a panel 200 according to another embodiment having an intermediate front layer 209 below the front skin 208 and an intermediate back layer 211 below the back skin 210. The panel 200 has the intermediate layers 209 and 211 due to its additional thickness compared to the panel 100. For example, the panel 100 may be a 1.375 inch panel and the panel 200 may be a 1.75 inch panel.

[0054] A method for manufacturing an acoustic ventilation panel, such as the panels 100, 200, is also provided. The steps include: (a) providing a frame having an upper rail, a lower rail, and two stiles; (b) providing a core assembly having a plurality of horizontal channels; (c) providing a pair of cartridges having a hollow center, the cartridges being located between the upper rail and the lower rail and on either side of the core assembly, each of the cartridges having a proximally facing side having a plurality of air channel side openings aligned with the plurality of horizontal channels, and a distally facing side having a plurality of sound resonator side openings; (d) providing a front skin and a rear skin, whereby the space between the stiles, the distally facing side, the front skin and the rear skin (the resonator cavity), and the sound resonator side openings define a resonator; and (e) forming a vertically oriented ventilation groove through the front skin and a front surface of a first one of the cartridges, and forming a vertically oriented ventilation groove through the rear skin and a rear surface of a second one of the cartridges, whereby the ventilation groove, hollow center, air channel side openings, and the horizontal channels together define a Z-shaped air flow path.

[0055] As shown in Figures 21A-21C, in some embodiments, step e. includes inserting a dust blocking insert 400 into the cartridge to prevent dust and debris from infiltrating the panel during formation of the ventilation grooves. The insert 400 has a blocking portion 402, a receiving portion 404, and a receiving groove 406. The blocking portion 402 substantially blocks the air passage opening and the acoustic resonator opening from the receiving portion 404 and the receiving groove 406, which are then shaped to trap and collect dust and debris generated by step e., the ventilation groove formation step. Because the shape of the insert 400 is configured the same on both the front and rear sides, dust and debris will be trapped and prevented from entering the air passage opening and the acoustic resonator opening regardless of whether the vertically oriented ventilation grooves are formed on the front or rear of the cartridge. After step e., the insert 400 can be withdrawn from the cartridge through the vertically oriented ventilation grooves, as shown in Figures 22A to 22D.

[0056] For example, compared to the embodiment described in U.S. Patent 10,612,239, the present method employs fewer total components and fewer components in the laying stage, so that each door can be assembled faster and more doors can be stacked, increasing manufacturing throughput. Furthermore, the components of the panels described herein can be modified to be sized for simple and precise placement and alignment during assembly, because their combined surface area accounts for a majority of the total surface area of ​​the panel (see, e.g., FIG. 1), and because each component is flush with or in contact with surrounding components (e.g., core elements are connected to form a substantially single core assembly, which is sandwiched between cartridges, which are sandwiched between rails, etc.), further increasing the ease and speed of assembly.

[0057] cartridge The cartridges 140 are elongated as shown in Figures 2A, 6A and 6B, and have a generally rectangular cross-section with a hollow center 142 as shown in Figures 7A-7D. Each cartridge 140 has a proximally facing side 143 with a plurality of air passage openings 144, and a distally facing side 145 with a plurality of sound resonator openings 146. Bridging the proximally facing side 143 and the distally facing side 145 are two supports 147, each having a front face 152 and a rear face 154. Figure 7A shows a cross-section of the cartridge 140 without showing the side views for the support members. Figures 7B-7D show a tongue and groove joiner, a tongue and groove joiner, and a drawer lock joiner, respectively.

[0058] The air flow channel side openings 144 align and connect with corresponding horizontal channels 122 to provide an uninterrupted flow of air therethrough. The air flow channel side openings 144 are identical, equally spaced, and arranged in series in a straight line. In some embodiments, the space 156 between the air flow channel side openings 144 is at least 1 inch to provide sufficient structural support and rigidity to the panel 100. In some embodiments, the air flow channel side openings 144 are different sizes and / or are not equally spaced.

[0059] The sound resonator side openings 146, the resonator 160, and the skins 108, 110 define the Hemholtz resonator of the panel 100. The sound resonator side openings 146 are identical, equally spaced, and arranged in a linear series. The sound resonator side openings 146 are smaller and more numerous than the air passage side openings 144. In some embodiments, the resonator can be tuned to absorb varying sound levels across different frequency bands by varying the size, shape, and spacing of the sound resonator side openings 146, the thickness of the distally facing side 145 (i.e., the length of the resonator neck), the volume of the resonator 160 between the stile 106 and the cartridge 140, and the addition of the amount and placement of sound absorbing material in the resonator 160. In some embodiments, the sound resonator side openings 146 are differently sized and / or not equally spaced.

[0060] A vertically oriented front ventilation groove 148 is formed through the front skin 108 and the front face 152 of the first cartridge 140, and a vertically oriented rear ventilation groove 150 is formed through the rear skin 110 and the rear face 154 of the second cartridge 140. The ventilation grooves 148, 150, the hollow center 142 and air passage side openings 144 of the cartridge 140, and the horizontal passages 122 of the core assembly 120 together define a Z-shaped air passage through the panel 100. The cartridge 140 provides structural support (tensile / compressive stiffness and strength) to the skins 108, 110 around the perimeter of the ventilation grooves 148, 150. The thickness and stiffness added by the cartridge 140 when adhered to the skins 108, 110 mitigates warping at the edges of the ventilation grooves 148, 150.

[0061] Because the interior of the cartridge 140 forms the visible inner surface of the panel 100, in some embodiments the cartridge 140 may be constructed of a higher quality material (e.g., plywood) having a surface suitable for being pre-finished before the cartridge 140 is assembled. Finishes may include primers, paints, clear coats, veneers, plastic laminates, and the like. These finishes may also be applied to the cut surfaces of the cartridge 140 after the ventilation channels 148, 150 have been formed.

[0062] 6A and 6B, the cartridge 140 has both horizontal and vertical planes of symmetry, allowing for vertically oriented ventilation grooves 148, 150 to be formed on either side 152, 154. In other words, the vertically oriented ventilation grooves 148, 150 are reversible, and vertically oriented ventilation grooves 148, 150 cannot be accidentally formed on the wrong side of the cartridge.

[0063] In some embodiments, each of the cartridges 140 extends at least 70%, at least 80%, or at least 90% of the height of the panel 100 .

[0064] Methods of manufacturing cartridges, such as cartridge 140, are also provided. As shown in Figures 11A and 11B, in some embodiments, prior to step c. of the method of manufacturing the panels, the proximal and distal facing sides of the cartridge may be manufactured by (i) cutting a rabbet into a rectangular block having the length of the cartridge, (ii) stacking the rabbet-cut blocks, and (iii) drilling air passage or sound resonator openings through the stacked blocks.

[0065] As shown in Figures 11C-11E (tongue and groove joinery) and Figures 11F-11H (drawer lock joinery), in some embodiments, prior to step c. of the method of making a panel, the proximal and distal facing sides of the cartridge may be manufactured by (i) drilling holes sized for the air passage side openings or sound resonator side openings through an elongated rectangular block having the length of the cartridge, (ii) scoring the joinery contour into the drilled elongated rectangular block, and (iii) ripping the contoured and drilled elongated block into individual proximal or distal facing sides.

[0066] As shown in Figures 12A to 12C, in some embodiments, prior to step c. of the method for manufacturing the panel, the proximal and distal facing sides of the cartridge may be manufactured by (i) preparing two sheets, each having the length of the cartridge, sandwiching a rib between the sheets with the rib spacing matched to the dimensions of the air flow passage side opening or the sound resonator side opening, and (ii) cutting the sheets into strips for the proximal or distal facing sides.

[0067] As shown in Figures 13A-13E, in some embodiments, prior to step c. of the method of manufacturing a panel, a cartridge may be manufactured by (i) gluing together a proximally facing side, a distally facing side, and two supports to form a cartridge, (ii) stacking a plurality of cartridges from step (i), and (iii) compressing the stacked cartridges vertically and / or horizontally. As shown in Figure 13A, a tongue and groove joint requires pressure in both directions, while as shown in Figures 13B and 13C, a tongue and groove joint requires horizontal pressure, and as shown in Figures 13D and 13E, a drawer lock joint requires vertical pressure.

[0068] In yet other embodiments, the cartridge may be constructed from other materials and printed, injection molded or extruded.

[0069] core In the panel 100, the core assembly 120 is formed from six dual channel core elements 126. The core assembly 120 occupies all or substantially all of the space between the pair of cartridges 140 and the rails 104. Figures 14A-15B show the dual channel core elements 126. Each dual channel core element 126 has two horizontal channels 122. Figure 14C shows a blank for the dual channel core elements 126. The blank is folded as shown in Figure 14B with the tabs 130 inserted into the creasing portions 128. The blank for the core elements 126 can be folded manually or automatically.

[0070] The core assembly 120, and therefore in the case of the panel 100, the core elements 126 may be constructed from corrugated cardboard. Corrugated cardboard material is lightweight compared to other wood composite fiberboards, inherently sound absorbing, inexpensive, and can be precisely cut to size and produced. Additionally, the relative resilience of corrugated cardboard limits the mechanical connection between the skins 108 and 110, thereby isolating vibration and sound transmission. Thus, constructing the core assembly 120 from corrugated cardboard provides the panel 100 with both structure (rigidity and compressive strength) and sound absorption.

[0071] In some embodiments, the core element 126 includes an acoustic absorbing lining 124, as shown in Figures 15A and 15B, to further absorb sound in the core assembly 120. The acoustic lining 124 may be made of any suitable acoustic material, such as open cell foam, mineral wool, and fiberglass.

[0072] 19A, 19B, and 20, in some embodiments, the core element may include a number of openings 342 in the walls 340 that separate the horizontal channels. The openings 342 may further enhance the sound absorption properties of the core assembly 120.

[0073] In some embodiments, the core assembly may include 6 to 24 horizontal channels arranged adjacently. Instead of dual channel core elements, in some embodiments the core elements may be, for example, single channel or triple channel. Figure 16 shows multiple single channel core elements assembled and then attached to each other by an adhesive, such as, for example, a hot melt glue.

[0074] FIG. 17 shows a core assembly according to another embodiment. Instead of a core element, the core assembly is composed of two flat sheets connected by a series of separators with a Z-shaped cross section. The separators define horizontal channels. FIG. 18A-C show partial cross sections of yet another embodiment of a core assembly. FIG. 18A shows a core assembly with a flat sheet connected to a raised sheet. FIG. 18B shows a core assembly with two alternating raised sheets. FIG. 18C shows a core assembly including a dual channel core element with an internal separator having a Z-shaped cross section.

[0075] Where a component (e.g., rails, stiles, skins, channels, linings, openings, grooves, etc.) is referred to above, unless otherwise noted, the reference to that component should be interpreted to include any component that performs the function of the described component (i.e., is functionally equivalent) as an equivalent of that component, including components that are not structurally equivalent to the disclosed structures that perform the function in the illustrated exemplary embodiments of the invention.

[0076] While several exemplary aspects and embodiments have been discussed above, those of ordinary skill in the art will recognize certain modifications, permutations, additions and subcombinations thereof.

[0077] It is therefore intended that the following appended claims, as well as any claims hereafter introduced, be construed to include all such modifications, permutations, additions and subcombinations consistent with the broadest interpretation of the entire specification.

Claims

1. A core assembly including a plurality of horizontal flow paths, A pair of cartridges having a hollow center and located on both side surfaces of the core assembly, A pair of hollow side surfaces located on the pair of cartridges, a soundproof ventilation panel comprising: Each of the cartridges includes a proximal-facing side surface having a plurality of air flow path side openings and a distal-facing side surface having a plurality of sound resonance portion side openings, Ventilation grooves oriented vertically are formed through the front surface of the first cartridge of the cartridges, and ventilation grooves oriented vertically are formed through the back surface of the second cartridge of the cartridges, Thereby, the ventilation groove formed through the front surface of the first cartridge, the ventilation groove formed through the back surface of the second cartridge, the hollow center, the air flow path side openings, and the horizontal flow paths together partially define a Z-shaped air flow path, Thereby, the sound resonance portion side openings and the hollow side surfaces partially define a plurality of resonance portions, a soundproof ventilation panel.

2. A frame including an upper rail, a lower rail, and two side frames, wherein the pair of cartridges are disposed between the upper rail and the lower rail, and the upper rail, the lower rail, the two side frames, and the distal-facing side surface partially define the hollow side surface, a frame and, A front skin and a back skin, further comprising, the frame, the core assembly, and the pair of cartridges are supportably disposed between the front skin and the back skin, and the vertically oriented ventilation groove formed through the front surface of the first cartridge of the cartridges is also formed through the front skin, and the vertically oriented ventilation groove formed through the back surface of the second cartridge of the cartridges is also formed through the back skin, the soundproof ventilation panel according to claim 1.

3. Each of the cartridges has a horizontal symmetry plane and a vertical symmetry plane, the soundproof ventilation panel according to claim 1 or 2.

4. Each of the plurality of air flow path side openings is aligned with a corresponding one of the plurality of horizontal flow paths, the soundproof ventilation panel according to claim 1 or 2.

5. The plurality of air flow path side openings are identical and equally spaced, and the plurality of sound resonance portion side openings are identical and equally spaced, the soundproof ventilation panel according to claim 1 or 2.

6. The plurality of air flow path side openings are larger and fewer in number than the plurality of sound resonance part side openings, the soundproof ventilation panel according to claim 1 or 2.

7. The plurality of air flow path side openings are arranged linearly in series, and the plurality of sound resonance part side openings are arranged linearly in series, the soundproof ventilation panel according to claim 1 or 2.

8. Each space between the air flow path side openings is at least 1 inch, the soundproof ventilation panel according to claim 1 or 2.

9. Each of the cartridges extends to at least 80% or at least 90% of the height of the soundproof ventilation panel, the soundproof ventilation panel according to claim 1 or 2.

10. The horizontal flow path is at least partially formed from folded cardboard, the soundproof ventilation panel according to claim 1 or 2.

11. The inner surface of the horizontal flow path includes a sound-absorbing lining of a porous dissipative material such as continuous bubble foam, mineral wool or glass fiber, the soundproof ventilation panel according to claim 1 or 2.

12. The core assembly occupies substantially all of the space between the pair of cartridges, the soundproof ventilation panel according to claim 1 or 2.

13. The core assembly includes 6 to 24 horizontally arranged adjacent flow paths, the soundproof ventilation panel according to claim 1 or 2.

14. The wall between adjacent horizontal flow paths has a plurality of openings to increase the exposed surface area of the sound-absorbing lining, the soundproof ventilation panel according to claim 1 or 2.

15. The hollow side surface includes a porous dissipative sound-absorbing material, the soundproof ventilation panel according to claim 1 or 2.

16. a. Prepare a frame including an upper rail, a lower rail and two side frames. b. Prepare a core assembly including a plurality of horizontal flow paths. c. Prepare a pair of cartridges having a hollow center, the cartridges being located between the upper rail and the lower rail and on both side surfaces of the core assembly, each of the cartridges having a proximal side surface with a plurality of air flow path side openings aligned with the plurality of horizontal flow paths, and a distal side surface with a plurality of sound resonance part side openings. d. Provide a front skin and a back skin, whereby the space between the sound resonance part side openings and the side frames, the distal side surface, the front skin and the back skin define a resonance part. e. forming a vertically directed ventilation groove passing through the front surface of the front skin and the first cartridge of the cartridge, and forming a vertically directed ventilation groove passing through the back surface of the back skin and the second cartridge of the cartridge, whereby the vertically directed ventilation groove passing through the front surface of the front skin and the first cartridge, the vertically directed ventilation groove passing through the back surface of the back skin and the second cartridge, the hollow center, the air flow path side opening, and the horizontal flow path together define a Z-shaped air flow path, a method of manufacturing a soundproof ventilation panel.

17. Step c. further includes inserting inserts into each of the cartridges, the inserts comprising a blocking portion and a receiving portion, the blocking portion substantially blocking the air flow path side opening and the sound resonance portion side opening from the receiving portion configured to receive the dust and debris generated by step e., regardless of whether the vertically directed ventilation groove is formed on the front or back surface of the cartridge, and after step e., the insert is removed from the cartridge through the vertically directed ventilation groove, a method of manufacturing a soundproof ventilation panel according to claim 16.

18. Before step c., the proximal-facing side surface and the distal-facing side surface are manufactured by (i) making incisions in a rectangular block having the length of the cartridge, (ii) stacking the incised blocks, and (iii) opening an air flow path side opening or a sound resonance portion side opening through the stacked blocks, a method of manufacturing a soundproof ventilation panel according to claim 16 or 17.

19. Before step c., the proximal-facing side surface and the distal-facing side surface are manufactured by (i) opening slots sized to the air flow path side opening or the sound resonance portion side opening through an elongated rectangular block having the length of the cartridge, (ii) making finger-shaped contours in the drilled elongated rectangular block, and (iii) splitting the contoured and drilled elongated block into individual proximal-facing or distal-facing side surfaces, a method of manufacturing a soundproof ventilation panel according to claim 16 or 17.

20. Before step c., the proximal-facing side and the distal-facing side are manufactured by: (i) preparing two sheets each having the length of the cartridge, sandwiching ribs with a gap therebetween, and matching the gap between the ribs to the dimension of the air flow path side opening or the sound resonance part side opening; and (ii) cutting the sheets into strips for the proximal-facing side or the distal-facing side. A method for manufacturing the soundproof ventilation panel according to claim 16 or 17.

21. Before step c., the cartridge is manufactured by: (i) adhesively bonding together the proximal-facing side, the distal-facing side, and two support parts to form a cartridge; (ii) stacking a plurality of cartridges obtained from step (i); and (iii) pressing the stacked cartridges in the vertical direction and / or the horizontal direction. A method for manufacturing the soundproof ventilation panel according to claim 16 or 17.

22. A cartridge for a soundproof ventilation panel, comprising: a hollow center; a front surface; a back surface opposite to the front surface; a proximal-facing side having a plurality of air flow path side openings; a distal-facing side having a plurality of sound resonance part side openings; a vertically oriented ventilation groove formed through the front surface or the back surface.

23. The cartridge according to claim 22, comprising a horizontal symmetry plane and a vertical symmetry plane.

24. In the cartridge according to claim 22 or 23, the plurality of air flow path side openings are identical and equally spaced, and the plurality of sound resonance part side openings are identical and equally spaced.

25. In the cartridge according to claim 22 or 23, the plurality of air flow path side openings are larger and fewer in number than the plurality of sound resonance part side openings.

26. In the cartridge according to any one of claims 22 or 23, the plurality of air flow path side openings are arranged linearly in series, and the plurality of sound resonance part side openings are arranged linearly in series.

27. In the cartridge according to any one of claims 22 or 23, each space between the air flow path side openings is at least 1 inch.

28. A core component for a soundproof ventilation panel, comprising a single corrugated sheet folded to define two channels having a rectangular cross-section.

29. The corrugated sheet includes a plurality of slots linearly arranged in an intermediate portion of the corrugated sheet and a corresponding plurality of tabs at an end of the corrugated sheet for engaging with the slots in order to facilitate forming at least one of the flow paths. The core component according to claim 28.

30. The core component according to claim 28 or 29, wherein the two flow paths are of equal size.

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