Soundproof door and door frame

Abstract

　A soundproof door and door frame comprising a door panel having an internal frame structure, horizontal reinforcing members contacting only one surface of the door panel, door panel surfaces having unequal thicknesses or internal weighting material to reduce vibration, additional horizontal reinforcing members formed with alternating grooves to enhance attenuation of sound energy entering a lower ventilation opening, vertical reinforcing members strengthen the ventilation opening, high-density polyester sound-absorbing panels are arranged within the ventilation opening, an automatic drop-down soundproof rubber seal is provided at a lower portion of the door panel, and a ventilation opening is formed at the bottom of the door panel without any visible slots on door panel surface, the door frame being formed of aluminum and configured to be adjustable to accommodate varying wall thicknesses, and comprising soundproof rubber seals.

Description

[0001] SOUNDPROOF DOOR AND DOOR FRAME

[0002] Field of the Invention

[0003] The present invention relates to the field of acoustical engineering and material engineering relating to soundproof doors.

[0004] Background of the Invention

[0005] Doors and door frames are essential components in construction and architectural works, serving purposes including spatial separation, privacy enhancement, security reinforcement, and aesthetic improvement of buildings, as well as additional functional purposes such as sound insulation, ventilation, and temperature control.

[0006] At present, doors have been developed according to their intended applications. Certain designs are capable of effectively controlling indoor temperature, while others permit ventilation or are configured to reduce external noise. Materials commonly used for manufacturing door panels include wood, metal, composite materials, and glass, which are selected and adapted according to the functional and aesthetic requirements of each area. Security doors may further incorporate high-strength materials and complex locking systems.

[0007] The door frame supports the door and enhances structural stability, reducing forces generated during opening and closing operations, and preventing light, sound, and air leakage through gaps between the door and the wall. Certain frame designs also provide installation flexibility, allowing size adjustment to accommodate varying wall thickness. Door frames are typically constructed from wood, aluminum, or composite plastics, selected to meet environmental conditions and the intended purpose of the door panel.

[0008] Various developments have been made in the design of doors and frames for noise insulation. Improvements include modification of the internal structure of the door panel and the incorporation of sound-absorbing materials to attenuate sound energy and reduce sound transmission. The configuration of internal cavities within the door panel, the installation of rubber seals around the perimeter of the door, the use of sealing members within the frame to close gaps, and engineering designs that consider the direction of sound waves within the internal cavity all contribute to reducing sound energy entering from outside. However, the design of soundproof doors and frames must also account for additional functional requirements, such as material durability under high humidity or elevated temperature conditions, which may cause materialdegradation and reduce soundproofing efficiency. Furthermore, the use of rubber seals may obstruct air ventilation and temperature regulation through door undercut and perimeter gaps.

[0009] As described above, existing soundproof doors and door frames remain subject to certain limitations. Accordingly, a soundproof door and door frame have been developed with improvements and modifications to overcome such limitations. A search of patent databases has identified related inventions having the following details.

[0010] Korean Patent Publication No. KR100675486B 1, entitled “Soundproof Ventilation Door,” discloses a multifunctional soundproof and ventilated door designed to protect privacy, reduce external noise, and provide effective ventilation without requiring the door to be fully opened. The system comprises an air inlet and an air outlet arranged in diagonal positions, together with soundabsorbing materials and air guide vanes configured to direct airflow so as to reduce noise transmission. An automatic opening and closing mechanism controls the air passages appropriately to enhance convenience and operational efficiency.

[0011] Japanese Patent Publication No. JP5682912B2, entitled “Soundproof Door,” discloses a hollow door having ventilation openings on both sides and an internal airflow passage system for noise reduction. The airflow passages are structured to generate standing waves in order to attenuate noise by altering the direction of airflow. The internal structure comprises horizontally and vertically arranged airflow passages disposed alternately so that sound waves travel in a spiral manner, thereby effectively reducing sound energy. In addition, sound-absorbing materials and internal reinforcing structures are provided to enhance durability and soundproofing performance.

[0012] Thai Petty Patent Application No. 1903000958, entitled “Ventilation Door,” discloses a ventilation door comprising two surface panels having a substantially rectangular configuration, wherein openings and closures are arranged in an offset manner to reduce noise and the velocity of air passing from one side of the door to the other, and to reflect sound waves so as to prevent transmission through the openings and closures. The door further comprises an airflow control device provided with a plurality of flow control openings and at least one control switch configured to regulate the size of the airflow gap and the flow control openings.

[0013] From the abovementioned prior inventions, it is found that the previously disclosed works possess varying characteristics and components depending on their intended purposes in order to suit the use of the door panels and door frames. However, certain limitations remain, including insufficient sound attenuation performance, maintenance concerns and material service life, and overall aesthetic considerations, particularly where ventilation slots remain visible on the surface of the door panel. Accordingly, the inventor has developed a soundproof door and door framecapable of providing effective ventilation, enhancing sound attenuation within the internal cavity of the door panel, utilizing durable and moisture-resistant materials, and allowing ease of installation.

[0014] Summary of the Invention

[0015] A soundproof door and door frame comprise a door panel having an internal frame structure enclosing the upper portion and both lateral edges of the door panel; horizontal reinforcing members contacting only one surface of the door panel to reduce transmission of sound waves; horizontal reflective members configured to reflect sound within the core; door surfaces having unequal thicknesses on two sides or provided with internal weighting materials to reduce vibration caused by different sound frequencies; additional horizontal reinforcing members formed with alternating grooves to enhance attenuation of sound energy entering a lower ventilation passage; vertical reinforcing members strengthening the ventilation passage; high-density polyester sound-absorbing panels arranged within the ventilation passage; an automatic dropdown soundproof rubber seal; a ventilation opening provided at a lower portion of the door panel; and a door frame configured to be adjustable to accommodate varying wall thicknesses, the door frame being provided with grooves for installing a double-fin soundproof rubber seal adapted to tightly close gaps between the frame and the wall.

[0016] The objective of the present invention is to provide a soundproof door and door frame capable of preventing noise intrusion, resisting moisture, offering durability in use, enabling ease of installation, and providing effective ventilation suitable for bedrooms, bathrooms, or other areas requiring quietness and privacy while maintaining adequate fresh air ventilation in conjunction with sound insulation.

[0017] Brief Description of the Drawings

[0018] Figure 1 illustrates the individual components of the soundproof door.

[0019] Figure 2 illustrates the internal side components of the soundproof door.

[0020] Figure 3 illustrates the components of the door frame.

[0021] Figure 4 illustrates the arrangement of the sound-absorbing panels.

[0022] Figure 5 illustrates the combined installation of the door panel and the door frame.

[0023] Figure 6 illustrates experimental results of sound attenuation values relative to sound frequency.Detailed Description of the Invention

[0024] With reference to Figures 1 and 2, various components of the door panel (1) and a side view of the door panel (1) are illustrated. The interior of the door panel (1) comprises a frame structure (2) enclosing the upper portion and both lateral edges of the door panel (1), and at least one horizontal reinforcing member (3) strengthening the door panel (1), each horizontal reinforcing member (3) being attached to one surface of the door panel surface (23) while defining an air gap without contacting the opposite surface of the door panel surface (23), thereby preventing most of the sound energy entering from one side of the door panel (1) from being transmitted to the other side through structure of the door panel (1), wherein sound entering the upper cavity is confined to reflect within the core to reduce sound energy by means of a first sound-absorbing panel (4) made of fiberglass or mineral wool.

[0025] A solid cross member (5) is provided, attached to both sides of the door panel surface (23), and a sound attenuation chamber (6) is disposed below the solid cross member (5) for absorbing sound entering from a ventilation cavity (13) formed as an air passage from beneath the door panel (1) without any visible slots on door panel surfaces (23) for aesthetic considerations, wherein at least one reinforcement block (7) is provided within the door panel (1) for supporting a door lock installation, and horizontal reinforcing members (9) formed with continuous grooves along both sides are arranged in an alternating configuration so that sound entering from the ventilation cavity (13) is directed toward the sound attenuation chamber (6), which is covered by a second sound-absorbing panel (8) to prevent fiberglass or mineral wool fibers within the sound attenuation chamber (6) from falling out over time.

[0026] Vertical reinforcing members (10) are provided to strengthen the structure adjacent to the ventilation cavity (13), and the ventilation cavity (13) contains the third sound-absorbing panels (11) arranged with spacing between adjacent panels to increase the cross-sectional area of the ventilation cavity (13) and reduce pressure loss of air flowing within the ventilation cavity (13).

[0027] The ventilation cavity (13) further comprises an air-blocking panel (14) disposed at a central position in combination with the third sound-absorbing panels (11) to force sound to pass through the third sound-absorbing panels (11) into the sound attenuation chamber (6) and then descend along the opposite side through the third sound-absorbing panels (11), and a rubber seal (12) is provided at the lower portion of the door panel (1), the rubber seal (12) being an automatic drop-down soundproof seal arranged to closely contact the floor to direct sound and air upward into the ventilation cavity (13), wherein the ventilation cavity (13) is provided on both sides of the door panel (1), and the second sound-absorbing panel (8) and the third sound-absorbing panel (11) are formed of high-density polyester material.The door panel (1) is formed from materials selected from fiberglass, mineral wool, honeycomb paper core, solid wood core, plywood, wood fiber board, wood-plastic composite, and uPVC plastic, and the door panel surface (23) is configured such that the two opposing surfaces have unequal thicknesses or are reinforced with internal weighting materials to produce different resonance frequencies on the two sides.

[0028] According to Figure 3, the door frame (15) is illustrated, the door frame (15) being formed of aluminum to provide resistance to water and moisture for long-term use, wherein the door frame (15) comprises a frame surface (16) designed to be flush with the door panel (1), and at least one anchoring protrusion (17), provided in three sections along the frame surface (16), to enhance attachment of a frame architrave (19) to the wall, the frame architrave (19) having leg ends engaging with the anchoring protrusions (17), which are formed as ribbed surfaces with spacing not exceeding 12 millimeters corresponding to the adjustment interval, the frame architrave (19) being adjustable to accommodate wall thicknesses ranging from 98 to 152 millimeters, and the aluminum leg thickness at the ribbed anchoring protrusions (17) being configured for temporary deformation to facilitate convenient adjustment.

[0029] The frame surface (16) and the frame architrave (19) are provided with wall-covering flanges (18) having grooves for inserting sealing strips to compensate for unevenly constructed wall openings, and a stop portion of the door frame (15) is provided with grooves for installing soundproof rubber seals (22), the soundproof rubber seals (22) being installed on more than one side and comprising more than one fin, specifically double fins, and the door frame (15) further comprises miter grooves (20) for concealed comer joint installation without visible screw heads, and a frontal cavity (21) configured to accommodate concealed hinge hardware and a latch receptacle.

[0030] According to Figure 4, the third sound-absorbing panels (11) may be arranged in two configurations which are

[0031] 1.) the surface of the third sound-absorbing panels (11) is positioned in close contact with the door panel surface (23) to reinforce structural strength of the door panel (1);

[0032] 2.) the surface of the third sound-absorbing panels is spaced apart from the door panel surface (23) to reduce sound transmission through the structure of the door panel (1), wherein the cross-sectional area of airflow passages between adjacent third sound-absorbing panels (11) is adjustable in accordance with the desired balance between sound insulation performance and ventilation capacity, which are inversely related.

[0033] According to Figure 5, the combined use of the door panel (1) and the door frame (15) is illustrated, wherein soundproof rubber seals (22) are installed on three sides and configured as doublefins having an initial angle of 30 45 degrees to press against the door panel surface (23) with minimal resistance, and further comprising a leg portion covering screw heads securing the door frame (15) to the wall opening.

[0034] According to Figure 6, experimental results of sound transmission loss when sound passes through the door panel (1 ) are illustrated, wherein the graph presents sound attenuation values as a function of sound frequency, comparing the actual sound attenuation performance of the door panel (1 ) with the standard sound transmission class rating (STC30), which is a standard used to measure the capability of materials or structures to reduce sound transmission, wherein the door panel (1 ) demonstrates effective attenuation at frequencies above 5 0 0 hertz, providing approximately 30 decibels of sound reduction, approaching the attenuation level specified by the STC30 standard, and wherein the door panel (1 ) exhibits an average sound attenuation value of approximately 30-35 decibels, compliant with the STC30 level.

[0035] Any modifications or variations may be clearly understood and effected by a person skilled in the art, provided that such modifications or variations fall within the scope and spirit of the present invention as defined in the appended claims.

[0036] Best Mode of the Invention

[0037] As previously described in the detailed description of the invention section.

Claims

Claims1. A soundproof door and door frame comprising a door panel (1), wherein the interior of the door panel (1) comprises a frame structure (2) enclosing an upper portion and both lateral edges of the door panel (1), and at least one horizontal reinforcing member (3), each horizontal reinforcing member (3) being attached to one surface of a door panel surface (23) while defining an air gap without contacting an opposite surface of the door panel surface (23) so as to prevent most sound energy entering from one side of the door panel (1) from being transmitted to the other side through the door structure, wherein sound entering an upper cavity is confined to reflect within a core to reduce sound energy by means of a first sound-absorbing panel (4), and wherein a solid cross member (5) is attached to both surfaces of the door panel surface (23), a sound attenuation chamber (6) being disposed below the solid cross member (5) to absorb sound entering from a ventilation cavity (13) formed beneath the door panel (1) without any visible slots on door panel surfaces (23) for aesthetic considerations, at least one reinforcement block (7) being provided within the door panel (1) for supporting a door lock installation, horizontal reinforcing members (9) formed with continuous grooves along both sides being arranged in an alternating configuration to direct sound from the ventilation cavity (13) toward the sound attenuation chamber (6), the sound attenuation chamber (6) being covered by a second sound-absorbing panel (8), vertical reinforcing members (10) being provided to strengthen the structure adjacent to the ventilation cavity (13), the ventilation cavity (13) containing third sound-absorbing panels (11) arranged with spacing therebetween to increase a cross-sectional area of the ventilation cavity (13) and reduce air pressure loss therein, the third sound-absorbing panels (11) being spaced apart from the door panel surface (23), the ventilation cavity (13) further comprising an air-blocking panel (14) disposed at a central position in combination with the third soundabsorbing panels (11) to force sound to pass through the third sound-absorbing panels (11) and enter into a sound attenuation chamber (6), a-an automatic drop-down rubber seal (12) being provided at a lower portion of the door panel (1) to closely contact a floor and direct sound and air into the ventilation cavity (13), and a door frame (15) comprising a frame surface (16) configured to be flush with the door panel (1), at least one anchoring protrusion (17) for enhancing attachment of a frame architrave (19) to a wall, the frame architrave (19) having leg ends engaging with the anchoring protrusion (17) formed as ribbed surfaces with spacing not exceeding 12 millimeters, the frame surface (16) and the frame architrave (19) comprising wall-covering flanges (18) having grooves for receiving sealing strips, a stopportion of the door frame (15) having grooves for installing soundproof rubber seals (22), the soundproof rubber seals (22) being installed on more than one side and comprising more than one fin forming as layers with an initial angle of 30 45 degrees to press against the door panel surface (23) with minimal resistance and including a leg portion covering screw heads securing the door frame (15) to a wall opening, and the door frame (15) further comprising miter grooves (20) for concealed comer joints and a frontal cavity (21) for accommodating concealed hinge hardware and a latch receptacle.

2. The soundproof door and door frame according to claim 1 , wherein the door panel (1 ) is formed from materials selected from fiberglass, mineral wool, honeycomb paper core, solid wood core, plywood, wood fiber board, wood-plastic composite, and uPVC plastic.

3. The soundproof door and door frame according to claim 1, wherein the first sound-absorbing panel (4) is selected from fiberglass or mineral wool.

4. The soundproof door and door frame according to claim 1, wherein the second sound-absorbing panel (8) and the third sound-absorbing panel (11) are high-density polyester sound-absorbing panels.

5. The soundproof door and door frame according to claim 1, wherein the third sound-absorbing panel (11) is selectively arranged such that a surface of the third sound-absorbing panel (11) is either in close contact with the door panel surface (23) or spaced apart from the door panel surface (23).

6. The soundproof door and door frame according to claim 1, wherein the ventilation cavity (13) is provided on both sides of the door panel (1).

7. The soundproof door and door frame according to claim 1, wherein the rubber seal (12) is an automatic drop-down soundproof rubber seal.

8. The soundproof door and door frame according to claim 1 , wherein the door frame (15) is formed of aluminum.

9. The soundproof door and door frame according to claim 1 , wherein the anchoring protrusions (17) are provided in three sections on the frame surface (16).

10. The soundproof door and door frame according to claim 1, wherein the door panel surface (23) is configured such that the two opposing surfaces have unequal thicknesses or are reinforced with internal weighting material to provide different resonance frequencies on the two sides.

11. The soundproof door and door frame according to claim 1 , wherein the soundproof rubber seals (22) are installed on three sides within grooves provided for receiving the soundproof rubber seals (22), and are configured as double fins.

12. The soundproof door and door frame according to claim 1 , wherein the frame architrave (19) is adjustable to accommodate wall thicknesses ranging from 98 to 152 millimeters.

13. The soundproof door and door frame according to claim 12, wherein the frame architrave (19) comprises an aluminum leg portion for engagement with the ribbed anchoring protrusions (17), the aluminum leg portion being configured to undergo temporary deformation to facilitate convenient positional adjustment.

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