Interlocking soundproofing block system and method

Abstract

A block ( 12 ) for use in interlocking, conjoined alignment with a plurality of like blocks to form a soundproofing barrier, said block ( 12 ) comprises a) a proximal panel ( 14 ) having a proximal right side and a proximal left side; b) a distal panel ( 16 ) having a distal right side and a distal left side, said distal panel ( 16 ) being longer, at its distal left side than the respective proximal right side forming a distal panel platform; the distal panel ( 16 ) and the proximal panel ( 14 ) being immovably coupled together and wherein at least one of the proximal panel ( 14 ) and the distal panel ( 16 ) comprises at least one corrugated flute.

1 . A block for use in interlocking, conjoined alignment with a plurality of like blocks to form a soundproofing barrier, said block comprising:
 a) a proximal panel comprising a proximal upper edge, a proximal lower edge, a proximal right edge and proximal left edge; and   b) a distal panel comprising a distal upper edge, a distal lower edge, a distal right edge and distal left edge,   the distal panel and the proximal panel being immovably coupled together in both vertical and horizontal offset thereby creating four engagement platforms: an upper engagement platform between the proximal upper edge and the distal upper edge, a lower engagement platform between the proximal lower edge and the distal lower edge, a right engagement platform between the proximal right edge and distal right edge, and a left engagement platform between the proximal left edge and distal left edge;   and wherein at least one of the proximal panel and the distal panel comprises at least one corrugated flute.   
     
     
         2 . The block of  claim 1  wherein both the proximal panel and distal panel comprise at least one corrugated flute. 
     
     
         3 . The block of  claim 1  wherein both the proximal panel and distal panel comprise at least two corrugated flutes. 
     
     
         4 . The block of  claim 1  wherein both the proximal panel and distal panel comprise three corrugated flutes. 
     
     
         5 . The block of  claim 1  comprising corrugated flutes separated by a separator sheet, and wherein disposition of the flutes relative to one another is such that a trough on one flute is aligned with a peak of an upper or lower adjacent flute and a peak on one flute is aligned with a trough on an upper or lower adjacent flute, thereby forming a plurality of discrete channel spaces between the flutes and the sheet. 
     
     
         6 . The block of  claim 5  wherein the plurality of discrete channel spaces are filled with a filler. 
     
     
         7 . The block of  claim 5  wherein the plurality of discrete channel spaces are filled with a particulate material. 
     
     
         8 . The block of  claim 5  wherein the plurality of discrete channel spaces are filled with a filler selected from the group consisting of sand, gravel, . . . . 
     
     
         9 . The block of  claim 5  wherein the plurality of discrete channel spaces are filled with dried silica sand. 
     
     
         10 . The block of  claim 1  wherein each panel is sealed on all edges. 
     
     
         11 . The block of  claim 1  wherein each panel has a thickness of from 5 mm to 30 mm. 
     
     
         12 . The block of  claim 1  wherein each corrugation is the same height and shape. 
     
     
         13 . The block of  claim 1  wherein entirety of each panel is sealed by cardboard sheets. 
     
     
         14 . A soundproofing barrier comprising a plurality of interlocking blocks, including a first block and a second block, each block comprising:
 a) a proximal panel comprising a proximal upper edge, a proximal lower edge, a proximal right edge and proximal left edge; and   b) a distal panel comprising a distal upper edge, a distal lower edge, a distal right edge and distal left edge,   the distal panel and the proximal panel being immovably coupled together in both vertical and horizontal offset thereby creating four engagement platforms: an upper engagement platform between the proximal upper edge and the distal upper edge, a lower engagement platform between the proximal lower edge and the distal lower edge, a right engagement platform between the proximal right edge and distal right edge, and a left engagement platform between the proximal left edge and distal left edge;   wherein at least one of the proximal panel and the distal panel comprises at least one corrugated flute; and wherein one engagement platform of the first block engages and overlaps another engagement platform on the second block to form a conjoined connection there between.   
     
     
         15 . The barrier of  claim 14  wherein both the proximal panel and distal panel comprise at least one corrugated flute. 
     
     
         16 . The barrier of  claim 14  wherein both the proximal panel and distal panel comprise at least two corrugated flutes. 
     
     
         17 . The barrier of  claim 14  wherein both the proximal panel and distal panel comprise three corrugated flutes. 
     
     
         18 . The barrier of  claim 14  wherein the corrugated flutes are separated by a separator sheet, and wherein disposition of the flutes relative to one another is such that a trough on one flute is aligned with a peak of an upper or lower adjacent flute and a peak on one flute is aligned with a trough on an upper or lower adjacent flute, thereby forming a plurality of discrete channel spaces between the flutes and the sheet. 
     
     
         19 . The barrier of  claim 18  wherein the plurality of discrete channel spaces are filled with a filler. 
     
     
         20 . The barrier of  claim 18  wherein the plurality of discrete channel spaces are filled with a particulate material. 
     
     
         21 . The barrier of  claim 18  wherein the plurality of discrete channel spaces are filled with sand or gravel. 
     
     
         22 . The barrier of  claim 18  wherein the plurality of discrete channel spaces are filled with dried silica sand. 
     
     
         23 . The barrier of  claim 14  wherein each panel is sealed on all edges. 
     
     
         24 . The barrier of  claim 14  wherein each panel has a thickness of from 5 mm to 30 mm. 
     
     
         25 . The barrier of  claim 14  wherein each corrugation is the same height and shape. 
     
     
         26 . The barrier of  claim 14  wherein the entirety of each panel is sealed by cardboard sheets. 
     
     
         27 . A method of making a sound proofing barrier which comprises:
 aligning a plurality of interlocking blocks, starting with a first block and a second block, each block comprising:
 a) a proximal panel comprising a proximal upper edge, a proximal lower edge, a proximal right edge and proximal left edge; 
 b) a distal panel comprising a distal upper edge, a distal lower edge, a distal right edge and distal left edge, 
   the distal panel and the proximal panel being immovably coupled together in both vertical and horizontal offset thereby creating four engagement platforms: an upper engagement platform between the proximal upper edge and the distal upper edge, a lower engagement platform between the proximal lower edge and the distal lower edge, a right engagement platform between the proximal right edge and distal right edge, and a left engagement platform between the proximal left edge and distal left edge;   wherein at least one of the proximal panel and the distal panel comprises at least one corrugated flute;   joining and overlapping at least part of one engagement platform of the first block with at least part of an adjacent engagement platform on the second block to form a conjoined connection therebetween;   joining and overlapping at least part of another as yet unengaged engagement platform of the first block with at least part of an adjacent engagement platform of a third engagement block to form a conjoined connection therebetween;   joining and overlapping at least part of another as yet unengaged engagement platform of the first block with at least part of an adjacent engagement platform on of a fourth engagement block to form a conjoined connection therebetween and thereafter joining and overlapping further engagement platforms, on the first, second, third and fourth blocks and additional blocks, until a full surface of the barrier is created by a multitude of ship lathe-like interconnections of the panels.   
     
     
         28 . The block of  claim 1  wherein the panels are substantially rectangular. 
     
     
         29 . The block of  claim 1  wherein one of the proximal and distal panels is thicker than the other panel. 
     
     
         30 . A block for use in interlocking, conjoined alignment with a plurality of like blocks to form a soundproofing barrier, said block comprising:
 a) a proximal panel having a proximal right side and a proximal left side; and   b) a distal panel having a distal right side and a distal left side, said distal panel being longer, at its distal left side than the respective proximal right side forming a distal panel platform; the distal panel and the proximal panel being immovably coupled together and wherein at least one of the proximal panel and the distal panel comprises at least one corrugated flute.   
     
     
         31 . The block of  claim 30  wherein the proximal left side and the distal left side are aligned. 
     
     
         32 . The block of  claim 1  wherein at least one panel is coated with a barrier coating. 
     
     
         33 . The block of  claim 1  wherein at least one panel is coated with one of SPECTRA GUARD 763A and SPECTRA-GUARD 763A-Flexo. 
     
     
         34 . The block of  claim 1  wherein the proximal panel and distal panel are seamless and integral.