The present disclosure relates generally to the field of acoustic systems for absorbing sound energy. More particularly, some embodiments relate to acoustic panels that absorb sound energy in a building structure.
The written disclosure herein describes illustrative embodiments that are non-limiting and non-exhaustive. Reference is made to certain of such illustrative embodiments that are depicted in the figures, in which:
Many locations are filled with various sources of sound and/or noise, including people, vehicles, music players, computers, televisions, appliances, musical instruments, etc. These sounds may cause confusions, strain, anxiety, privacy concerns, and/or miscommunication. Accordingly, sound dampening and/or acoustic materials may be used to absorb, dampen, reflect, etc., sound energy in an attempt to control the sound in a desired manner.
The present disclosure relates to acoustic panels used to absorb, dampen, and/or reflect sound energy in an acoustic system. In some embodiments, the acoustic panels can be applied to a building structure, such as a ceiling, wall, or suspension system. As further detailed below, the embodiments may be best understood by reference to the drawings, wherein like parts are designated by like numerals throughout. It will be readily understood that the components of the present disclosure, as generally described and illustrated in the drawings herein, could be arranged and designed in a wide variety of different configurations. Thus, the following more detailed description of the embodiments is not intended to limit the scope of the disclosure, but is merely representative of possible embodiments of the disclosure. In some cases, well-known structures, materials, or operations are not shown or described in detail. While the various aspects of the embodiments are presented in drawings, the drawings are not necessarily drawn to scale unless specifically indicated.
The terms “first,” “second,” and the like in the description and in the claims, if any, are used for distinguishing between similar elements and not necessarily for describing a particular sequential or chronological order. It is to be understood that the terms so used are interchangeable under appropriate circumstances such that the embodiments of the invention described herein are, for example, capable of operation in sequences other than those illustrated or otherwise described herein. Similarly, if a method is described herein as comprising a series of steps, the order of such steps as presented herein is not necessarily the only order in which such steps may be performed, and certain of the stated steps may possibly be omitted and/or certain other steps not described herein may possibly be added to the method. Furthermore, the terms “comprise,” “include,” and “have,” and any variations thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements is not necessarily limited to those elements, but may include other elements not expressly listed or inherent to such process, method, article, or apparatus.
The phrase “coupled to” is broad enough to refer to any suitable coupling or other form of interaction between two or more entities, including mechanical interaction. Two components may be coupled to each other even though they are not in direct contact with each other. Objects described herein as being “adjacent” to each other may be in physical contact with each other, in close proximity to each other, or in the same general region or area as each other, as appropriate for the context in which the phrase is used.
As shown in
The acoustic panel 100 includes a base 111 or central region. The acoustic panel 100 further includes a plurality of sidewalls 102, 104, 106, 108 extending around a periphery of the base 111. In the illustrated embodiment, the acoustic panel 100 includes four sidewalls 102, 104, 106, 108. In other embodiments, the acoustic panel 100 includes a number of sidewalls that corresponds to the number of edges around the panel 100. For example, a triangular shaped panel can include 3 sidewalls, a pentagonal shaped panel can include 5 sidewalls, and hexagonal shaped panel can include 6 sidewalls, etc. Other shapes and numbers of sidewalls are also contemplated.
The acoustic panel 100 further includes a plurality of hinges 112, 114, 116, 118 that extend around the periphery of the base 111. As shown in the illustrated embodiment, the hinges 112, 114, 116, 118 can be disposed between the base 111 and the sidewalls 102, 104, 106, 108. In some embodiments, the hinges 112, 114, 116, 118 are living hinges made of the same material as the base 111 and sidewalls 102, 104, 106, 108. In some of such embodiments, the base 111, hinges 112, 114, 116, 118, and sidewalls 102, 104, 106, 108 are made of a unitary piece of material. For instance, the hinges 112, 114, 116, 118 can be formed by cutouts in the material and/or structure. In other embodiments, individual hinge structures 112, 114, 116, 118 can be used to couple individual sidewall structures 102, 104, 106, 108 to the base 111.
With reference to
With reference to
In some embodiments, the hinges 112, 114, 116, 118 can comprise a substantially v-shaped cross-sectional cutout shape, as shown in
As further shown in the illustrated embodiment, edges 102a, 104a, 106a, 108a of the sidewalls 102, 104, 106, 108 can also be cut or shaped with an angled or sloped surface. The edges 102a, 104a, 106a, 108a can further be configured to correspond and interface with an edge 102a, 104a, 106a, 108a of an adjacent sidewall 102, 104, 106, 108 when folded or assembled, as shown in
As further shown in
In some embodiments, the connection interfaces 123, 125, 127, 129 include a recess, channel, or groove formed in the sidewall 102, 104, 106, 108. As shown in the illustrated embodiment, the connection interfaces 123, 125, 127, 129 are also disposed towards the second side 120 of the panel 100, or the side opposite the hinges 112, 114, 116, 118 such that the connection interfaces 123, 125, 127, 129 are directed outward when the sidewalls 102, 104, 106, 108 are folded into the assembled configuration. The connection interfaces 123, 125, 127, 129 are also disposed at an upper edge of the sidewalls 102, 104, 106, 108, below the extension members. As further detailed below, the connection interface 123, 125, 127, 129 can be configured to receive a portion of a building structure (e.g., a runner or rail) to couple the acoustic panel 100 to a building structure. The connection interface 123, 125, 127, 129 can further extend along a portion of or the entirety of the sidewall 102, 104, 106, 108, as shown in
The acoustic panel 100 illustrated in
The size of the acoustic panel 100 may also vary as desired. For example, in some embodiments, the thickness T of the base 111 of the acoustic panel 100 is between about ⅛ inch and about 2 inches, or between about ¼ inch and about 1 inch. When assembled, the height H of the acoustic panel 100 can also vary as desired. For example, in some embodiments, the height H of the acoustic panel 100 is between about 1 inch and about 24 inches, between about 1 inch and about 20 inches, or between about 1 inch and about 12 inches. Further, in some instances, the height H of the acoustic panels 100 vary within a system. For example, various acoustic panels 100 can be used having various heights (as shown in
As previously discussed, the acoustic panels 100 may be coupled to a building structure, such as a ceiling, wall, or suspension system to absorb, dampen, and/or reflect sound energy. Each acoustic panel 100 may comprise various types of sound dampening materials. Exemplary sound dampening materials that can be used include, but are not limited to, cotton, rayon, acetate, nylon, wood, olefins (or polyolefins), polyesters, acrylics, fiberglass, petroleum based fibers, biofibers (e.g., fibers manufactured from soybean oil, corn oil, sugar cane, bamboo, etc.) and mixtures thereof. In certain embodiments, the acoustic panel 100 comprises polyester and/or fiberglass. In a particular embodiment, the acoustic panel 100 comprises polyester. And in another particular embodiment, the acoustic panel 100 comprises fiberglass. In certain embodiments, the sound dampening material is fibrous. For example, the acoustic panel 100 may comprise fiberglass, a spunbonded olefin, or a spunbonded polyester sound dampening material. In some embodiments, the fibrous material can also be an extruded fibrous material.
The sound dampening material of the acoustic panel 100, and/or layers of the acoustic panel 100, can also be non-woven. Non-woven materials can be useful in acoustic sound control due to their porous structure, high surface area, and low cost of production. The non-woven materials may also be porous. For example, non-woven materials can have a porosity greater than 70%, 80%, or 90%. This porosity can increase the amount of sound energy the acoustic panel 100 may absorb.
In some embodiments, the acoustic panel 100 comprises mixtures of different types of sound dampening materials (such as mixtures of different types of polyesters). For example, the acoustic panel 100 can comprise a high melt material and a low melt material (e.g., such as high and low melt polyesters). High melt materials can refer to materials having a melting point greater than about 330° F., such as between about 330° F. and about 450° F. Low melt materials can refer to materials having a melting point lower than about 320° F., such as between 220° F. and about 320° F. For instance, in a particular embodiment, the acoustic panel 100 comprises a mixture of at least one high melt polyester having a melting point greater than about 330° F., such as between about 330° F. and about 450° F., and at least one low melt polyester having a melting point lower than about 320° F., such as between 220° F. and about 320° F. In some of these embodiments, the acoustic panel 100 may comprise between about 50% and 95%, or between about 70% and 90% by weight of a high melt material, and between about 5% and 50%, or between about 10% and 30% by weight of a low melt material.
The acoustic panel 100 may also comprise acoustic materials having various weights, thicknesses, or deniers. For example, in certain embodiments, the acoustic materials can comprise a first portion of fibers having a first average denier and a second portion of fibers having a second average denier. In some of such embodiments, the first average denier is smaller than the second average denier. Additional sizes, such as a third average denier, fourth average denier, etc., can also be used.
In some embodiments, the acoustic panel 100 can comprise a plurality of layers that are fabricated into a mat. In some of such embodiments, fabrication of the acoustic panel 100 comprises disposing acoustic material into two or more layers. The acoustic material can then be treated. For example, the acoustic material can be compressed and/or subjected to heat or elevated temperatures, such as with a hot iron or heat press to form a mat. Other manufacturing methods and/or processes can also be used. For example, in some embodiments, acoustic materials can be entangled within a layer. Entanglement can occur prior to laying the adjacent layer (e.g., second layer) or after laying the adjacent layer.
As previously indicated, the acoustic panel 100 may be configured to absorb, dampen, and/or reduce acoustic energy. In some embodiments, the acoustic panel 100 may reduce acoustic energy by at least 20%, at least 30%, at least 40%, at least 50%, at least 60%, at least 70%, at least 80%, or at least 90%. In other embodiments, the acoustic panel 100 may reduce acoustic energy in an amount ranging from 50% to 90%. The standard for measuring such a reduction of acoustic energy may be a Noise Reduction Coefficient (NRC) as tested under ASTM C423.
The acoustic panel 100 can be coupled to various types of building structures. For instance, the acoustic panels 100 can be coupled to ceiling, wall, or suspension system. The mounting of an acoustic panel 100 to an exemplary suspension system 10 is shown in
As further shown in
With reference to
With the sidewalls 102, 104, 106, 108 folded into the assembled configuration, the method can further comprise a step of coupling the acoustic panel 100 to a building structure. In some embodiments, the coupling step comprises coupling the acoustic panel 100 to a ceiling, wall, or suspension system 10. In doing so, the extension members 103, 105, 107, 109 can be inserted into an opening in the building structure, such as the opening 20 of the grid depicted in
In similar fashion, a plurality of acoustic panels 100, 200, 300, 400 can be coupled to a building structure 10 as shown in
A desired visual or aesthetic appeal can also be achieved by imparting design features to the panels.
Any variety of design features 530 can be used. In the illustrated embodiment, the design features 530 comprise linear lines or grooves extending across the side or surface 520 of the acoustic panel 500. Other design features 530 are also contemplated, including non-linear lines, arcs, curved lines, patterns, etc. Further, the design features 530 can extend in one or more directions, including, but not limited to, laterally across the acoustic panel 500, longitudinally across the acoustic panel 500, and/or diagonally across the acoustic panel 500 as desired.
Methods of using and/or making an acoustic system are also disclosed herein. In particular, it is contemplated that any of the components, principles, and/or embodiments discussed above may be utilized in either an acoustic system or a method of using and/or making the same.
It will be appreciated that any methods disclosed herein include one or more steps or actions for performing the described method. The method steps and/or actions may be interchanged with one another. In other words, unless a specific order of steps or actions is required for proper operation of the embodiment, the order and/or use of specific steps and/or actions may be modified. Moreover, sub-routines or only a portion of a method described herein may be a separate method within the scope of this disclosure. Stated otherwise, some methods may include only a portion of the steps described in a more detailed method.
Reference throughout this specification to “an embodiment” or “the embodiment” means that a particular feature, structure, or characteristic described in connection with that embodiment is included in at least one embodiment. Thus, the quoted phrases, or variations thereof, as recited throughout this specification are not necessarily all referring to the same embodiment.
Similarly, it should be appreciated by one of skill in the art with the benefit of this disclosure that in the above description of embodiments, various features are sometimes grouped together in a single embodiment, figure, or description thereof for the purpose of streamlining the disclosure. This method of disclosure, however, is not to be interpreted as reflecting an intention that any claim requires more features than those expressly recited in that claim. Rather, as the following claims reflect, inventive aspects lie in a combination of fewer than all features of any single foregoing disclosed embodiment. Thus, the claims following this Detailed Description are hereby expressly incorporated into this Detailed Description, with each claim standing on its own as a separate embodiment. This disclosure includes all permutations of the independent claims with their dependent claims.
Recitation in the claims of the term “first” with respect to a feature or element does not necessarily imply the existence of a second or additional such feature or element. All ranges include both endpoints.
Without further elaboration, it is believed that one skilled in the art can use the preceding description to utilize the invention to its fullest extent. The claims and embodiments disclosed herein are to be construed as merely illustrative and exemplary, and not a limitation of the scope of the present disclosure in any way. It will be apparent to those having ordinary skill in the art, with the aid of the present disclosure, that changes may be made to the details of the above-described embodiments without departing from the underlying principles of the disclosure herein. In other words, various modifications and improvements of the embodiments specifically disclosed in the description above are within the scope of the appended claims. Moreover, the order of the steps or actions of the methods disclosed herein may be changed by those skilled in the art without departing from the scope of the present disclosure. In other words, unless a specific order of steps or actions is required for proper operation of the embodiment, the order or use of specific steps or actions may be modified. The scope of the invention is therefore defined by the following claims and their equivalents.
This application claims priority to U.S. Provisional Application No. 63/040,197, filed Jun. 17, 2020, and titled ACOUSTIC PANELS AND RELATED METHODS, and U.S. Provisional Application No. 63/144,286, filed Feb. 1, 2021, and titled ACOUSTIC PANELS AND RELATED METHODS, each of which is hereby incorporated by reference in its entirety.
Number | Date | Country | |
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63040197 | Jun 2020 | US | |
63144286 | Feb 2021 | US |