Patent Application
20230417054
The present invention relates to an acoustic panel, a suspended acoustic system using such acoustic panels, and a baseboard intended to be cut up into a plurality of acoustical panels.
Acoustic panels comprising compressed fibre material, such as glass or stone wool, may be arranged in a room or in another accommodation and may serve a variety of purposes. The panels are used for improving the acoustical characteristics of the room and may also be used for concealing wiring, piping, as well as devices related to heating, ventilation, and air condition.
The panels may form part of a panel system and may constitute horizontally arranged ceiling tiles, vertically arranged baffle elements, wall mounted elements or free-standing screens.
The side edges of the panels may be provided with groove arrangements enabling mounting, for instance in a grid of profiles.
The panels are typically made from large baseboards which are cut or by other means split up into panels of suitable size. Subsequently, the panels may be provided with groove arrangements along the side edges, for instance by a milling operation.
When designing a panel made of compressed fibre material, there are conflicting interests when choosing the density of the panel and thus also of choosing the density of the baseboard from which the panel is to be made.
On the one hand, a low-density panel may be preferable since it enhances absorption of lower sound frequencies. Also, a low-density panel will have a reduced weight which facilitates transport and handling. Further, the material cost will be lower since the amount of fibre material in each panel will be reduced.
On the other hand, a high density is preferable since it provides a more robust panel. The side edges of the panel may, as mentioned above, be provided with a groove arrangement for mounting, and a panel having a higher density facilitates the provision of the groove arrangement, and also ensures that the groove arrangement exhibits the required strength for enabling mounting. Further, a higher density may also make the panel less sensitive to damages during transport and handling, and may also prevent problems associated with sagging of the panel.
Thus, the chosen density for the acoustical panel will in most cases be a compromise between the conflicting interests presented above.
There is hence a need for a low-density acoustic panel which still may present the advantages of a high-density panel in terms of robustness to thereby allow provision of the groove arrangement and which also may resist sagging.
In view of that stated above, the object of the present invention is to provide a robust acoustical panel made of compressed fibre material and having a low density which is robust enough to be suspended in a substantially horizontal direction without sagging.
Another object is to provide a low-density acoustical panel which is robust enough to allow a groove arrangement along its side edges.
It is also an object to provide a baseboard from which such acoustical panels may be manufactured.
These and other objects are solved by an acoustic panel made of a compressed mineral fibre material comprising two major surfaces and at least one side edge connecting the two major surfaces,
In the context of the invention the term “perimeter region” is to be understood as a zone of the acoustic panel having a three-dimensional extension and extending along at least a portion of the perimeter of the acoustic panel while delimiting a central region of the panel. The perimeter region must not have a continuous extension as seen along the perimeter of the acoustic panel. It is sufficient that it is associated with at least one side edge of the acoustic panel. This may be the case in the event the acoustic panel has a rounded shape, such as being circular or oval. It is preferred that it is associated with at least two side edges. Further, the boundary region must not extend across the full thickness of the acoustic panel.
In the context of the invention the term “central region” is to be understood as a zone of the acoustic panel delimited by the boundary region. The central region has a three-dimensional extension.
The acoustic panel may have a rounded shape as seen across its major surface, i.e. being circular or oval. Alternatively, the acoustic panel may have a polygonal shape as seen across its major surface. Thus, in the event of a polygonal shape, the shape may have three or more side edges, such as being triangular, quadrangular, pentagonal, hexagonal etc.
By the present invention, an acoustic panel is provided which comprises a reinforcing structure which has an extension starting from a first position in the perimeter region, across the central region and ending in a second portion of the perimeter region. The first and second positions are separate from each other. Thereby the acoustic panel is provided with an improved rigidity which prevents/reduces, i.e. counteracts sagging of the panel when used in a mounted position. Accordingly, by the first reinforcing structure, the acoustic panel may be made of a low-density material while still being robust.
By the strip-shaped configuration, one or more reinforcing structures may be arranged in any suitable pattern across the cross-sectional area and with varying thicknesses depending on the design of the individual acoustic panel and its properties. The first reinforcing structure may further, within the scope of the invention, be arranged in any position as seen in the thickness direction of the acoustic panel. Thus, it may be arranged on one or both of the major surfaces, i.e. the exterior surfaces, or have an extension into the body as seen in the thickness direction. It may even be arranged as a layer in the body of the acoustic panel in the event of a laminate structure.
The reinforcing structure may be arranged either as a structural rigid unit in the form of a lath, a tape or as a coating. The structural rigidity may be provided for after application, e.g. by activation. No matter form, it is preferred that the first reinforcing structure has a continuous extension.
Sagging is typically caused by gravity. The skilled person is aware of that a panel's tendency towards sagging depends on physical parameters and environmental parameters. Non-limiting examples of physical parameters are the type of material, density, thickness, cross-sectional area, and geometry of the perimeter. A non-limiting example of an environmental parameter is humidity in its intended mounting. The present invention allows an economy in tailor-making individual acoustic panels to meet specific installation requirements/installation patterns depending on such physical and/or environmental parameters.
In the event of the acoustic panel comprises more than one first reinforcing structure, such plurality of structures may at least partially overlap each other. One such embodiment is in the event the structures are arranged in a net-like pattern. Another embodiment is in the event the first reinforcing structure as such is formed by different uni-directional layers.
A distance, as measured along a first axis, between a virtual point on the first reinforcing structure and the mid-point of the acoustic panel may equal or be smaller than a distance, as measured along said first axis, between the virtual point and anyone of the at least one side edge. The measurements should be made in one and the same plane of the acoustic panel. The measurement is preferably made in the plane where the reinforcing structure is arranged. This means that there exists a virtual point on the first reinforcing structure which is located closer to the mid-point than the at least one side edge, or at least located in the middle between the mid-point and the at least one side edge. Hereby sagging of the central region may be more efficiently counteracted.
In the context of the invention, the term “mid-point” is to be understood as the centre of the acoustic panel as seen in a plane extending in parallel with a major surface of the acoustic panel. In the event of a rectangular panel, the mid-point is the point where the two virtual diagonal lines meet.
The perimeter region may comprise a second reinforcement structure having an extension only in the perimeter region.
The second reinforcement structure may have a continuous or a dis-continuous extension.
The first reinforcing structure may be applied on at least one of the two major surfaces. The first reinforcing structure may be arranged on one or both major surfaces. In the event the panel is intended to be mounted in the ceiling or along a wall, the first reinforcing structure may be applied on the major surface which is configured to face the room.
The acoustic panel may comprise a laminated structure and the first reinforcing structure may be applied between two layers of the laminated structure.
The first reinforcing structure may be a coating applied in liquid form as a strip having a continuous extension. The coating may by way of example be applied by extrusion, printing, painting, spraying or 3D printing.
Alternatively, the first reinforcing structure may be a structural rigid unit in the form of a lath or a tape having a continuous extension. The lath may by way of example be an extruded piece of plastic or metal material.
The coating may be activated after application by using UV light or heat. This may also be used to activate any binding material or adhesive. In the event of UV light, this may be provided by a fluorescent lamp or by a UV-LED. In the event of a UV-LED, the typical wavelength may be 385 nm, 395 nm or 405 nm depending on the type of material to be activated, i.e. cured.
The second reinforcing structure may have a strip-shaped extension along the at least one side edge of the panel and in the perimeter region.
The thus reinforced at least one side edge may be provided with groove arrangements along an associated side edge even if the panel as such comprises compressed mineral fibre material of a relatively low density. A lightweight acoustic panel made of compressed mineral fibre material and having enhanced properties for absorption of lower sound frequencies may thus be obtained, while the panel simultaneous may exhibit improved robustness enabling provision of groove arrangements and making the panel less sensitive to damages during transportation and handling.
The second reinforcing structure may extend along all side edges of the acoustic panel. Alternatively, the second reinforcing structure may extend along two opposing side edges of the acoustic panel.
The second reinforcing structure and/or the first reinforcing structure may be a reinforcement agent which is introduced into the acoustic panel in liquid form by diffusing, pressing, blowing, sucking or injecting and then activated. A panel made of compressed mineral fibre material has a porous structure, and that porosity may be utilized for introducing the reinforcement agent in liquid form into the panel. Alternatively, the reinforcement agent may be in pulverulent form and be introduced into the panel by vibrating the reinforcement agent into the panel. The porosity of the panel may be utilized for introducing the pulverulent reinforcement agent into the panel.
It is to be understood that the penetration depth of the reinforcement agent may differ depending on whether it is a first reinforcing structure or a second reinforcing structure to be formed. It is also to be understood that the penetration depth may differ along the longitudinal extension of an individual reinforcing structure. Also, in the event the acoustic panel comprises more than one reinforcing structure of the same type, e.g. two or more first reinforcing structures, these may have different penetration depths.
The reinforcement agent may be selected from the group consisting of lignosulphonate, silicates, such as sodium silicates, polyesters, melamine, urea formaldehyde, polyamides, furane-based resins, and phenolic resin-based binders.
The reinforcement agent may be activated by drying, curing or heating. The choice of activation is applicable no matter if the reinforcement agent is applied in liquid or pulverulent form.
The reinforcement agent may be introduced such that the second reinforcing structure and/or the first reinforcing structure formed after activation of the reinforcement agent exhibits an extension E in a thickness direction of the acoustic panel which is smaller than the thickness T of the acoustic panel.
The first reinforcing structure may at least partially overlap the second reinforcing structure in the first and second positions in the perimeter region.
The overlap may be a physical overlap with the two types of reinforcing structures physically contacting each other as seen in the thickness direction of the acoustic panel. Alternatively, the overlap may be non-physical by two types of reinforcing structures being arranged in different layers as seen in the thickness direction of the acoustic panel.
The compressed mineral fibre material may be a glass wool having a density ranging within 10-80 kg/m3. Alternatively, the compressed mineral fibre material may be a stone wool having a density ranging within 30-150 kg/m3. These ranges of density are qualified in the art as low-density compressed mineral fibre materials.
According to another aspect, a baseboard intended to be cut up into a plurality of acoustic panels is provided. The baseboard comprises a body made of compressed mineral fibre material and a reinforcing grid, wherein
The features and advantages previously discussed in view of the acoustic panel are equally applicable to the baseboard as such. In order of avoiding undue repetition, reference is made to the discussion above relating to the acoustic panel.
It is to be understood that one and the same baseboard may be configured to be cut into a plurality of acoustic panels which have different designs of their reinforcing structures. Thus, the reinforcing grid of the baseboard must not be strictly symmetrical. It is also to be understood that different sub-portions of the reinforcing grid may be formed by different application methods. Further, it is to be understood that different sub-portions of the reinforcing grid may be formed with different penetration depths. Thus, in a non-limiting example, the first reinforcing structure may be arranged to have a substantially two-dimensional extension across one or both of the two major surfaces of the acoustic panel, whereas the second reinforcing structure may be arranged to have a three-dimensional extension as seen in the thickness direction. Further, the second reinforcing structure may have a circumferential extension along the side edge of the acoustic panel to be cut.
According to yet another aspect, a suspended acoustic system is provided which comprises an acoustic panel according to any of claims 1-12. The acoustic system may be configured to be mounted in the ceiling or be mounted on the wall. Advantages and features previously discussed in the light of the acoustic panel as such are equally applicable to the suspended acoustic system.
The suspended acoustic system may further comprise a grid of profiles supporting the acoustic panel.
The grid of profiles may comprise supporting flanges configured to engage with the perimeter region of the acoustic panel. The engagement may be made by the supporting flanges engaging one or more recesses formed in or adjacent the at least one side edge of the panel, or by the acoustic panel resting on-top of the supporting flanges.
Generally, all terms used in the claims are to be interpreted according to their ordinary meaning in the technical field, unless explicitly defined otherwise herein. All references to “a/an/the [element, device, component, means, step, etc]” are to be interpreted openly as referring to at least one instance of said element, device, component, means, step, etc., unless explicitly stated otherwise. The steps of any method disclosed herein do not have to be performed in the exact order disclosed, unless explicitly stated.
The above, as well as additional objects, features and advantages of the present invention, will be better understood through the following illustrative and non-limiting detailed description of preferred embodiments of the present invention, with reference to the appended drawings, where the same reference numerals will be used for similar elements, wherein:
The present invention will now be described more fully hereinafter with reference to the accompanying drawings, in which currently preferred embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as being limited to the embodiments set forth herein; rather, these embodiments are provided for thoroughness and completeness, and fully convey the scope of the invention to the skilled person.
Starting with
The acoustic panel 1 comprises a body 4 made of a compressed fibre material, for instance mineral wool such as glass wool or stone wool. As a consequence, the acoustic panel 1 has a porous structure. The acoustic panel 1 having a body 4 made of glass wool may have a density in the range of 10-80 kg/m3 and have a binder content in the range of 6-10%. An acoustic panel 1 having a body 4 made of stone wool may have a density in the range of 30-150 kg/m3 and have a binder content in the range of 2-6%.
The acoustic panel 1 comprises an perimeter region 5 which is associated with the at least one side edge 3. The perimeter region 5 delimits a central portion 6 of the panel 1 which forms an central region 7. The perimeter region 5 and the central region 7 should be seen as virtual geometrical zones rather than physical zones.
The perimeter region 5 has a three-dimensional extension and extends in the disclosed embodiment along the full circumference of the acoustic panel 1.
The acoustic panel 1 comprises a first reinforcing structure 8 having a strip-shaped extension across the central region 7 from a first position A in the perimeter region 5 to a second position B in the perimeter region 5. The purpose of the first reinforcing structure 8 is to counteract sagging of the acoustic panel. Especially, the first reinforcing structure counteracts sagging of the central region 7 of the panel 1.
The first reinforcing structure 8 is disclosed as being arranged across one of the two opposing major surfaces 2 of the panel 1. It is to be understood that the first reinforcing structure 8 alternatively may be arranged across both opposing major surfaces 2 of the panel 1
The first reinforcing structure 8 may be arranged as a structural rigid unit in the form of a lath, a tape or as a coating. The lath may by way of example be an extruded piece of plastic or metal material. In the event of a coating, the structural rigidity thereof may be provided for after application, e.g. by activation. No matter form, it is preferred that the first reinforcing structure 8 has a continuous extension.
In the disclosed embodiment, one single strip is arranged across the major surface 2. Depending on the required robustness of the acoustic panel 1, two or more reinforcing structures 8 of the first type may be arranged. These may be arranged in several possible patterns.
Now turning to
No matter the pattern of the first reinforcing structure 8, this may be formed as a coating which is applied in liquid form as a strip having a continuous extension. Depending on the viscosity of the coating, the coating may be applied as a bead. The coating may by way of example be applied by extrusion, printing, painting, spraying or 3D printing. Depending on the formula of the coating, the coating may require an activation, i.e. curing, to receive its structural rigidity. The first reinforcing structure 8 may be arranged to have a thickness t3 that corresponds to the thickness T of the acoustic panel 1, see
The activation may be provided for by subjecting the applied coating to UV light or heat to thereby activate the same. In the event of UV light, this may be provided by a fluorescent lamp or by a UV-LED. In the event of a UV-LED, the typical wavelength may be 385 nm, 395 nm or 405 nm depending on the type of material to be activated. In the event of heat, this may be made by IR or by oven. The UV light or heat may also be used to activate ant binder or adhesive used.
Alternatively, the first reinforcing structure 8 may be a structural rigid unit in the form of a lath or a tape having a continuous extension. The lath may by way of example be an extruded piece of plastic or metal material. The lath or tape may be configured as a laminate. Further, the lath or tape must not have a uniform with or thickness but may be provided with non-disclosed cut-outs to reduce weight.
Now turning to
The second reinforcing structure 10 may extend along all side edges of the acoustic panel 1. Alternatively, the second reinforcing structure 10 may extend along two opposing side edges of the acoustic panel 1. The skilled person realizes that the sagging of the acoustic panel 1 is primarily counteracted by the first reinforcing structure 8. Also the second reinforcing structure 10 may, depending on its position, contribute to the counteraction.
The second reinforcing structure 10 provides an overall reinforcement of the acoustic panel 1 which protects the edges 3 of the panel 1 during transport and handling. The thus reinforced at least one side edge 3 may be provided with a groove arrangement 11 configured to engage a grid of profiles in a condition when the acoustic panel 1 is suspended, see
The second reinforcing structure 10 and/or the first reinforcing structure 8 may be a reinforcement agent which is introduced into the acoustic panel 1 in liquid form by diffusing, pressing, blowing, sucking or injecting and then activated. The activation is made to cure the reinforcement agent. A panel 1 made of compressed mineral fibre material has an inherent porous structure, and that porosity may thus be utilized for introducing the reinforcement agent in liquid form into the panel 1. Alternatively, the reinforcement agent may be in pulverulent form and be introduced into the panel 1 by vibrating the reinforcement agent into the panel. The porosity of the panel 1 may be utilized for introducing the reinforcement agent into the panel.
The reinforcement agent may be selected from the group consisting of lignosulphonate, silicates, such as sodium silicates, polyesters, melamine, urea formaldehyde, polyamides, furane-based resins, and phenolic resin-based binders.
The reinforcement agent may be activated by drying, curing or heating. The choice of activation is applicable no matter if the reinforcement agent is applied in liquid or pulverulent form.
It is to be understood that the penetration depth of the reinforcement agent may differ depending on whether it is a first reinforcing structure 8 or a second reinforcing structure 10 to be formed. It is also to be understood that the penetration depth may differ along the longitudinal extension of an individual reinforcing structure 8, 10. Also, in the event the acoustic panel 1 comprises more than one reinforcing structure of the same type, e.g. two or more first reinforcing structures 8, these may have different penetration depths.
In the event both the first and the second reinforcing structures 8, 10 are formed by a reinforcement agent that is introduced into the acoustic panel 1 in liquid form, it is to be understood that the two reinforcing structures 8, 10 may be formed at different stations in the production chain.
Now turning to
Turning to
Now turning to
Each acoustic panel 1 to be cut comprises a perimeter region 5 delimiting a central region 7. The perimeter region 5 of a first acoustic panel 1 to be cut from the baseboard 100 merges with the perimeter regions 5 of three or more adjacent acoustic panels 1 to be cut from the baseboard 100. Each panel 1 to be cut comprises a single first reinforcing structure 8 which extends from a first position A in the perimeter region 5, across the central region 7 to a second position B in the perimeter region 5. Each panel 1 to be cut further comprises a second reinforcing structure 10 which extends in the perimeter region 5.
The body 104 of the baseboard 100 comprises a compressed mineral fibre material having a low density, such as 10-80 kg/m3 in case of glass wool and 30-150 kg/m3 in case of stone wool.
The reinforcing grid 200 may be seen as comprising a first global reinforcing structure 208 and a second global reinforcing structure 210. When cutting the baseboard 200 into the individual acoustic panels 1, the first and second global reinforcing structures 208, 210 will be cut so that each panel 1 will receive its respective first and second reinforcing structure 8, 10 of the type that has been described above.
Starting with the first global reinforcing structure 208, this is in the disclosed embodiment formed as two parallel strip-shaped extensions extending along the length L of the baseboard 100 and between two opposite side edges 103 of the baseboard 100. The first global reinforcing structure 208 is in the disclosed embodiment formed as a rigid lath that is fixedly arranged on top of the upper major surface 102 of the baseboard 100.
The second global reinforcing structure 210 extends as a grid in the width direction and in the length direction of the baseboard 100. The second global reinforcing structure 210 virtually divides the body 104 in predetermined zones corresponding to side edges and hence the perimeter regions 5 of the plurality of acoustical panels 1 to be cut from the baseboard 100. The lower left-hand corner of the baseboard 100 has been cut away to illustrate the global reinforcing structures 108, 110 more clearly. In this embodiment there is a physical overlap between the first and second global reinforcing structures 208, 210.
The second global reinforcing structure 210 is disclosed as having a continuous extension along the predetermined zones. Also, the predetermined zones correspond to all side edges of each acoustical panel 1 to be cut. Thereby, each panel 1 obtained from the baseboard 100 will exhibit a continuous second reinforcing structure 10 which extends along all its side edges.
The strip-shaped second global reinforcing structure 210 has a width WA which corresponds to the double dimensioned width WB of the second reinforcing structure 10 of an individual acoustic panel 1 to be cut. Thereby, when cutting the baseboard 100 along a centreline extending along such second global reinforcing structure 210, each individual acoustic panel 1 thus cut will receive a second reinforcing structure 10 having its dimensioned width WB.
The second global reinforcing structure 210 is in the disclosed embodiment formed by an activated reinforcement agent.
The second global reinforcing structure 210 is disclosed in the embodiment of
Now turning to
The skilled person will understand that it is possible to provide a global reinforcing structure with some portions thereof having a continuous extension and some portions thereof having a non-continuous extension.
In the following it will be exemplified how the first and/or second global reinforcing structures 208, 210 of the reinforcing grid 200 may be formed by using a reinforcement agent to be activated. The reinforcement agent is introduced into the baseboard 100 along the intended extension of the reinforcing structures 208, 210 by utilizing the porous structure of the body 104 of the baseboard 100. It is to be understood that the very same principles to be described below are applicable if only forming an acoustic panel 1.
The reinforcement agent may for instance be diffused into the baseboard 100, as illustrated in
Alternatively, the reinforcement agent 40 may be pressed into the baseboard 100, as illustrated in
According to another alternative, the reinforcement agent 40 may be blown into the baseboard 100, as illustrated in
According to yet another alternative, the reinforcement agent 40 may be sucked into the baseboard 100, as illustrated in
According to yet another alternative, the reinforcement agent 40 may be injected into the baseboard 100, as illustrated in
According to yet another alternative, the reinforcement agent 40 may be vibrated into the baseboard 100, as illustrated in
No matter application method, the reinforcement agent 40 which is introduced into or applied to the baseboard 100 is subsequently activated to form the reinforcing structure 208, 210. The reinforcement agent 40 may be activated by drying, curing or heating. For instance, after introducing the reinforcement agent 40 into the porous body 104 of the baseboard 100, the baseboard 100 may be transferred to an oven (not disclosed) where the baseboard 100 is exposed to heat for activation of the reinforcement agent 40. Alternatively, the baseboard 100 may be transferred to pass a non-disclosed source of UV light.
The reinforcement agent 40 may be selected from the group consisting of lignosulphonate, silicates, such as sodium silicates, polyesters, melamine, urea formaldehyde, polyamides, furane-based resins, and phenolic resin-based binders.
In the embodiments above, the second reinforcing structure 210 has been described as extending through the entire thickness T of the baseboard 100. It is understood that this is not necessarily the case. An acoustic panel 1 obtained from a baseboard 100 in which the reinforcing structure 210 does not extend through the entire thickness T of the baseboard 100 will thus exhibit a reinforcing structure 10 with an extension E in a thickness direction of the panel 1 which is smaller than the thickness T of the panel 1, as illustrated in
In
An acoustic panel 1 obtained from a baseboard 100 in accordance with the present invention will as mentioned above have a second reinforcing structure 10 which extends along a side edge of the panel 1. The second reinforcing structure 10 will thus reinforce the associated side edge which may be provided with a groove arrangement 11 for instance by a milling operation.
Now turning to
The suspension may in another embodiment, see
It will be appreciated that the present invention is not limited to the embodiments shown. Several modifications and variations are thus conceivable within the scope of the invention which thus is exclusively defined by the appended claims.
The acoustic panel 1 has been exemplified as having a quadrangular, i.e. a polygonal shape, as seen across its major surface. Thus, in the event of a polygonal shape, the shape may have three or more side edges, such as being triangular, quadrangular, pentagonal, hexagonal etc. It is to be understood that the invention is equally applicable to an acoustic panel 1 having a rounded shape as seen across its major surface, i.e. being circular or oval.
The first reinforcing structures have been exemplified as having a straight-linear extension. It is to be understood that non-straight extensions are equally possible within the scope of the invention.
It is to be understood that one and the same baseboard may be formed and be configured to be cut into a plurality of acoustic panels which have different designs of their reinforcing structures. Thus, the reinforcing grid of the baseboard must not be strictly symmetrical.
Different sub-portions of the reinforcing grid may be formed by different application methods. Further, it is to be understood that different sub-portions of the reinforcing grid may be formed with different thicknesses/penetration depths.
| Number | Date | Country | Kind |
|---|---|---|---|
| 20208292.1 | Nov 2020 | EP | regional |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/EP2021/080751 | 11/5/2021 | WO |
