Patent Grant
11286662
The present disclosure relates generally to acoustic panels, for example, suitable for acoustic ceiling surfaces. The present disclosure relates more particularly to panels including a panel body (e.g., formed of fiberglass) supported by a perimeter frame attached to the outer edge of panel body.
Certain acoustic panels provide excellent acoustic performance. Accordingly, such panels are desirable for various construction products. For example, because of their ability to be manufactured with high noise reduction coefficients, acoustic panels make excellent ceiling panels. The panels can be secured to a ceiling grid and positioned adjacent to one another in order to form a continuous ceiling surface. Alternatively, the panels can be hung individually in certain areas of an indoor space in order to enhance the acoustic performance of the space.
A typical acoustic panel may include a body formed of a fiberglass material and a supporting frame that surrounds the fiberglass component. The frame can be composed of several frame elements that are secured to the fiberglass using an adhesive. The adhesive is applied between the fiberglass and the frame and allowed to set. Once the adhesive cures the acoustic panel is a robust structural element with excellent acoustic properties and an attractive aesthetic.
The present inventors have recognized that many adhesives that are advantageous for providing a durable and strong bond between the fiberglass (or other panel material) and the frame have long working times. As a result, after the panels are assembled they should be set aside to wait as the adhesive sets. Otherwise, unless the panels are handled with great care, the various components of the panels may begin to shift and require adjustment or reassembly. Thus, the present inventors have recognized that an acoustic panel that can be further processed and handled soon after assembly would be desirable to manufacturers.
In one aspect, the present disclosure provides an acoustic panel comprising:
In another aspect, the disclosure provides an acoustic panel comprising:
In another aspect, the disclosure provides a method of manufacturing an acoustic panel according the disclosure, the method comprising:
In another aspect, the disclosure provides a method of manufacturing an acoustic panel according to the disclosure, the method comprising:
Additional aspects of the disclosure will be evident from the disclosure herein.
The accompanying drawings are included to provide a further understanding of the methods and devices of the disclosure, and are incorporated in and constitute a part of this specification. The drawings are not necessarily to scale, and sizes of various elements may be distorted for clarity. The drawings illustrate one or more embodiment(s) of the disclosure, and together with the description serve to explain the principles and operation of the disclosure.
As described above, the present inventors have noted that conventional acoustic panels may be subject to relative movement between the components soon after assembly unless they are handled with great care. The present inventors have determined that an acoustic panel that can be further processed and handled soon after assembly would be desirable to manufacturers.
Accordingly, one aspect of the disclosure is an acoustic panel including a panel body and a perimeter frame. The panel body includes an upper surface, a lower surface, and a side edge. The perimeter frame extends around the side edge of the panel body and has a plurality of frame members including a first frame member and a second frame member. A first adhesive bonds a first portion of an inner surface of the first frame member to the side edge of the panel body and a second adhesive bonds a second portion of the inner surface of the first frame member to the side edge of the panel body. The second adhesive has a substantially reduced working time compared to the first adhesive.
Such an acoustic panel is schematically shown in various views in
The panel body can be formed of a variety of materials. For example, in certain desirable embodiments, the panel body is formed of fiberglass. The person of ordinary skill in the art will appreciate that fiberglass is a common and desirable material for acoustic panels. A variety of fiberglass materials can be used in practicing various embodiments of the disclosure. In certain embodiments, the fiberglass is a mineral wool, e.g., glass wool, slag wool, stone wool, vitreous ceramics. Of course, the person of ordinary skill in the art can contemplate use of other similar organic or inorganic materials, e.g., one or more of polyester, polypropylene, polyethylene, acrylic, cotton, silk, wool, cellulose fiber, wood pulp, denim, jute, seagrass, hemp, potassium titanate fiber, Meerschaum (Hydrated Magnesium Silicate) and carbon fiber; these also can be provided in combination with fiberglass. Foamed polymers, e.g., foamed polyurethanes, can also be used to provide the panel body.
In certain desirable embodiments as otherwise described herein, the panel body has a noise reduction coefficient (“NRC”) value of at least 0.5, e.g., at least 0.7, at least 0.8, or at least 0.85. For example, in certain embodiments as otherwise described herein, the panel body has an NRC value in the range of 0.5-0.99, e.g., 0.5-0.95, or 0.5-0.9, or 0.7-0.99, or 0.7-0.95, or 0.7-0.9. In certain embodiments as otherwise described herein, the panel body has an NRC value in the range of 0.8-0.99, e.g., 0.8-0.95, or 0.8-0.9, or 0.85-0.99, or 0.85-0.95, or 0.85-0.9. As used herein, a “noise reduction coefficient” or “NRC” describes the arithmetic average (e.g., rounded to the nearest multiple of 0.05), of the absorption coefficients for a specific panel determined at 250 Hz, 500 Hz, 1000 Hz, and 2000 Hz. The person of ordinary skill in the art will appreciate that an “absorption coefficient” of a panel may be determined through standardized testing procedures described in ASTM C423-17 (“Standard Test Method for Sound Absorption and Sound Absorption Coefficients by the Reverberation Room Method”).
The panel body also desirably meets the E84 fire safety specification, and has a light-colored surface.
A perimeter frame 120 extends around side edge 116 of panel body 110 and includes a plurality of frame members 122, 124, 126, 128, which include first frame member 122 and second frame 124. A first adhesive 160 bonds a first portion of an inner surface 132 of first frame member 122 to side edge 116 of panel body 110. Further a second adhesive 166 bonds a second portion of inner surface 132 of first frame member 122 to side edge 116 of panel body 110.
The members of perimeter frame 120 are coupled to one another using a bracket 180. For example, as shown in
In certain embodiments as otherwise described herein, the first adhesive bonds a first portion of the inner surface of each of the plurality of frame members to the side edge of the panel body, and the second adhesive bonds a second portion of the inner surface of each of the plurality of frame members to the side edge of the panel body. For example, in acoustic panel 100, each of second frame member 124 as well as frame members 126 and 128 are also bonded to the side edge 166 by first adhesive 160 and second adhesive 166. In particular,
In certain embodiments as otherwise described herein, the working time of the second adhesive is no more than 20% of the working time of the first adhesive, e.g., no more than 10%, e.g., no more than 5%. For example, in certain embodiments, the first adhesive requires several hours to dry and set before the bond of the first adhesive is sufficiently strong to allow additional manufacturing or working steps of the acoustic panel without any additional supports holding the panel together. In contrast, in such embodiments the second adhesive may have a working time of several minutes or less. For example, in some embodiments, the second adhesive reaches 95% of its adhesive strength within 20 minutes of application, e.g., within 10 minutes of application, e.g., within 5 minutes of application, e.g., within 3 minutes of application. In certain embodiments, the second adhesive has an open time of less than 10 minutes, e.g., less than 5 minutes, e.g., less than 3 minutes, e.g., less than 2 minutes.
In certain embodiments as otherwise described herein, the second adhesive is a hot melt adhesive. For example, in some embodiments the second adhesive is a thermoplastic that is applied while heated and sets quickly as the temperature of the adhesive cools. Examples of appropriate hot melt adhesives include polyamides, polyesters, styrene block copolymers, polyethylene, ethylene vinyl acetate polymers, ethylene-acrylate copolymers, such as ethylene-methyl acrylate (EMA) or ethylene n-butyl acrylate (EnBA), and polyolefins.
In certain embodiments, the second adhesive may one or more additives that influence certain performance properties of the adhesive. For example, in some embodiments the second adhesive includes a resin that influences the tack and/or adhesive strength of the adhesive. Examples of possible resins include rosin, hydrogenated rosin, rosin ester, hydrogenated hydrocarbon and terpene phenolics. In some embodiments the second adhesive includes a wax that influences the open time and set time of the adhesive, i.e., the time required for the adhesive to form a bond and the time required to form a bond of a particular strength. Examples of possible waxes include natural waxes, microcrystalline waxes and synthetic waxes. In some embodiments the second adhesive includes an antioxidant that influences the adhesive's degradation. Possible antioxidants include phenols, aromatic amines, phosphates and phosphites. In some embodiments, the second adhesive includes a plasticizer for influencing the flexibility and durability of the adhesive. Other additives are also possible, such as biocides and flame retardants.
In certain embodiments as otherwise described herein, the first adhesive is provided in strips along a length of the first frame member and the second adhesive is provided between the strips of first adhesive along the length of the first frame member. For example, in acoustic panel 100, first adhesive 160 is provided in several strips along the length of first frame member 122. The position of first adhesive 160 ensures that, upon setting of first adhesive 160, a strong bond is formed between first frame member 122 and panel body 110 along the entire length of first frame member 122. Additionally, gaps are provided in the placement of first adhesive 160 along the length of first frame member 122 allowing second adhesive 166 to be periodically positioned between the strips of first adhesive. With its comparably short working time, the sections of second adhesive 166 provided between the strips of first adhesive 160 provide fast bonding between the frame members (e.g., 122) and the panel body 110.
In certain embodiments as otherwise described herein, the first frame member is coupled to the second frame member by a bracket. The bracket includes a first portion that is received in a slot in the first frame member and a second portion that is received in a slot in the second frame member. The first portion includes a first laterally extending projection that engages an inner surface of the slot in the first frame member so as to hinder removal of the bracket from the first frame member. Likewise, the second portion includes a second laterally extending projection that engages an inner surface of the slot in the second frame member so as to hinder removal of the bracket from the second frame member.
An acoustic panel with first and second frame members that are coupled to one another using such a bracket is shown in
While acoustic panel 400 includes both multiple adhesives 460, 466 as well as a bracket 480 that includes laterally extending projections, other embodiments may use these features in the alternative. For example, bracket 100, described above, uses a bracket 180 without any lateral projection. Likewise, in some embodiments, a bracket having the laterally extending projections is used with a single adhesive.
For example, in another aspect, the disclosure provides an acoustic panel including a panel body (e.g., comprising fiberglass, or having an NRC value in the range of at least 0.5, e.g., 0.5-0.95 or 0.5-0.9) and a perimeter frame. The panel body includes an upper surface, a lower surface, and a side edge. The perimeter frame extends around the side edge of the panel body and has a plurality of frame members including a first frame member and a second frame member. A first adhesive bonds a first portion of an inner surface of the first frame member to the side edge of the panel body. A bracket couples the first frame member to the second frame member. The bracket includes a first portion that is received in a slot in the first frame member and a second portion that is received in a slot in the second frame member. The first portion includes a first laterally extending projection that engages an inner surface of the slot in the first frame member so as to hinder removal of the bracket from the first frame member. Similarly, the second portion includes a second laterally extending projection that engages an inner surface of the slot in the second frame member so as to hinder removal of the bracket from the second frame member.
Such an acoustic panel is shown in
In certain embodiments as otherwise described herein, friction between the first laterally extending projection and the inner surface of the slot in the first frame member hinders removal of the bracket from the first frame member and friction between the second laterally extending projection and the inner surface of the slot in the second frame member hinders removal of the bracket from the second frame member. For example, in some embodiments, a laterally outward force on each of the laterally extending projections pushes the respective laterally extending projection against the slot in the corresponding frame. This outward force imparts a frictional engagement between the laterally extending projection and an inner surface of the slot that hinders removal of the bracket from the slot.
In certain embodiments as otherwise described herein, the bracket includes a bent metal strip. The term metal strip, as used herein, is not limited to any particular thickness and may include materials conventionally referred to as metal foil, sheet metal, or metal plate. For example, a schematic perspective depiction of bracket 480 is shown alone in
In certain embodiments as otherwise described herein, the first and second laterally extending projections are bent outward from a surface of the metal strip. For example, as shown in
In certain embodiments as otherwise described herein, the thickness of each leg of the bracket is thicker than the slot in the corresponding frame member. For example, the thickness of first leg or first portion 482 of bracket 480, when including the laterally extending projection 484, is thicker than the slot 436 is first frame member 422. In particular, while the thickness of the metal strip that forms bracket 480 is thinner than slot 436, the laterally extending projection 484 increases the thickness of first portion 482 to the extent that the first bracket portion 482 is thicker than slot 436. As a result, the initial insertion of the end of first portion 482 into slot 436 is not met with any resistance. However, as laterally extending projection 484 is inserted into slot 436, it is deformed and pressed closed, such that laterally extending projection 484 exerts an outward force against the inside surface 448 of slot 436.
In certain embodiments as otherwise described herein, the first and second laterally extending projections protrude from a side edge of the metal strip. For example,
In certain embodiments as otherwise described herein, the width of each leg of the bracket is thicker than the width of the slot in the corresponding frame member. For example, the width of first leg or first portion 982 of bracket 980, when including the laterally extending projection 984, may be thicker than the slot is a frame member in which the bracket 980 is inserted. In particular, while the width of the metal strip along much of the bracket 980 may be smaller than the corresponding slot, the laterally extending projection 984 increases the width of first portion 982 to the extent that the first bracket portion 982 is wider than the corresponding slot. As a result, the initial insertion of the end of first portion 982 into the slot is not met with any resistance. However, as laterally extending projection 984 is inserted into the slot, it is deformed and pressed inward, such that laterally extending projection 984 exerts an outward force against the inside surface of the corresponding slot.
In certain embodiments as otherwise described herein, the first laterally extending projection includes a sharp edge that engages the inner surface of the slot in first frame member, and the second laterally extending projection includes a sharp edge that engages the inner surface of the slot in the second frame. For example, first laterally extending projection 484 of bracket 480 of an acoustic panel 400 has a sharp edge 486 that engages the inner surface 438 of the slot 436 in first frame member 422. Likewise, second laterally extending projection 490 has a sharp edge 492 that engages an inner surface 442 of slot 440 in second frame member 424. The sharp edges may deform the inner surface of the corresponding slot and form an indent therein, which aids in hindering removal of the bracket from the slot. Similarly, first laterally extending projection 684 of bracket 680 of acoustic panel 600 has a sharp edge 686 that engages the inner surface 638 of the slot 636 in first frame member 622. Likewise, second laterally extending projection 690 has a sharp edge 692 that engages an inner surface 642 of slot 640 in second frame member 624. The sharp edges may deform the inner surface of the corresponding slot and form an indent therein, which aids in hindering removal of the bracket from the slot.
In certain embodiments, the sharp edge of each laterally extending projection faces toward the middle of the bracket. For example, the sharp edge on the first laterally extending projection faces the joint where the first and second laterally extending projections meet. In some embodiments, the sharp edge is at the inner end of the laterally extending projection. For example, sharp edge 486 is disposed on the inward end of first laterally extending projection 484 and faces the joint where first portion 482 and second portion 488 meet. In contrast, the outer end of laterally extending projection 484 is gradually sloped. Accordingly, as the first portion 482 of bracket 480 is inserted into the slot in first frame member 422, the gradual slope causes the laterally extending projection 484 to bend inward. On the other hand, if a force is exerted on bracket 480 to remove the first portion 482 from the slot, the sharp edge 486 will catch against the inner surface of the slot. The second laterally extending projection 490 has a similar configuration, where the sharp edge is disposed at the inner end of the laterally extending projection 490 and faces the joint.
Bracket 980 shows another example including laterally extending projections that have sharp edges with a similar configuration. Specifically, sharp edge 986 is disposed on the inward end of first laterally extending projection 984 and faces the joint where first portion 982 and second portion 988 meet. In contrast, the outer end of laterally extending projection 984 is gradually sloped toward the sharp edge. Accordingly, as the first portion 982 is inserted into a receiving slot in a first frame member, the gradual slope of the laterally extending projection 984 will allow it to bend inward. On the other hand, if a force is exerted on bracket 980 to remove it from the first frame member, the sharp edge 986 will catch on an inner surface of the slot, hindering its removal. Likewise, laterally extending projection 990 has a similar configuration, with sharp edge 992 facing the joint between first portion 982 and second portion 988. As a result, laterally extending projection 990 will also allow insertion into the slot of the second frame member but hinder removal therefrom.
In certain embodiments as otherwise described herein, the first and second frame members are formed of a first material and the bracket is formed of a second material, and wherein the first material is softer than the second material. Once the brackets are inserted into the slots in the corresponding frame members, the sharp edge of the bracket can pierce the surface of the softer frame material, which strengthens the connection between these components and prevents removal of the bracket from the slot. For example, in some embodiments, the brackets are formed of steel and the frame members are formed of a softer material, such that the sharp edge of the steel brackets can form an indent into the surface of the frame member. In some embodiments, the brackets are formed of an aluminum alloy, which provides a particularly strong connection between the sharp edge of a bracket of steel and the frame member.
In certain embodiments, the bracket is punched from a metal sheet. For example, bracket 480 is formed by being punched from a metal sheet while simultaneously forming the laterally extending projection during the punching process. In some embodiments the bend between the first and second portions of the bracket is formed after the shape of the bracket has been punched from the metal sheet. In other embodiments, the bracket is bent during the punching process.
In certain embodiments, the bracket is cut from a metal sheet. For example, bracket 980 is cut from a flat metal sheet and then the first and second portions 982, 988 are bent with respect to one another. As will be appreciated by those of ordinary skill in the art, the bracket can be cut from the metal sheet using various different methods, such as laser cutting or water jet cutting.
In certain embodiments as otherwise described herein, the bracket has a width in a range from ¼ inch to 2 inches, e.g., from ¼ inch to 1 inch, e.g., from ⅜ inch to ½ inch. In certain embodiments as otherwise described herein, each of the first and second portions of the bracket has a length in a range from ½ inch to 3 inches, e.g., from 1 inch to 2 inches.
In certain embodiments as otherwise described herein, the ends of the bracket include chamfered or rounded corners. For example, bracket 980 includes rounded corners. The rounded or chamfered corners are beneficial for guiding the bracket as it is inserted into the slot of the corresponding frame member.
In certain embodiments as otherwise described herein, the panel has a length in a range from 1 ft. to 20 ft., e.g., in a range from 2 ft. to 10 ft., e.g., about 2 ft., about 3 ft., about 4 ft., about 5 ft., about 6 ft., about 7 ft., about 8 ft., about 9 ft., or about 10 ft. In certain embodiments as otherwise described herein, the panel has a width in a range from 1 ft. to 10 ft., e.g., about 1 ft., about 2 ft., about 3 ft., about 4 ft., about 5 ft., about 6 ft., about 7 ft., about 8 ft., about 9 ft., or about 10 ft. For example, one embodiment of an acoustic panel has length of 10 ft. and a width of 4 ft. Of course, a wide range of other combinations are possible. The term length and width, as used herein, are not confined to any particular shape of the acoustic panel. The term length is used to identify the longest dimension of the panel along a surface of the panel and between parallel edges thereof. The term width is used to identify a direction that is perpendicular to the length and extends from one edge of the panel to another. For example, the length and width of a circular panel are the same and the length and width dimensions are both measured from opposite sides of the panel where the opposing edges are parallel to one another.
In certain embodiments as otherwise described herein, the acoustic panel has a thickness in a range from 0.5 inches to 3 inches, e.g., 1 inch to 2.5 inches. The term thickness, as used herein, refers to the measurement through the acoustic panel at a particular point on the surface of the panel. Thus, the term thickness does not incorporate the overall height dimension of the panel resulting from curvature in the surface of the panel. In other words, a curved panel (such as that shown in
In certain embodiments as otherwise described herein, the acoustic panel has a noise reduction coefficient of at least 0.5, e.g., at least 0.7, e.g., at least 0.8, e.g., at least 0.85. As used herein, a “noise reduction coefficient” or “NRC” describes the arithmetic average (e.g., rounded to the nearest multiple of 0.05), of the absorption coefficients for a specific panel determined at 250 Hz, 500 Hz, 1000 Hz, and 2000 Hz. The person of ordinary skill in the art will appreciate that an “absorption coefficient” of a panel may be determined through standardized testing procedures described in ASTM C423-17 (“Standard Test Method for Sound Absorption and Sound Absorption Coefficients by the Reverberation Room Method”). The person of ordinary skill in the art will further appreciate that, while intended to describe the fraction of randomly incident sound power absorbed by a surface, an absorption coefficient is defined operationally, and accordingly, highly absorptive panels can have an absorption coefficient exceeding unity at one or more frequencies.
In certain embodiments as otherwise described herein, a surface of the panel has a light reflectance of at least 75%, e.g., at least 80%, e.g., about 90%. For example, the lower surface of acoustic panel used as a ceiling panel may be tinted white, for example by paint, and have a light reflectance of 85%. In other embodiments, the panel may have other decorative characteristics and have a lower light reflectance. For example, in some embodiments, the surfaces of the acoustic panels is dark and has low light reflectance.
In certain embodiments as otherwise described herein, the panel is planar. For example, acoustic panel 100 includes flat upper and lower surfaces resulting in a planar panel. In other embodiments, the panel has a curved contour. For example, acoustic panel 1000, shown in
In certain embodiments as otherwise described herein, each of the frame members is formed of an aluminum alloy. In certain embodiments as otherwise described herein, each of the frame members is an extruded member. For example, each of the frame members 122, 124, 126, 128 of acoustic panel 100 is formed as an extruded aluminum member. The aluminum provides a strong and light material for the outer perimeter of the panel.
In certain embodiments as otherwise described herein, each of the frame members includes an upper arm that covers a portion of the upper surface of the panel body and a side arm that forms the inner surface that is bonded to the side edge of the panel. For example, as shown in
In certain embodiments as otherwise described herein, each of the frame members includes a flange extending inward from the inner surface and the panel body includes a slot extending inward from the side edge, where the flanges of the frame members are received in the slot. For example, frame member 122, as shown in
In certain embodiments, the flange includes a textured surface. The textured surface of the flange may promote a positive engagement between the flange and the slot of the panel body. For example, flange 148 includes a plurality of ribs that engage with the slot 118 of panel body 110 and form a positive engagement between frame member 122 and panel body 110 hindering removal of flange 148 from slot 118.
In certain embodiments as otherwise described herein, the first and second frame members are straight, and wherein the acoustic panel as a polygonal shape. For example, first frame member 122 and second frame member 124 are both straight and acoustic panel 100 has the shape of a square. Likewise,
In certain embodiments as otherwise described herein, the first and second frame members are coupled in a miter joint. For example, as shown in
In certain embodiments as otherwise described herein, the first and second frame members are curved, and wherein the panel body has a curved edge. For example, first frame member 1222 and second frame member 1224 of acoustic panel 1200 are both curved and extend around the perimeter of panel body 1210. The shape of panel body 1210 and the corresponding shape of acoustic panel 1200 is elliptical. In other embodiments, the acoustic panel has other curved shapes, such as rounded squares, circles, ovals or irregular curved shapes. Further, in some embodiments the frame includes both curved and straight frame members.
In certain embodiments as otherwise described herein, the panel body has a density in a range of 4 to 15 lbs. per cubic foot, e.g., 5 to 10 lbs. per cubic foot, e.g., 6 to 7 lbs. per cubic foot. In combination with the materials of the frame members, the density of the panel body controls the overall weight of the acoustic panel.
In certain embodiments as otherwise described herein, the first adhesive is an elastomeric glue. For example, the first adhesive may include natural or synthetic elastomers, such as rubber. In some embodiments, the first adhesive includes one or more resins that increase the tack and shear properties of the adhesive.
In certain embodiments as otherwise described herein, the first adhesive is a water-based glue. For example, in some embodiments the first adhesive is a water-based solvent-free glue.
In certain embodiments as otherwise described herein, the first adhesive is a white glue.
In certain embodiments, the first adhesive requires at least one hour from application to achieve 95% of its adhesive strength. For example, in some embodiments, the first adhesive requires several hours to set. In other embodiments, the first adhesive may be a fast setting adhesive.
In another aspect, the disclosure provides a method of manufacturing an acoustic panel according to the disclosure. The method includes applying a first adhesive between a side edge of a panel body (e.g., comprising fiberglass, or having an NRC value in the range of at least 0.5, e.g., 0.5-0.95 or 0.5-0.9) and an inner surface of a first frame member of a perimeter frame. A second adhesive is also applied between the side edge of the panel body and the inner surface of the first frame member, where the second adhesive has a substantially reduced working time compared to the first adhesive. The frame members of the perimeter frame are then secured around the side edge of the panel body.
Acoustic panel 100 illustrates an embodiment of a panel manufactured according to such a method. In order to introduce the adhesives between the side edge 116 of panel body 110 and inner surface 132 of first frame member 122, the adhesives may be applied to either or both of the frame member and the panel body before they are secured to one another. During assembly, the frame members 132, 134, 136, 138 are coupled to one another and secured around the side edge 116 of the panel body 110 to form the assembled acoustic panel 100.
In another aspect, the disclosure provides a method of manufacturing an acoustic panel according to the disclosure. The method includes applying a first adhesive between a side edge of a panel body (e.g., comprising fiberglass, or having an NRC value in the range of at least 0.5, e.g., 0.5-0.95 or 0.5-0.9) and an inner surface of a first frame member of a perimeter frame. The method also includes coupling the first frame member to a second frame member of the perimeter frame using a bracket by inserting a first portion of the bracket into a slot in the first frame and inserting a second portion of the bracket in to a slot in the second frame. The first portion of the bracket includes a first laterally extending projection having a sharp edge that engages an inner surface of the slot in the first frame member so as to hinder removal of the bracket from the first frame member and the second portion of the bracket includes a second laterally extending projection having a sharp edge that engages an inner surface of the slot in the second frame member so as to hinder removal of the bracket from the second frame member.
Acoustic panel 400 illustrates an embodiment of a panel manufactured according to such a method. In order to introduce the adhesive between the side edge 416 of panel body 410 and inner surface 432 of first frame member 422, the adhesive may be applied to either or both of the frame member and the panel body before they are secured to one another. During assembly, the frame members 422, 424, 426, 428 are coupled to one another using brackets. For example, first frame member 422 is coupled to second frame member 434 by inserting a first portion 482 of the bracket 480 into a slot 436 in first frame 422 and inserting a second portion 488 of bracket 480 into a slot 440 in second frame 424. The first portion 482 of bracket 480 includes a first laterally extending projection 484 having a sharp edge 486 that engages an inner surface 438 of slot 436 of first frame member 422 so as to hinder removal of the bracket from first frame member 422. Likewise, the second portion 488 of bracket 480 includes a second laterally extending projection 490 having a sharp edge 492 that engages an inner surface 442 of slot 440 in second frame member 424 so as to hinder removal of bracket 480 from second frame member 424.
In certain embodiments as otherwise described herein, each of the frame members includes a flange extending inward from the inner surface, and wherein the panel body includes a slot extending inward from the side edge, the method further comprising inserting the flange of each frame member into the slot in the side edge of the panel body. For example, as first frame member 122 is secured to panel body 110, flange 148 of first flange 122 is inserted into slot 118 formed on side edge 116 of panel body 110.
Further aspects of the disclosure are provided by the enumerated embodiments listed below, which can be combined in any combination and in any number that is not logically or technically inconsistent.
An acoustic panel comprising:
The acoustic panel according to embodiment 1, wherein the first adhesive bonds a first portion of the inner surface of each of the plurality of frame members to the side edge of the panel body, and the second adhesive bonds a second portion of the inner surface of each of the plurality of frame members to the side edge of the panel body.
The acoustic panel according to embodiment 1 or embodiment 2, wherein the working time of the second adhesive is no more than 20% of the working time of the first adhesive, e.g., no more than 10%, e.g., no more than 5%.
The acoustic panel according to any of embodiments 1 to 3, wherein the second adhesive is a hot melt adhesive.
The acoustic panel according to any of embodiments 1 to 4, wherein the first adhesive is provided in strips along a length of the first frame member and the second adhesive is provided between the strips of first adhesive along the length of the first frame member.
The acoustic panel according to any of embodiments 1 to 5, wherein the first frame member is coupled to the second frame member by a bracket, the bracket comprising:
An acoustic panel comprising:
The acoustic panel according to embodiment 6 or embodiment 7, wherein friction between the first laterally extending projection and the inner surface of the slot in the first frame member hinders removal of the bracket from the first frame member, and
The acoustic panel according to embodiment 6 or embodiment 7, wherein the first laterally extending projection includes a sharp edge that engages the inner surface of the slot in first frame member, and
The acoustic panel according to any of embodiments 6 to 9, wherein the bracket includes a bent metal strip.
The acoustic panel according to embodiment 10, wherein the first and second laterally extending projections are bent outward from a surface of the metal strip.
The acoustic panel according to embodiment 11, wherein the first and second laterally extending projections protrude from a side edge of the metal strip.
The acoustic panel according to any of embodiments 6 to 12, wherein the first and second frame members are formed of a first material and the bracket is formed of a second material, and wherein the first material is softer than the second material.
The acoustic panel according to any of embodiments 6 to 13, wherein the bracket comprises steel.
The acoustic panel according to any of embodiments 1 to 14, wherein the acoustic panel has a length in a range from 1 ft. to 20 ft., e.g., in a range from 2 ft. to 10 ft., e.g., about 2 ft., about 3 ft., about 4 ft., about 5 ft., about 6 ft., about 7 ft., about 8 ft., about 9 ft., or about 10 ft.
The acoustic panel according to any of embodiments 1 to 15, wherein the acoustic panel has a width in a range from 1 ft. to 10 ft., e.g., about 1 ft., about 2 ft., about 3 ft., about 4 ft., about 5 ft., about 6 ft., about 7 ft., about 8 ft., about 9 ft., or about 10 ft.
The acoustic panel according to any of embodiments 1 to 16, wherein the acoustic panel has a thickness in a range from 0.25 inches to 7 inches, e.g., 0.5 inches to 3 inches, e.g., 1 inch to 2.5 inches.
The acoustic panel according to any of embodiments 1 to 17, wherein the acoustic panel has a noise reduction coefficient of at least 0.7, e.g., at least 0.8, e.g., at least 0.85.
The acoustic panel according to any of embodiments 1 to 18, wherein a surface of the acoustic panel has a light reflectance of at least 75%, e.g., at least 80%, e.g., about 90%.
The acoustic panel according to any of embodiments 1 to 19, wherein the acoustic panel is planar.
The acoustic panel according to any of embodiments 1 to 19, wherein the acoustic panel has a curved contour.
The acoustic panel according to any of embodiments 1 to 21, wherein each of the frame members is formed of an aluminum alloy.
The acoustic panel according to any of embodiments 1 to 22, wherein each of the frame members is an extruded member.
The acoustic panel according to any of embodiments 1 to 23, wherein each of the frame members includes:
The acoustic panel according to any of embodiments 1 to 24, wherein each of the frame members includes a flange extending inward from the inner surface, and
The acoustic panel according to any of embodiments 1 to 25, wherein the first and second frame members are straight, and wherein the acoustic panel as a polygonal shape.
The acoustic panel according to embodiment 26, wherein the first and second frame members are coupled in a miter joint.
The acoustic panel according to any of embodiments 1 to 25, wherein the first and second frame members are curved, and wherein the panel body has a curved edge.
The acoustic panel according to any of embodiments 1 to 28, wherein the panel body has a density in a range from 2 to 20 lbs. per cubic foot, e.g., 4 to 15 lbs. per cubic foot, e.g., 5 to 10 lbs. per cubic foot, e.g., 6 to 7 lbs. per cubic foot.
The acoustic panel according to any of embodiments 1 to 29, wherein the panel body comprises fiberglass.
The acoustic panel according to any of embodiments 1 to 29, wherein the panel body comprises one or more of one or more of polyester, polypropylene, polyethylene, acrylic, cotton, silk, wool, cellulose fiber, wood pulp, denim, jute, seagrass, hemp, potassium titanate fiber, Meerschaum (Hydrated Magnesium Silicate) and carbon fiber.
The acoustic panel according to any of embodiments 1 to 31, wherein the panel body has a noise reduction coefficient (“NRC”) value of at least 0.5, e.g., at least 0.7, at least 0.8, or at least 0.85.
The acoustic panel according to any of embodiments 1 to 31, wherein the panel body has an NRC value in the range of 0.5-0.99, e.g., 0.5-0.95, or 0.5-0.9, or 0.7-0.99, or 0.7-0.95, or 0.7-0.9.
The acoustic panel according to any of embodiments 1 to 31, wherein the panel body has an NRC value in the range of 0.8-0.99, e.g., 0.8-0.95, or 0.8-0.9, or 0.85-0.99, or 0.85-0.95, or 0.85-0.9.
The acoustic panel according to any of embodiments 1 to 34, wherein the first adhesive has is an elastomeric glue.
The acoustic panel according to any of embodiments 1 to 34, wherein the first adhesive is a water-based glue.
The acoustic panel according to any of embodiments 1 to 36, wherein the first adhesive is a white glue.
The acoustic panel according to any of embodiments 1 to 37, wherein the first adhesive requires at least one hour from application to achieve 95% of its adhesive strength.
A method of manufacturing an acoustic panel according to any of embodiments 1 to 38, the method comprising:
The method of embodiment 39, further comprising coupling the first frame member to a second frame member of the perimeter frame using a bracket by inserting a first portion of the bracket into a slot in the first frame and inserting a second portion of the bracket in to a slot in the second frame,
A method of manufacturing an acoustic panel according to any of embodiments 1 to 38, the method comprising:
42. The method according to any of embodiments 39 to 41, wherein each of the frame members includes a flange extending inward from the inner surface, and wherein the panel body includes a slot extending inward from the side edge, the method further comprising inserting the flange of each frame member into the slot in the side edge of the panel body.
It will be apparent to those skilled in the art that various modifications and variations can be made to the processes and devices described here without departing from the scope of the disclosure. Thus, it is intended that the present disclosure cover such modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents.
This application claims the benefit of priority of U.S. Provisional Patent Application No. 62/809,495, filed Feb. 22, 2019, which is hereby incorporated herein by reference in its entirety.
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