CA2226601A1 - Pre-fabricated fabric covered acoustical wall panels - Google Patents
Pre-fabricated fabric covered acoustical wall panels Download PDFInfo
- Publication number
- CA2226601A1 CA2226601A1 CA 2226601 CA2226601A CA2226601A1 CA 2226601 A1 CA2226601 A1 CA 2226601A1 CA 2226601 CA2226601 CA 2226601 CA 2226601 A CA2226601 A CA 2226601A CA 2226601 A1 CA2226601 A1 CA 2226601A1
- Authority
- CA
- Canada
- Prior art keywords
- core material
- frame
- panel
- edge
- fabricated
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
- 239000004744 fabric Substances 0.000 title description 15
- 239000011162 core material Substances 0.000 description 34
- 230000009977 dual effect Effects 0.000 description 14
- 238000000034 method Methods 0.000 description 9
- 238000004519 manufacturing process Methods 0.000 description 4
- 239000000853 adhesive Substances 0.000 description 3
- 230000001070 adhesive effect Effects 0.000 description 3
- 238000010276 construction Methods 0.000 description 3
- 238000003780 insertion Methods 0.000 description 2
- 230000037431 insertion Effects 0.000 description 2
- 239000000463 material Substances 0.000 description 2
- 239000002184 metal Substances 0.000 description 2
- 238000003908 quality control method Methods 0.000 description 2
- 239000011347 resin Substances 0.000 description 2
- 229920005989 resin Polymers 0.000 description 2
- 239000002023 wood Substances 0.000 description 2
- 241000217377 Amblema plicata Species 0.000 description 1
- 241000282320 Panthera leo Species 0.000 description 1
- 239000003000 extruded plastic Substances 0.000 description 1
- 239000003292 glue Substances 0.000 description 1
- 238000009413 insulation Methods 0.000 description 1
- 239000004033 plastic Substances 0.000 description 1
- JTTAUPUMOLRVRA-UHFFFAOYSA-N prothipendyl Chemical compound C1=CN=C2N(CCCN(C)C)C3=CC=CC=C3SC2=C1 JTTAUPUMOLRVRA-UHFFFAOYSA-N 0.000 description 1
- 229960000957 prothipendyl Drugs 0.000 description 1
Classifications
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/62—Insulation or other protection; Elements or use of specified material therefor
- E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
- E04B1/82—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to sound only
- E04B1/84—Sound-absorbing elements
- E04B1/86—Sound-absorbing elements slab-shaped
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/62—Insulation or other protection; Elements or use of specified material therefor
- E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
- E04B1/82—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to sound only
- E04B2001/8263—Mounting of acoustical elements on supporting structure, e.g. framework or wall surface
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/62—Insulation or other protection; Elements or use of specified material therefor
- E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
- E04B1/82—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to sound only
- E04B1/84—Sound-absorbing elements
- E04B2001/8423—Tray or frame type panels or blocks, with or without acoustical filling
- E04B2001/8452—Tray or frame type panels or blocks, with or without acoustical filling with peripheral frame members
Landscapes
- Physics & Mathematics (AREA)
- Acoustics & Sound (AREA)
- Engineering & Computer Science (AREA)
- Architecture (AREA)
- Electromagnetism (AREA)
- Civil Engineering (AREA)
- Structural Engineering (AREA)
- Finishing Walls (AREA)
Description
t FIELD OF THF. INVENTION
This invention relaters to pre-fabricated fabric covered acoustical wall panels used to reduce noise in rooms which have large areas of acoustically reflective surfaces.
Particularly this invention relates to a method of panel fabrication consisting of pre-fabricated frames, which are designed to accept and hold, rigid, flat acoustical core rnaterials.The frames are pre-fabricated as complete units and define the finished size of the panel.
During fabrication the core material is positioned over the open back of the frame. The core material is then pushed into the frame and impaled on teeth which protrude $om the frame. These teeth held the core material in place and also keep the frame square and at the prescribed dimen lion.
The frame is designed to mate with a separate dual purpose clip. After the core material is impaled on the teeth of the frame, dual purpose clips are pushed into a double walled channel along the exl:erior edge of the frame section. The flange of the clip overlaps the back of the core material holding it in place.
Fabric is then wrappf;d over the face of the panel and glued to the frame edge. Excess fabric is returned to the back of the panel and glued into place.
The dual purpose clips can also be used to mount the panel. Clips are attached to the wall using adhesive or mechanical mounting methods. The wall mounted clips are positioned to line up with the edsae of the frame section. The fabric is cut along the double walled leg Page 1 of 8 of the frame where i~t intersects the wall mounted clips. The panel is pushed onto the wall mounted clips, securimg it into place.
SACKGROUNID OF THE INVENTION
Fabric covered acoustical wall panels have been used for many years to reduce echo in rooms which have large acoustically reflective wall areas Panels are constructf;d as pre-fabricated units or can be constructed on site.
Most pre-fabricated fabric covered acoustical panels are constructed in essentially the same way.
A core material of se~xni-rigid acoustical insulation is covered with a fabric facing and fastened to a wall area with a variety of types of fasteners. These fasteners can include adhesives, hook and loop mounting or mechanical systems.
With all types of panel construction, the edge of the core material must be hardened to show clean finished c;dges and to strengthen the panel. Typically two edge hardening methods pre-dominal:e in the industry. Resin hardening of the edges and the application of a frame work to thue edge of the core material.
Frameworks can be extruded plastic, wood or metal channels shaped into different edge profiles.
Page 2 of 8 Purpose of the invention and problems solved There are a number of fundamental quality control problems with all pre-fabricated panel construction nnethods. The invention of the open back, pre-fabricated frame method of panel construction addresses and solves these problems.
I. The size of i:he panel ultimately relies on the precision in the cutting of the core material Whether the edges of the panel are hardened with resin, or with channels made of wood, plastic or metal, the size of the panel is dictated by the size of the core material.
With the inve~:ntion of the pre-fabricated back loading frame system, the core material is cul; to a size big enough in area to engage the toothed edge of the frame section. Core material does not have to be cut to an exact size. Quality control issues regarding precision cutting of the core material are eliminated and productivity c;an be increased.
Page 3 of 8 ' CA 02226601 1998-03-17
This invention relaters to pre-fabricated fabric covered acoustical wall panels used to reduce noise in rooms which have large areas of acoustically reflective surfaces.
Particularly this invention relates to a method of panel fabrication consisting of pre-fabricated frames, which are designed to accept and hold, rigid, flat acoustical core rnaterials.The frames are pre-fabricated as complete units and define the finished size of the panel.
During fabrication the core material is positioned over the open back of the frame. The core material is then pushed into the frame and impaled on teeth which protrude $om the frame. These teeth held the core material in place and also keep the frame square and at the prescribed dimen lion.
The frame is designed to mate with a separate dual purpose clip. After the core material is impaled on the teeth of the frame, dual purpose clips are pushed into a double walled channel along the exl:erior edge of the frame section. The flange of the clip overlaps the back of the core material holding it in place.
Fabric is then wrappf;d over the face of the panel and glued to the frame edge. Excess fabric is returned to the back of the panel and glued into place.
The dual purpose clips can also be used to mount the panel. Clips are attached to the wall using adhesive or mechanical mounting methods. The wall mounted clips are positioned to line up with the edsae of the frame section. The fabric is cut along the double walled leg Page 1 of 8 of the frame where i~t intersects the wall mounted clips. The panel is pushed onto the wall mounted clips, securimg it into place.
SACKGROUNID OF THE INVENTION
Fabric covered acoustical wall panels have been used for many years to reduce echo in rooms which have large acoustically reflective wall areas Panels are constructf;d as pre-fabricated units or can be constructed on site.
Most pre-fabricated fabric covered acoustical panels are constructed in essentially the same way.
A core material of se~xni-rigid acoustical insulation is covered with a fabric facing and fastened to a wall area with a variety of types of fasteners. These fasteners can include adhesives, hook and loop mounting or mechanical systems.
With all types of panel construction, the edge of the core material must be hardened to show clean finished c;dges and to strengthen the panel. Typically two edge hardening methods pre-dominal:e in the industry. Resin hardening of the edges and the application of a frame work to thue edge of the core material.
Frameworks can be extruded plastic, wood or metal channels shaped into different edge profiles.
Page 2 of 8 Purpose of the invention and problems solved There are a number of fundamental quality control problems with all pre-fabricated panel construction nnethods. The invention of the open back, pre-fabricated frame method of panel construction addresses and solves these problems.
I. The size of i:he panel ultimately relies on the precision in the cutting of the core material Whether the edges of the panel are hardened with resin, or with channels made of wood, plastic or metal, the size of the panel is dictated by the size of the core material.
With the inve~:ntion of the pre-fabricated back loading frame system, the core material is cul; to a size big enough in area to engage the toothed edge of the frame section. Core material does not have to be cut to an exact size. Quality control issues regarding precision cutting of the core material are eliminated and productivity c;an be increased.
Page 3 of 8 ' CA 02226601 1998-03-17
2. The thickne;~~s of the core material must Ibe to an exacting tolerance to accommodate channels.
Problems can also occzxr in the fabrication process when channels are applied to the edge of the core material. The thickness of the core material must be of exactly the right tolerance to accommodate the channel. If the edge of the core material is too thick or too narrow, the channels will be either too small to fit around the edlge or too large to provide a snug fit. Since the thickness tolerance of the core material sheet is dictated by the material manufacturers a premium must be paid to gei: material which has a fine tolerance. Panel fabricators must either pay this prem.:ium or risk lowered productivity and a lower quality panel.
The pre-fabri~;;ated back loading panel frame system allows the fabricator to use core material chat isn't made to an exacting thickness tolerance. Less costly core material can be used to achieve the same noise control specification.
Productivity is increased and quality of the finished panel is higher.
Problems can also occzxr in the fabrication process when channels are applied to the edge of the core material. The thickness of the core material must be of exactly the right tolerance to accommodate the channel. If the edge of the core material is too thick or too narrow, the channels will be either too small to fit around the edlge or too large to provide a snug fit. Since the thickness tolerance of the core material sheet is dictated by the material manufacturers a premium must be paid to gei: material which has a fine tolerance. Panel fabricators must either pay this prem.:ium or risk lowered productivity and a lower quality panel.
The pre-fabri~;;ated back loading panel frame system allows the fabricator to use core material chat isn't made to an exacting thickness tolerance. Less costly core material can be used to achieve the same noise control specification.
Productivity is increased and quality of the finished panel is higher.
3. channels can be misaligned at the corners or impa~operly attached at the edge of the core material When channels are used to harden the core material edge. They must be lined up with and secured firmly to the edge of the core material. The corners must then be attached, Page 4 of 8 usually with tape or ,glue. A great deal of care must be taken during this step in the fabrication process to insure a properly sized and square panel.
Panels built this wa~~ are weak at the corners and risk damage from light impacts.
The pre-fabricated open back frame system employs a corner key and keyway to attach and align the sides a~ad corners of the frame. The frame sections can be shaped in a number of profiles arid a perfectly square and aligned corner can be achieved every time using this method. Panels made with the corner key can withstand impacts with little risk of damage. The keys can be made at different angles to produce panels of different shapes.
Dual Purpose Chip System Due to the open bacl~: design of the pre-fabricated back loading frame system, a method had to be invented to~ ensure that the core material stayed in place on the toothed edge of the frame section until the fabric was installed.
The dual purpose clip consists of a flange and a barbed leg attached at a right angle. The barb has three ridges along each side. These ridges are designed to interlock with furrows along the interior sides of the double walled leg of the frame section. When the dual purpose clip is pushed into and mated with the double walled side of the frame section, the flange of the clip .overlaps the core material locking it into place. This stabilizes the frame and ensures the core material stays in place.
Page 5 of 8 The dual purpose clip is also used to mount the panel. Clips are attached to the wall using adhesive or mf:chanical mounting methods. The clips which are approximately two inches long are attached to the wall at intervals according to the size of the panel.They are positioned to Line up with the double walled edge of the frame section.
The fabric and the horizontal suppozt are cut at this point along the double walled leg .The panel is pushed onto the wall mounted clips which secure it in place.
INVENTION DIESCRIPTION
Tooth edged, pre fanricated back loading panel fYame system (dual purpose clipj A pre-fabricated wall panel frame system consisting of frame sections cut into lengths and mitered.(FigG) '.Che end of each frame section is attached and aligned with ends of other frame sections by inserting a corner key 16 into a keyway 5. This keyway 5 is located at the base 6 of the frame section between legs 1 and 3. The corner key 16 is positioned within the keyway 5 at the point where the mitered frame sections meet.
By inserting the corner key 16 into the keyway 5, the frame sections will be positioned so that the base 6 of the frame section is parallel and adj acent to the face of the panel core material 12 when it is. loaded into the panel frame.
Page 6 of 8
Panels built this wa~~ are weak at the corners and risk damage from light impacts.
The pre-fabricated open back frame system employs a corner key and keyway to attach and align the sides a~ad corners of the frame. The frame sections can be shaped in a number of profiles arid a perfectly square and aligned corner can be achieved every time using this method. Panels made with the corner key can withstand impacts with little risk of damage. The keys can be made at different angles to produce panels of different shapes.
Dual Purpose Chip System Due to the open bacl~: design of the pre-fabricated back loading frame system, a method had to be invented to~ ensure that the core material stayed in place on the toothed edge of the frame section until the fabric was installed.
The dual purpose clip consists of a flange and a barbed leg attached at a right angle. The barb has three ridges along each side. These ridges are designed to interlock with furrows along the interior sides of the double walled leg of the frame section. When the dual purpose clip is pushed into and mated with the double walled side of the frame section, the flange of the clip .overlaps the core material locking it into place. This stabilizes the frame and ensures the core material stays in place.
Page 5 of 8 The dual purpose clip is also used to mount the panel. Clips are attached to the wall using adhesive or mf:chanical mounting methods. The clips which are approximately two inches long are attached to the wall at intervals according to the size of the panel.They are positioned to Line up with the double walled edge of the frame section.
The fabric and the horizontal suppozt are cut at this point along the double walled leg .The panel is pushed onto the wall mounted clips which secure it in place.
INVENTION DIESCRIPTION
Tooth edged, pre fanricated back loading panel fYame system (dual purpose clipj A pre-fabricated wall panel frame system consisting of frame sections cut into lengths and mitered.(FigG) '.Che end of each frame section is attached and aligned with ends of other frame sections by inserting a corner key 16 into a keyway 5. This keyway 5 is located at the base 6 of the frame section between legs 1 and 3. The corner key 16 is positioned within the keyway 5 at the point where the mitered frame sections meet.
By inserting the corner key 16 into the keyway 5, the frame sections will be positioned so that the base 6 of the frame section is parallel and adj acent to the face of the panel core material 12 when it is. loaded into the panel frame.
Page 6 of 8
4 CA 02226601 1998-03-17 'Fig C and Fig D' Tlie double walled edge of the frame section 2&3 will be parallel to and adj acent to the perimeter edges of the core material 12. The toothed edge 1 of the frame section will protrude into the core material 12 to the frame section base 6.
'Fig A' The profile of each frame member is a section consisting of a base 6 from which three perpendicular legs protrude 1&2&3.
Leg 1 consists of equally spaced pointed teeth. It is located on the inside edge of the frame section perpendicular to the base 6, Leg 2 extends perpendicular to the base 6 and from the opposite edge of the section. The interior face of leg 2 is lined with a series of rounded ridges 17.
Leg 3 falls between ll&2 and is a mirror image of leg 2, with a series of rounded ridges 17 which appose the ridges 17 of leg 2. It is positioned at a distance from leg 2 that will permit the insertion awd engagement of the dual purpose clip 'Fig B and Fig F' between the interior sides of l~.;g 2&3.
A horizontal extention 4 of leg 3 prevents leg 2 from moving toward leg 3 when fabric 18 is wrapped around the edge of the frame. Sections of this extention 4 must be removed to allow the insertion of the dual purpose clip. The cut out is illustrated in Fig G.
Page 7 of 8 ' ~ CA 02226601 1998-03-17 The raised ridge 7 along the base 6 of the frame lifts the panel fabric 18 slightly above the face of the panel. This eliminates the risk of the interior edge of the frame or imperfections in the core material showing through the fabric 18.
A dual purpose clip 'Fig B and Fig F' is designed to hold core material 12 into the frame section. It consists o:F a flange 9 from which a pointed barb 10 protrudes at a perpendicular angle. Ridges 8 along each side of the barb 10 are designed to intersect with and lock into the ridges 17 of legs 2&3 of the frame section.
Fig C illustrates the nse of the dual purpose clip as a mounting clip. Screws 15 attach the dual purpose clip to the wall 14. The fabric 18 and the horizontal brace 4 are removed to allow the frame section to be engaged with the clip.
Fig D illustrates the 'use of the dual purpose clip as a core material lock.
The flange 9 of the clip overlaps the core material 12 holding it in place. The fabric I8 is installed after this clip is in place.
Page 8 of 8
'Fig A' The profile of each frame member is a section consisting of a base 6 from which three perpendicular legs protrude 1&2&3.
Leg 1 consists of equally spaced pointed teeth. It is located on the inside edge of the frame section perpendicular to the base 6, Leg 2 extends perpendicular to the base 6 and from the opposite edge of the section. The interior face of leg 2 is lined with a series of rounded ridges 17.
Leg 3 falls between ll&2 and is a mirror image of leg 2, with a series of rounded ridges 17 which appose the ridges 17 of leg 2. It is positioned at a distance from leg 2 that will permit the insertion awd engagement of the dual purpose clip 'Fig B and Fig F' between the interior sides of l~.;g 2&3.
A horizontal extention 4 of leg 3 prevents leg 2 from moving toward leg 3 when fabric 18 is wrapped around the edge of the frame. Sections of this extention 4 must be removed to allow the insertion of the dual purpose clip. The cut out is illustrated in Fig G.
Page 7 of 8 ' ~ CA 02226601 1998-03-17 The raised ridge 7 along the base 6 of the frame lifts the panel fabric 18 slightly above the face of the panel. This eliminates the risk of the interior edge of the frame or imperfections in the core material showing through the fabric 18.
A dual purpose clip 'Fig B and Fig F' is designed to hold core material 12 into the frame section. It consists o:F a flange 9 from which a pointed barb 10 protrudes at a perpendicular angle. Ridges 8 along each side of the barb 10 are designed to intersect with and lock into the ridges 17 of legs 2&3 of the frame section.
Fig C illustrates the nse of the dual purpose clip as a mounting clip. Screws 15 attach the dual purpose clip to the wall 14. The fabric 18 and the horizontal brace 4 are removed to allow the frame section to be engaged with the clip.
Fig D illustrates the 'use of the dual purpose clip as a core material lock.
The flange 9 of the clip overlaps the core material 12 holding it in place. The fabric I8 is installed after this clip is in place.
Page 8 of 8
Claims
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA 2226601 CA2226601A1 (en) | 1998-03-17 | 1998-03-17 | Pre-fabricated fabric covered acoustical wall panels |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA 2226601 CA2226601A1 (en) | 1998-03-17 | 1998-03-17 | Pre-fabricated fabric covered acoustical wall panels |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2226601A1 true CA2226601A1 (en) | 1999-09-17 |
Family
ID=29409045
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA 2226601 Abandoned CA2226601A1 (en) | 1998-03-17 | 1998-03-17 | Pre-fabricated fabric covered acoustical wall panels |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA2226601A1 (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| EP1630311A3 (en) * | 2004-08-25 | 2007-06-27 | Sabine Keggenhoff | Sound absorbing device, specially for mounting on a ceiling or wall |
-
1998
- 1998-03-17 CA CA 2226601 patent/CA2226601A1/en not_active Abandoned
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| EP1630311A3 (en) * | 2004-08-25 | 2007-06-27 | Sabine Keggenhoff | Sound absorbing device, specially for mounting on a ceiling or wall |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| FZDE | Dead |