CH712343A2 - Sound-absorbing panel for the interior construction of buildings or for the weatherproof outdoor area and method for its production. - Google Patents

Abstract

The sound-absorbing panel is suitable for the interior work of buildings, as well as for the weather-protected outdoor area. It consists of a porous or perforated or protected base plate (1) of 4 mm to 40 mm thickness. In the example shown, a coating (2) made of 0.2 mm to 2 mm thick material is glued to this base plate (1) on one side. Depending on the aesthetic requirements, the surface (5) is optionally treated on this coating. In this coating (2) and treated surface (5) are introduced from the outside by means of a laser beam introduced holes (3) of 0.2 mm to 1.0 mm in diameter. The holes (3) penetrate the coating (2) and surface (5) entirely, so that the sound can pass through them on the porous base plate (1). The following steps are carried out according to the method for producing this sound-absorbing plate: a) applying an adhesive (4) to an air-permeable base plate (1), b) applying a coating (2) of 0.2 mm to 2 mm thickness, c) pressing the coating (2) with the base plate (1) by means of a pressing or rolling process, d) optionally treating the surface (5) of the coating (2) by means of a rolling or spraying method or by hand, e) burning through holes (3) or Slits from the coating by means of a laser beam.

Description

Description [0001] This invention relates to a sound absorbing panel used for interior construction of buildings. This plate can also be used outdoors, as far as it is not exposed to the weather. Moreover, the invention relates to the method according to which this sound-absorbing plate is produced.

In many buildings, it is desirable that the sound, no matter from which source he comes, whether from the outside or inside, is as well damped, so that a pleasant working, living or living atmosphere arises. This goal is achieved especially with the interior design of buildings. But this creates a multi-dimensional conflict of goals. On the one hand, the sound absorption should be optimal, but on the other hand, the cladding of the interior walls and ceilings should as far as possible meet aesthetic expectations or incorporate into the formal and design language of the interiors. Finally, this cladding, that is, the material for interior design, should meet economic, ecological and health criteria and the installation of the panels should be easy, quick and inexpensive to implement.

Conventional interior panels for this purpose assets to meet these requirements only partially. Porous carrier plates are used, which are afterwards provided with a mineral plaster for indoor use. An advantage of such a cladding is that the seamless plaster creates an optically continuous surface as a wall or ceiling. However, the subsequent plastering is associated with a considerable effort, and a cozy interior with wood veneer finish is not feasible.

Alternatively, perforated or grooved medium-density wood fiber boards or medium density fiberboard (MDF boards) are installed, which are provided with a thin cover layer, which has small holes of about 2 mm in diameter. Such plates consist of a wood material or wood fibers. The term MDF is derived from the fact that the density lies between that of sawn timber and that of wet fiber boards. Thus MDF boards have a density of 650 kg / m3 to 800 kg / m3, light MDF boards have a density of 550 kg / m3 to 650 kg / m3 and ultralight MDF boards have a density of less than 550 kg / m3 , Such boards are coated with film-like laminates or laminates, on the one hand with Continuous Pressed Laminates HPL and on the other hand with High Pressure Laminates HPL with a thickness of> 2 mm. These are according to standard EN 438 compact disks. However, the acoustic absorption effect is limited in these plates and, moreover, they are still relatively heavy for assembly.

The object of the present invention is to provide an improved sound-absorbing panel, suitable for the interior of buildings or the weatherproof outdoor area, which is particularly lightweight, inexpensive to produce and assemble, and which provides an efficient sound absorption and optical against this background hardly distinguishable from an interior finish in wood or wood veneer.

In addition, it is an object of this invention to provide a method for producing such a sound-absorbing plate.

This object is achieved on the one hand by a sound-absorbing panel, suitable for the interior of buildings or for the weather-protected outdoor area, consisting of an air-permeable base plate of 4 mm to 40 mm thickness, which is characterized in that this base plate on one side by means a laser beam generated holes or slits of 0.2 mm to 1.0 mm in diameter or 0.2 mm to 1.0 mm wide.

The object is on the other hand solved by a method for producing a sound-absorbing plate, which is characterized in that a base plate, which is rendered permeable to air either through a plurality of blind holes or grooves over the depth, the blind holes or grooves beyond its bottom leave a wall of 0.3 mm to 3 mm, or alternatively a base plate, which is made permeable to air by means of a continuous perforation or which consists of air-permeable material and is provided in both latter cases with a continuous coating, then by burning through holes or slots from the wall or, if present, the entire coating is made permeable to air by means of a laser beam.

In the drawings, several embodiments of this sound-absorbing plate are shown schematically or close to reality and the methods and features for producing these different variants of the sound-absorbing plate are explained.

It shows:

Fig. 1: A base plate in a regular pattern of introduced blind holes in the back to form thin areas or walls on the front;

Fig. 2: The base plate of Figure 1 seen from the other, front side, with the introduced on this front by means of a laser beam holes or slots for the refraction of sound.

Fig. 3: shows an edge portion of a base plate according to Figures 1 and 2, wherein the edge region as a cross section through the centers of the blind holes a series of blind holes leads, and shown enlarged below a section of a border area or cross section.

Fig. 4: provided the back of an MDF board with grooves which are milled in sections, so that among the

Grooved floors a thin wall is allowed to stand;

Fig. 5: The back of a MDF board with grooves cut at right angles to each other, which are milled in sections, so that a thin wall is left under the Nutenböden;

Fig. 6: The minimal structure of a sound-absorbing plate with a blown glass base plate and a film-like, applied material as a coating and a surface treatment of the coating;

Fig. 7: The structure of a sound-absorbing plate with a blown glass base plate and applied material for the front, as well as with an additional filter mat on its back;

Fig. 8: The construction of a sound-absorbing plate with a blown glass base plate and applied material for the front, as well as in addition a thick rock wool mat on its back;

Fig. 9: An air-permeable base plate in the initial state;

Fig. 10: The air-permeable base plate of Figure 9 after the application of a glue layer.

Fig. 11: The air-permeable base plate of Figure 9 with glue layer 4, on which a film-like material 2 on it, and afterwards a surface material 5, which is applied to the material 2.

12 shows a schematic representation of a device for the last method step, namely the introduction of a multiplicity of holes or slots by means of a movable laser beam.

Basically, the sound-absorbing panel for interior design of an air-permeable base plate of 4 mm to 40 mm thickness. The material of the base plate is thus permeable to air, which is ensured for example by a porous base plate. If you place your mouth against the base plate and you can blow or suck air through it, so the requirement of air permeability in the case of a base plate made of air-permeable material is met. For example, a base plate made of porous expanded glass is suitable. Such a Blähglasplatte offers sufficient stability and strength for the Innausbau as well as for the weather-protected outdoor area. Instead of expanded glass, any other material can be chosen which has similar properties. For example, Perlite or similar materials are suitable, which can be glued and pressed into a porous base plate. Alternatively, a base plate made of air-impermeable material can initially be made permeable to air, for example by the introduction of blind holes, wherein the stood walls behind the bottoms of the blind holes are subsequently finely perforated. Or, a plate may be provided with a plurality of penetrating holes, thus creating a perforation. On this plate, a coating is then glued, from which by means of a laser beam many very fine holes or slots are burned out. In order to achieve efficient sound absorption, the base plate 1 must ultimately be permeable to air or porous.

Instead of a base plate of porous material as described above, a common medium-density fiberboard MDF occur. Because this is not permeable to air or at least not sufficiently permeable to air, it is first made permeable to air by many blind holes 10 are introduced from one side in it, as shown with reference to FIG. 1. In the example shown so that a pattern is created, which is similar to honeycombs, only that the "honeycomb" or the blind holes 10 are circular because of production through holes and the webs 12 or partitions between these blind holes 10 are stronger than honeycomb. These blind holes 10 of, for example, 9 mm diameter or, if necessary, also much larger diameter are introduced so deeply into the plate material that they still left with respect to the other side of the plate 1, a wall 11 of about 0.3 mm to 3 mm thickness. As a result, a thin wall 11 of 0.3 mm to 3 mm thickness is produced at the lower end of each blind hole 10 over its cross section. The generated pattern of holes 10 may be regular as shown. Meanwhile, the holes 10 may be arranged irregularly, and the holes may be different in size. Instead of creating the blind holes by drilling, other methods may be used. For example, grooves of up to 10 mm in width can be milled in sections into the plate, but each leave a thin wall at its bottom. Such an embodiment is shown in Figs. 4 and 5. As a variant, through holes can also be made if the plate is subsequently provided with a coating 2. The aim is to make the MDF board 1 by introducing these holes 10 first easier and secondly, at least initially over the depth of the holes 10 permeable to air.

Now follows a step, which is optional, so it can be omitted: The continuous surface on that side opposite to the blind holes 10 perforated side of the plate 1, can be either painted, oiled, waxed or painted. With or without such a surface treatment, in a next step on this side of the perforated plate 1, fine holes or slits 3 of merely 0.2 mm, merely 1.0 mm in diameter or 0.2 mm to 1.0 mm in width are introduced. An example of such holes 3 introduced on the front side of the plate 1 is shown in FIG. So many holes 3 or slots are burnt out that there are about 1 to 40 fine holes or fine such slots per cm 2. These are guideline values. Deviations from below and above are possible. These small holes 3 or slots are so fine that they can be rationally introduced into the plate material only with a laser beam. In an MDF base plate 1, these holes 3 produced by means of a laser beam are introduced in much greater density than the blind holes 10, as shown here. Seen from a distance of a few meters, these holes 3 are no longer visible and give the impression of a continuous wood or veneer. If such panels are installed on walls or ceilings, the viewer will notice nothing of the fine holes 3. Nevertheless, the panels offer excellent sound insulation.

Fig. 3 shows an edge portion of such a plate according to FIGS. 1 and 2 and including an enlarged section thereof. In the areas where the blind holes 10 form thin walls 11, these fine holes 3 are continuously cut off by an automatically controlled laser beam 8, so that the holes 3 or slots from the front of the plate 1 lead directly into the interior of the blind holes 10. There, where a laser beam 8 impinges on a web 12 between two blind holes 10, ie on the full, thick layer of material MDF plate 1, a fine blind hole 13 is generated by him, which is slightly more than 0.3 mm to 3 mm deep, depending after how thick is the wall 11 to be penetrated in the region of the blind holes 10. This is a so prepared MDF board 1 finished and can be installed in the simplest case directly in this form as a sound-absorbing, air-permeable and lightweight interior panel, with the finely perforated side as a visible front.

Instead of drilled blind holes 10, as already mentioned, slots or grooves 14 can be introduced into an MDF board. FIG. 4 shows a possible example for this. With a cutter grooves 14 are milled out of the material of the plate 1 sections, with a thin wall 15 is allowed to stand, that is, the distance from the bottom of the groove 14 to the other side of the plate 1 is only 0.3 mm to 3 mm. Here, one looks at the back of the plate 1, and in the next step, a large number of laser holes are burned through the sections of thin walls 15 on its front side. Where there is no groove 14, the laser beam penetrates slightly deeper than what makes the wall thickness of the walls 15 in the material of the plate 1 a. There, however, where the laser beam passes through a wall 15, a small through hole of 0.2 mm to 1.0 mm in diameter, through which air can flow and which serves to receive sound.

5 shows another pattern of how the grooves 14 and slots can be arranged. They can also be arranged irregularly. Finally, simply recesses must be produced that leave only a thin wall of 0.3 mm to 3 mm in many places of the plate 1, which can be perforated afterwards by means of a laser beam from the other side.

Further embodiments of sound-absorbing plates 1 are described below with reference to FIGS. 6 to 12: The starting point can be both an MDF plate, which by means of a perforation, ie a plurality of through holes of e.g. 5 mm to 20 mm, or is permeable to air on the basis of a plate 1 due to their material, as already described in section [0011] and as shown here in FIG. Such an air-permeable plate 1 is first provided with a film-like coating 2. This coating 2 of about 0.2 mm to 2 mm thickness is glued to a glue layer 4 and pressed with the base plate 1. Thereafter, the surface of the coating 2 is treated, that is, the coating 2 is optionally painted, oiled, waxed or painted. The resulting surface layer is denoted by 5 here. Subsequently, with a laser beam guided by a laser device, fine holes 3 or fine slits are burned in the surface layer 5 and the underlying coating 2, those of 0.2 mm-1.0 mm in diameter or width. The holes 3 or slots are created so that they completely penetrate the coating 2 and the treated surface 5. So many holes 3 or slots are burnt out that there are about 1 to 40 fine holes or fine such slots per cm 2. These are guideline values. Deviations from below and above are possible. The holes 3 ensure that the sound can penetrate the coating 2 and the surface layer 5 and is then absorbed in the porous base plate 1. In a perforated plate of otherwise air-impermeable material hits a plurality of fine holes 3 or slots on the perforation holes due to their tight arrangement, whereby the air and its sound is guided into the interior of the plate. The fineness of the holes 3 or slots has the advantage that in addition to the efficient sound absorption these holes 3 or slots are barely visible at a distance and the inner panel therefore preserves the desired aesthetics of the selected surface layer.

Various materials can be used for the coating. For example, known decorative papers with densities of between 60 gsm and 350 gsm are suitable. Another suitable laminate are so-called Kraft papers that are impregnated with phenolic resin and are referred to as core layers, since they are pressed in the laminate core. The basis weight of Kraft papers is in the range of 80 g / m 2 to 300 g / m 2, with high grammages being used predominantly for compact plates. Next is an overlay, that is a bleached, transparent paper with high resin absorption capacity. It is used to improve the abrasion resistance and to protect the decorative print image. An underlay or a barrier paper is a paper layer between decorative and soda kraft paper, to prevent chemical interference between the resins or to achieve optical effects. Melamine-formaldehyde resins give transparent and hard surfaces and are therefore ideally suited for impregnating decorative papers. To impregnate the core layers of brown and relatively elastic phenol-formaldehyde resins are used.

Decorative sound absorbing Innenausbauplatten preferably consist of expanded glass plates with a coating of cellulose fiber webs (paper), which are impregnated with thermosetting resins, or even from IV1DF

Sheets which are perforated and coated or provided with blind holes on their backs. The cover layer on the front usually consists of a melamine resin impregnated overlay, decorative paper and, if applicable, a barrier. The core of a laminate consists of Kraft papers impregnated with phenolic resin. The supply of heat and pressure causes a flow and subsequent curing of the resins. The crosslinking of the resins, reinforced by the cellulose fibers of the papers, results in a very dense material with a closed surface. The laminate structure provides information about the number of paper layers and their composition, ie the laminate thickness and the qualitative properties. In addition to the decorative paper, the number and weights of the core papers as well as the use of overlay and underlay are taken into account. In this coated front, the fine holes 3 or slits are introduced by means of a laser beam.

So-called continuous pressure laminates (Continuous Pressure Laminate CPL) are produced in continuous double belt presses with a pressure between 30 bar and 70 bar and temperatures between 150 ° C and 170 ° C. Depending on the laminate thickness and the press zone length, the feed rate of production varies between 8 m / min. and 15 m / min. A CPL is therefore a laminate that results from the continuous pressing of several layers of paper with hardening melamine resin. The surface is provided with a protective film of melamine resin. That makes them extremely resilient. CPL surfaces are significantly more abrasion, scratch and impact resistant than other surfaces. They withstand light scratches as well as crayons. They are resistant to solvents and heat, smudge-proof and easy to clean. Light soiling can be easily removed. CPL surfaces are colourfast and lightfast, so they do not darken. These CPL are cut widthwise, ground on the back and wound on a reel, directly after the press. They are also suitable as a coating material 2 for application to the expanded glass base body. 1

Another material for the coating 2, which is suitable for application to the base plate 1 made of blown glass, high-pressure laminates (High Pressure Laminates HPL), which in discontinuously operating multi-day presses with a pressure between 50 bar and 90 bar and temperatures of> 120 ° C are produced. The floor presses have between 10 and 20 storeys and each floor holds approx. 8 laminate boards with a nominal thickness of 0.5 mm to 0.8 mm. Depending on the press feed and the maximum temperature, the complete press cycle including re-cooling takes between 20 and 60 minutes. The length and width formatting of HPL is done in separate steps.

The base plate 1 of porous expanded glass and of 4 mm to 40 mm thickness can therefore be coated on its front with several variants of coating materials 2. In addition, it may be provided on its back with the same or a similar coating as on the visible side, or with a fleece or a filter mat 5, for example, 1 mm thickness, as shown in Fig. 7. Such a plate can also be used for doors, as well as needed for other pieces of furniture.

Fig. 8 shows in a variant of the structure of the sound-absorbing plate with expanded glass base plate 1 and applied thereon coating material 2 with fine through holes 3 for the front, as well as a stone wool mat 6 of 10 mm to 80 mm thickness their back, for particularly good sound absorption values.

9 to 12 show the production of this sound-absorbing plate in chronological order. First, as shown in Fig. 9, one starts from a porous base plate such as a blown glass plate 1, which is cut into the desired size. Thereafter, it is coated on one side with a glue 4 as shown in FIG. 10, and then, as shown in FIG. 11, a coating material 2 in the form of, for example, a melamine paper, a laminate of paper, soaked in malamine, or an HPL or CPL film or a CPL laminate. The coating 2 may also consist of a wood veneer, and this has a thickness of about 0.2 mm to 2 mm. It is pressed with the base plate 1 by means of a pressing process. For example, a suitable pressing device can accommodate plates of 4.10 mx 1.50 m size. The base plate 1 with the coating 2 is optionally painted, oiled, waxed or painted by means of a rolling or spraying method or by hand.

The coated plate 1 thus produced is provided on the coating side afterwards with very fine holes 3 or slots. For this purpose, the coated plate 1 is inserted in a device with a mobile laser device 7, as shown in FIG. 12. The laser device is guided along a rail 9 and can also be moved vertically to this rail CNC-controlled. In seconds, the laser beam 8 holes 3 or slits of from 0.2 mm to 1.0 mm in the surface 5 and coating 2. The leadership of the laser 8 is controlled by a special software CNC controlled in all hole and slot pitches and shapes in great precision, and so the holes 3 are lasered to the plate format. The base plate 1 may optionally on its back, which faces away from the coating side, the same as on the front, or be equipped with a rock wool mat or a filter mat. Instead of a rock wool mat is any other similar material that is useful for sound absorption. In addition, this plate can also be used in the outdoor area of buildings, as far as the weather conditions allow.

Digit directory [0026] 1 plate

Claims (15)

2 coating 3 holes 4 glue layer 5 surface 6 rock wool mat 7 laser device 8 laser beam 9 rail for guiding the laser device 10 blind hole 11 thin wall 12 webs between the blind holes 13 small laser holes 14 grooves (instead of blind holes) 15 thin walls below the groove floors claims 1. Sound-absorbing panel, suitable for the interior of buildings or for the weather-protected outer area, consisting of an air-permeable base plate (1) of 4 mm to 40 mm thickness, characterized in that this base plate (1) on one side (5) by means of a Laser beam (8) generated holes (3) or slots of 0.2 mm-1.0 mm diameter or 0.2 mm to 1.0 mm wide. 2. Sound-absorbing panel according to claim 1, characterized in that that side (5) with the holes (3) or slots coated area-covering, oiled, waxed or painted. 3. Sound-absorbing panel according to one of the preceding claims, characterized in that this base panel (1) is provided on one side surface with a regular or irregular pattern of blind holes (10), blind holes or grooves (14), so that on the opposite side between each Blind hole bottom or each groove bottom and the opposite outside of the base plate (1) at the locations of the holes (10), blind holes or grooves (14) depending on a thin wall (11, 15) of 0.3 mm to 3 mm thickness stops and is thus formed, and from this opposite side by means of a laser beam (8) has the thin wall (11, 15) penetrating holes (3) or slots of 0.2 mm to 1.0 mm in diameter or 0.2 mm to 1.0 mm in width, while in places (13), where the base plate (1) remains solid, the holes (3) produced by means of the laser beam (8) penetrate into the material of the plate (1) piece by piece as fine blind holes (13). 4. Sound-absorbing plate according to one of claims 1 or 2, characterized in that on the base plate (1) made of air-permeable material or on a perforated base plate (1) made of air-permeable or luftundurchlässigem material on at least one side of a separate coating (2) 2 mm thick material is applied, and that from this outer side by means of a laser beam (8) in this coating (2) the coating penetrating holes (3) or slots of 0.2 mm to 1.0 mm diameter or 0.2 mm to 1.0 mm Width are introduced. 5. Sound-absorbing plate according to one of the preceding claims, characterized in that on this base plate (1) on at least one side a separate coating (2) is applied from a material up to 2 mm thick, which painted, oiled, waxed or painted (5 ), and from the outside by means of a laser beam (8) the coating (2) and the surface treatment (5) penetrating holes (3) or slots of 0.2 mm to 1.0 mm diameter or 0.2 mm to 1.0 mm width are introduced. 6. Sound-absorbing plate according to one of the preceding claims, characterized in that the air-permeable base plate (1) consists of porous expanded glass or glued and pressed Perliten or is a solid solid plate by means of perforations, blind holes (10) or grooves (14) and is made permeable to air by means of inserted slots (3). 7. Sound-absorbing panel according to one of claims 4 or 5, characterized in that the coating (2) consists of one of the following materials: - Of melamine paper with a density of between 60 g / m2 and 250 g / m2, - out Decorative paper with a density of between 60 g / m2 and 250 g / m2, - consists of kraft paper impregnated with phenolic resin, - consists of a wood veneer. 8. A sound absorbing panel according to any one of claims 4 or 5, characterized in that said coating (2) consists of a laminate composed of the continuous pressing of several layers of paper with hardening melamine resin, the surface having a protective film of melamine resin is provided. 9. Sound-absorbing panel according to one of claims 5 or 6, characterized in that said coating (2) consists of a high-pressure laminate (High Pressue Laminate HPL) or of a continuous pressure laminate laminate (Continuous Pressure Laminate CPL). 10. Sound-absorbing plate according to one of the preceding claims, characterized in that on the back of the base plate (1), that is on the opposite side of the introduced holes (3) or slots a filter mat (5) of 0.5 mm to 2 mm thickness on the Base plate (1) is applied. 11. Sound-absorbing plate according to one of claims 1 to 9, characterized in that on the back of the base plate (1), that is on the opposite side of the introduced holes (3) or slots, a sound-absorbing mat (6) of 10 mm to 60 mm Strength based on rock wool or other sound-absorbing material on the base plate (1) is applied. 12. A method for producing a sound-absorbing plate according to any one of claims 1 or 2, characterized in that a base plate (1), which is made either through a plurality of blind holes (10) or grooves (14) permeable to air over the depth, wherein the Blind holes or grooves beyond their bottom a wall (11) from 0.3 mm to 3 mm, or alternatively a base plate (1) which is made permeable to air by means of a continuous perforation or consists of air-permeable material and in both latter cases with a continuous Coating (2) is provided, thereafter by burning through holes (3) or slits from the wall (11) or if available from the coating (2) by means of a laser beam (8) is made completely permeable to air. 13. The method according to claim 12, characterized in that prior to introducing the fine holes (3) or slots (3) in the base plate (1) by means of a laser beam, the relevant side of the base plate (1) painted, oiled, waxed or with a Paint is painted. 14. The method according to claim 12, characterized in that on the with blind holes (10) or grooves (14) provided or perforated base plate (1) or on the base plate of air-permeable material, a coating (2) by means of a rolling or spraying method or Hand is applied, and thereafter by burning out through holes (3) or slots from the base plate (2) and its coating (2) by means of a laser beam (8) is made the same air permeable. 15. A method for producing a sound-absorbing plate according to claim 14, characterized in that the coating (2) is painted, oiled, waxed or painted with a paint before by burning through holes (3) or slots from the base plate (2) and their coating (2) by means of a laser beam (8) is made the same air permeable.