EP0170473A2 - Platten, geeignet zum Gebrauch als Deckenplatten - Google Patents

Platten, geeignet zum Gebrauch als Deckenplatten Download PDF

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Publication number
EP0170473A2
EP0170473A2 EP85305137A EP85305137A EP0170473A2 EP 0170473 A2 EP0170473 A2 EP 0170473A2 EP 85305137 A EP85305137 A EP 85305137A EP 85305137 A EP85305137 A EP 85305137A EP 0170473 A2 EP0170473 A2 EP 0170473A2
Authority
EP
European Patent Office
Prior art keywords
layer
panel
sheet
carpet
compound
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.)
Withdrawn
Application number
EP85305137A
Other languages
English (en)
French (fr)
Other versions
EP0170473A3 (de
Inventor
Richard Azzopardi
Brian Malcolm Thomson
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
FLORTIME Pty Ltd
Original Assignee
FLORTIME Pty Ltd
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by FLORTIME Pty Ltd filed Critical FLORTIME Pty Ltd
Publication of EP0170473A2 publication Critical patent/EP0170473A2/de
Publication of EP0170473A3 publication Critical patent/EP0170473A3/de
Withdrawn legal-status Critical Current

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Classifications

    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B9/00—Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation
    • E04B9/04—Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation comprising slabs, panels, sheets or the like
    • E04B9/045—Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation comprising slabs, panels, sheets or the like being laminated
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B44—DECORATIVE ARTS
    • B44C—PRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
    • B44C7/00—Paperhanging
    • B44C7/02—Machines, apparatus, tools or accessories therefor
    • B44C7/022—Tapestry work

Definitions

  • THIS INVENTION relates to panels. More particularly, the invention relates to panels suitable for use as ceiling panels and to a method of manufacturing such panels.
  • carpets have often been used as wall coverings and as roof or ceiling coverings, because of their various beneficial properties, particularly when used in larger sized building constructions. More particularly, and because of strict building regulations in many countries, carpets have very good fire retardent properties in addition to the good acoustic and heat insulation properties carpets generally have.
  • carpets when used as wall coverings and/or as roof or ceiling coverings, are usually directly applied onto the required walls, roofs or ceilings by means of a suitable adhesive, or the like.
  • the carpets are therefore used in their conventional form, as when used as a floor covering, in their normal mode.
  • carpets used as a wall covering and/or as a roof or ceiling covering may be provided in an extended form or, alternatively, may be provided as a carpet tile, or the like.
  • carpets cannot be used in their natural form unless they can be directly applied onto a rigid support surface such as a wall, a roof, a ceiling, or the like. Carpets, in their normal form, can therefore not be used for suspended ceiling applications and the above defined benefits associated with the use of carpets for the defined applications can therefore not be utilised as such.
  • a panel which comprises a profiled sheet-like element including a carpet-like first layer of material bonded onto a second layer of material which is substantially rigid and determines the profile of the sheet-like element.
  • the carpet-like first layer includes a fabric material, which may be a material as is conventionally used for carpets, and which has been processed to define the carpet-like layer, having a desired outer surface profile, by a conventional carpet manufacturing technique.
  • the carpet-like first layer may be formed by weaving, tufting, needlepunching or the like.
  • a preferred embodiment of the panel of the invention includes a sheet-like element having a first layer, of natural or synthetic fibres, formed into a wad and consolidated by a needlepunching process in which the fibres become entwined with one another to thereby form a continuous layer of material.
  • This first layer may additionally include a backing cloth, such as a scrim cloth, into which the fibres are punched by the needlepunching process.
  • the second layer of the sheet-like element may be a moulded layer of a mouldable compound such as a suitable resin-like compound, or the like.
  • the mouldable compound may be styrene butadene rubber resin which is a thermoplastic compound, phenol formaldehide resin which is a thermo setting compound, a suitable acrylic based compound, or the like.
  • the above compounds may have suitable fire retardents added thereto.
  • the first and second layers of the sheet-like element may particularly be bonded together during and as a result of the moulding process of the second layer.
  • the resin-like compound of the second layer may be a compound whereby the profile of the sheet-like element is stabilised through thermosetting of the compound.
  • the panel may include a third layer of material formed to enhance the rigidity of the panel.
  • This third layer of material may be of a substance that is in a liquid form when applied onto the second layer of material and which has set after application.
  • the third layer of material may be a planar sheet element secured onto the second layer of the sheet-like element by a suitable adhesive.
  • the third layer may be a metal, timber, plastics or cardboard sheet.
  • the material forming the first, second and/or third layers of the sheet-like element may be materials which render the panel fire retardent.
  • the profile of the sheet-like element may be such as to enhance the rigidity thereof, the profile essentially being defined by indentations, channel formations, depressions, and/or projecting formations formed with respect to a planar plane which defines the overall plane of the panel.
  • the profile may further be adapted to enhance the appearance of the panel.
  • the panel may be specifically adapted for use as a ceiling panel and, more particularly, the panel may be specifically adapted for use as a ceiling panel in a suspension ceiling construction.
  • the panel in accordance with the invention, is of a rigid construction its use as a panel for a suspension ceiling construction is made possible and, as such, all the benefits of utilising a carpet as a covering is rendered possible.
  • such panels need not only be used as panels for a suspension ceiling construction but can also be used by securing panels directly onto suitable support surfaces such as walls, roofs, ceilings, or the like to provide a covering therefor.
  • a method of manufacturing a panel which includes
  • the carpet-like layer of material may be formed by a needlepunching process whereby a wad of natural or synthetic fibres are needlepunched to thereby become entwined with one another and form a continuous layer of material.
  • This needlepunch layer of material may clearly also be needlepunched into a backing cloth such as a scrim cloth, or the like.
  • the carpet-like layer of material may be formed by a weaving or tufting process, as is conventionally used for carpet manufacturing.
  • the moulding of the mouldable compound such as a resin
  • the moulding of the mouldable compound may be effected by a pressure moulding process by pressing the formed layers of material between opposing mould forms and thereafter allowing the mouldable compounds to set.
  • the method of the invention further includes, applying a third layer of material onto the moulded layer of material to increase the effective rigidity of the panel.
  • This third layer of material may be of a settable compound applied to the moulded layer in any suitable manner while in a liquid form which is thereafter allowed to set.
  • This settable compound may typically be a compound such as polyurethane, a resin, or the like.
  • this third layer of material may be applied by utilising the mould forms used for moulding or similar mould forms, suitably spaced apart to permit the material of this layer to be injected between the mould forms onto the moulded layer of material where it can set. If polyurethane is used for this layer it can be allowed to expand and set between the mould forms. Alternatively, the material of the said further layer may be applied by spraying, pouring, brushing, or the like.
  • the further layer of material may be a solid sheet material which is applied to the moulded layer of material by a suitable adhesive.
  • this further layer of material may be of metal, cardboard, timber, plastics, or the like.
  • the method of the invention may further include, designing the desired profile of the sheet-like element forming the panel to provide the panel with required rigidity.
  • the method of the invention may further include trimming and finishing the panel. Trimming may be done immediately after moulding while the formed panel is still held between the mould forms.
  • the method of the invention may particularly provide for the manufacture of a panel which constitutes a ceiling panel suitable for use in a suspension ceiling application.
  • a ceiling panel in accordance with the invention, is generally indicated by the reference numeral 10.
  • the panel 10 comprises a profiled sheet-like element 12 which has a first layer 14 of a fabric material, a second moulded layer 16 of a mouldable compound and a third layer 18 of a settable compound.
  • the layer of fabric material is, in the particular embodiment, a needlepunched layer comprising a wad of natural or synthetic carded staple fibres consolidated by a needlepunching process, during which the fibres become entwined with one another to thereby form a continuous layer of material.
  • the needlepunched layer of material may be needlepunched into a backing cloth, such as a scrim cloth (not shown).
  • the outer surface appearance of the fabric layer 14 is optional and is provided by additional needlepunching steps which may, for example, cause looping of the fibres.
  • the moulded layer 16 may typically be of a mouldable resin such as styrene butadene rubber resin, phenol formaldehide resin, or any acrylic based resin, or a like resin which is applied onto the fabric layer 14 whereafter it is moulded to define the desired profile of the panel 10 and allowed to set.
  • the above resin may have suitable fire retardent substances added thereto.
  • the layer of settable material 18 is essentially an optional layer, which may be of a settable resin or of a material such as polyurethane, and is provided to add to the rigidity of the sheet-like element 12 and thus the panel 10.
  • the actual mode of manufacturing the panel 10 is described hereinafter.
  • a mould press for manufacturing panels 10 is generally indicated by the reference numeral 30.
  • the press 30 is only partially shown and essentially comprises two opposing mould forms, 32 and 34 respectively, which can be urged towards one another in the direction of arrows 36 as shown.
  • a first layer of fabric material is initially provided, this layer typically being a needlepunched layer as described hereinabove and manufactured in accordance with the steps defined.
  • a mouldable compound such as a liquid resin is next applied onto one side of the needlepunched layer, typically by lick rolling, whereafter the needlepunched layer including the mouldable resin applied thereon is passed through a heated oven in order to permit curing of the resin.
  • the needlepunched layer including the mouldable resin is positioned onto the bottom mould form 34 whereafter the opposing mould forms 32 and 34 are urged towards one another causing moulding of the mouldable compound into the shape defined by the complementary formations of the opposing mould forms.
  • the third layer 18 can be done by merely positioning a spacer between the mould forms 32 and 34 allowing a settable material to be injected between these mould forms 32 and 34 onto the moulded layer 16.
  • a typical material for this purpose may be polyurethane which can be injected and then activated to cause expansion thereof and setting which is controlled by the spacing of the mould forms 32 and 34.
  • the actual mould forms 32 and 34 used for moulding can be utilised or, alternatively, any other two complementary similar mould forms.
  • the method of the invention also includes trimming the completed panel, a suitable stage for performing the trimming being immediately after moulding while the sheet-like element 12 formed is still held between the mould forms 32 and 34.
  • a suitable stage for performing the trimming being immediately after moulding while the sheet-like element 12 formed is still held between the mould forms 32 and 34.
  • the exact shape and configuration of the panels is clearly optional and may depend on the intended use thereof.
  • panels 10 are intended as ceiling panels and, more particularly, as ceiling panels in suspension ceiling systems.
  • the exact peripheral configuration of the panels and size thereof may be determined by the intended mode of suspension of these panels, various known modes of suspension of ceiling panels being known to the Applicants and being in general use.
  • Modes of suspension can be conventional or, alternatively, a specific mode of suspension for the panels 10 can be designed to accommodate specifically the panels 10 as described above. Since the mode of constructing suspension ceilings is well known this is not described in any further detail herein.
  • the panels 10 can clearly also be directly applied onto a ceiling surface, in which case the panels 10 can be adhered to such a surface by means of a suitable adhesive.
  • the third layer 18 of the panel 10 need not conform to the profile thereof but may be a planar layer of material, such as a metal, timber, plastics, cardboard or like sheet of material directly adhered onto the moulded layer 16 by means of an adhesive. This will permit the entire panel to be adhered to the ceiling surface and not merely regions thereof which result from the profile of the panel.
  • the typical depth of the formations 20.or any other formations may be between 10 and 20mm, the particular depth of these formations also determining the eventual rigidity of the panel 10 in its required applications. It will be appreciated that the formations 20 and the resulting profile of the panel 10 not only enhance the rigidity thereof but also determine the outward appearance thereof. The outward appearance is, of course, also determined by the surface appearance of the fabric layer 14 and, when used as a ceiling panel, it is believed that the carpet-like appearance may be very suitable because of the resulting acoustic properties of the panel 10.
  • panels 10 having a carpet-like exposed layer of material will have particularly suitable acoustic properties as well as thermal insulating properties and fire retardent properties. As such, panels 10 will be particularly suitable for use in bigger buildings where the use of suspension ceilings is generally used.
  • panels 10 can be made in smaller sizes to essentially define ceiling tiles which may be more suitable for use in domestic homes for 'do-it-yourself' purposes.
  • the needlepunch layer 14 may alternatively be a tufted or woven carpet layer which will provide a different outward appearance while still fulfilling the same purpose of the panel 10 as above described.
  • the materials of the moulded layer 16 and settable layer 18 are also entirely optional, the required fire retardent properties of the panel 10 often determining the particular materials used. Panels 10 need clearly not be used only as ceiling panels and may be used for other applications.

Landscapes

  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Laminated Bodies (AREA)
  • Building Environments (AREA)
EP85305137A 1984-07-27 1985-07-18 Platten, geeignet zum Gebrauch als Deckenplatten Withdrawn EP0170473A3 (de)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
ZA845835 1984-07-27
ZA845835 1984-07-27

Publications (2)

Publication Number Publication Date
EP0170473A2 true EP0170473A2 (de) 1986-02-05
EP0170473A3 EP0170473A3 (de) 1987-04-15

Family

ID=25577435

Family Applications (1)

Application Number Title Priority Date Filing Date
EP85305137A Withdrawn EP0170473A3 (de) 1984-07-27 1985-07-18 Platten, geeignet zum Gebrauch als Deckenplatten

Country Status (3)

Country Link
EP (1) EP0170473A3 (de)
AU (1) AU578717B2 (de)
ES (1) ES296083Y (de)

Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3706171A (en) * 1971-04-02 1972-12-19 Harry I Shayman Decorative acoustical ceiling panel
FR2355970A1 (fr) * 1976-06-23 1978-01-20 Rischmueller Wilhelm Plaque en mousse rigide

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3706171A (en) * 1971-04-02 1972-12-19 Harry I Shayman Decorative acoustical ceiling panel
US3765141A (en) * 1971-04-02 1973-10-16 H Shayman Decorative acoustical panel
FR2355970A1 (fr) * 1976-06-23 1978-01-20 Rischmueller Wilhelm Plaque en mousse rigide

Also Published As

Publication number Publication date
AU578717B2 (en) 1988-11-03
ES296083Y (es) 1989-02-16
ES296083U (es) 1988-07-01
AU4525385A (en) 1986-01-30
EP0170473A3 (de) 1987-04-15

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Inventor name: THOMSON, BRIAN MALCOLM

Inventor name: AZZOPARDI, RICHARD