EP1826750A2 - Overlay and panel with noise absorbing properties and method for its manufacture - Google Patents

Abstract

The method for producing cover layer (2) involves layer of adhesive applied to the coating then the layer of adhesive get partially activated and forms a bond with the coating. The bonded coating and adhesive layer are then perforated (8). The laminated material is placed on both sides of the coating before applying adhesive. Independent claims are also included for the following: (A) Cover layer to cover a support plate of sound absorbing panel; and (B) Panel with sound absorbing characteristics.

Description

The invention relates to a cover layer and a panel with sound-absorbing properties. Likewise, the invention relates to a process for their preparation. In particular, the invention relates to a sound absorbing panel having a cover layer attached to at least one of the side surfaces.

To improve the acoustics of rooms, walls and ceilings are covered with sound-absorbing panels. For example, the applications concern concert halls, meeting rooms as well as work rooms. Similarly, vehicle interior rooms can be equipped with sound-absorbing panels.

A measure of the quality of the acoustics in a room is the so-called reverberation time. This is the time that elapses until a sound level drops from a baseline by a predetermined amount. The reverberation time depends on the frequency of the sound.

It is known from the prior art that the panels have a good sound absorption capacity if they have a high porosity. Thus, the penetrating sound is absorbed and distributed in the voids generated by the porosity. The essential part of the sound in the panel is therefore absorbed and not reflected back into the room.

In most cases, the sound-absorbing panels consist of a complex structure, wherein a cover layer forming the visible side of the panel is provided, which is provided with a plurality of holes. Through the holes, the sound penetrates into the interior of the structure of the panel.

In the manufacture of the structure of the panel, the cover layer is applied to a support plate by gluing. For this purpose, the cover layer, which is already provided with the holes, provided with an adhesive layer. However, the application of the adhesive layer has the disadvantage that the adhesive is applied flat, so that a part of the arranged in the cover layer holes is closed again.

The carrier plates used so far consist of a particularly porous material, ie not of a standard available material. The production of sound-absorbing panels is therefore expensive, since a special plate material is used. For example, it is known that a chipboard with a particularly low density is used as the carrier plate. Likewise, it is known to arrange a mineral wool layer or other insulating material within a frame construction and to cover it to the side surfaces with the perforated cover layers.

The aim of this effort is in each case not to let the sound penetrated into the panel re-emerge on the room side, but to absorb it within the volume of the panel or to return it to the side of the panel facing away from the room.

From the prior art of EP 0 504 629 B2 a sound absorbing plate is known, wherein in the plate channels are arranged, which connect a first side of the carrier plate with a second side of the plate. Likewise, grooves are arranged in the first side of the plate, wherein the grooves and the channels are arranged to each other, that the channels are connected to at least one groove. The sound conducted through the grooves is conducted through the channels to the other side of the plate and thus directed away from the first side, the visible side.

First, the plate described above has the disadvantage that this is only to be used together with a frame construction, since the actual sound absorption takes place in a stone or Glaswollmatraze. This can not easily connect to the plate, so that it requires an additional holding and reinforcing construction. Likewise, it is disadvantageous that the panel can be used only from one visible side, while the side facing away from the visible side is aligned only in the direction of a wall or a ceiling.

Another disadvantage of this plate is on the one hand the lack of a suitable surface design, since the visible side of the panel with the grooves and Kanalstrultur is directly visible. On the other hand, there is a disadvantage in that this panel, when cut to size and having a severing cut along one of the grooves, has only a small surface area on the side surface. This makes coating the side surface difficult or even impossible.

The invention is therefore based on the technical problem of improving a cover layer and a panel as well as a method for the production thereof, so that the sound absorption properties are improved and / or the production costs are reduced. Also, a technical problem is that good sound absorption properties can be combined with an improved appearance.

The above-mentioned technical problem is solved according to a first teaching of the present invention by a method for producing a cover layer, in which a layer of adhesive is applied to a coating, in which the adhesive layer is partially activated and connected to the coating and in which the coating and the adhesive layer is provided in the connected state with holes.

According to the invention, it has been found that the hole structure of the cover layer remains substantially better if the holes are not introduced until the coating and the adhesive layer have already been joined together. The fact that the subsequent application of the adhesive layer is avoided, the holes can not be added by the adhesive. Also, subsequent re-activation of the adhesive for bonding to a backing plate of a sound-absorbing panel will not result in re-clogging of the holes since the flowability of the adhesive need not be increased so much that it will flow.

The holes in the coating and the holes in the adhesive layer are aligned with each other and thus have substantially the same cross-sectional area. Because these are generated in one process, so that only small cross-sectional differences result. These are mainly based on the fact that the material of the coating and / or the material of the adhesive is yielding, frayed and parts of the material are arranged in the cross-sectional opening or caused by shrinkage or stretching due to thermal stress. As a measure of the permissible cross-sectional differences within the scope of the invention, a limit of up to 10% can be specified. In any case, a complete closing of the holes is largely excluded.

The coating itself can consist of almost any materials. The properties of the material only have to allow the insertion of holes and the coating with an adhesive layer. Preferably, the coating consists of a veneer, a laminate, a wood material, a natural material or a plastic. In this case, the laminate again consists of at least two layers of paper impregnated with a synthetic resin, ie in particular of a laminate.

The wood material may consist of a plywood board, a thin chipboard, a hardboard, a medium density fiberboard (MDF board), a high density fiberboard (HDF board). When using a wood material then arises for optical reasons usually the need to use the visible surface with a laminate - for example, as before has been described - to coat. For this purpose, the coating of wood-based material is laminated on both sides with a laminate before applying the adhesive layer. The laminating on both sides of the wood-based material coating takes place for reasons of stability, the adhesive layer facing the laminate acts as Gegenzugschicht.

When a coating of natural material is provided, the coating is preferably leather, rubber or a web of natural fibers.

In the case of a plastic coating, this consists, for example, of linoleum or of PVC.

In principle, no limits are provided for the thickness of the coating. However, one condition for the coating is that it has sufficient stability to be able to form a stable surface on a carrier plate despite holes being introduced. Preferably, the coating has a thickness between 0.25 and 5 mm.

A further embodiment of the present invention relates to the formation of the adhesive layer. The adhesive layer must in principle be suitable to be applied to the coating in a first step. For this purpose, the adhesive must be partially activated before application to a predetermined degree, so as to be in turn deactivated after application, or after application still have a residual amount of activatability. Because the adhesive layer must on the one hand be firmly connected to the coating, so that a common processing is possible. On the other hand, the adhesive layer at a later time must allow bonding with another workpiece surface, for example with a support plate of a sound-absorbing panel.

Preferably, the adhesive layer consists of a thermoplastic adhesive, in particular a hot melt adhesive. Furthermore, the adhesive layer may consist of a contact adhesive, of a multi-component adhesive or of a microencapsulated adhesive system. All adhesive forms are characterized by the fact that they can be applied on the one hand to the coating, but on the other hand can also be activated again.

Preferably, the adhesive layer is applied substantially over the entire surface, in the form of beads or as a nonwoven. So it does not depend on a complete degree of coverage. Likewise, various techniques of application can be used, in particular the adhesive layer can be rolled, poured or sprayed on.

For the introduction of the holes in the layer structure of coating and adhesive layer there are different options depending on the type of materials to be processed and depending on the shape of the holes. Preferably, the holes are introduced through a perforation, ie with the aid of knives or punches in the layer structure. Likewise, the holes can be introduced into the coating and the adhesive layer by drilling, by needling, by cutting or by laser machining become. All these methods are characterized by a fast processing speed and lead to precise results.

It is particularly preferred that the holes are introduced in a freely selectable form, in particular as round holes or as slots, in the coating and the adhesive layer. Thus, there is sufficient scope for adaptation to particular acoustic and / or optical properties of the cover layer. When slits are made in the cover layer, it is preferred to produce the cover layer with sufficient strength. Because a plurality of slots can weaken too thin or unstable material too much, so that a reliable application to a support plate of a sound-absorbing panel can be ensured.

The size and number of holes to be used in the cover layer depends above all on the desired acoustic properties. Preferably, the holes having a largest dimension or a diameter of 0.5 to 10 mm, preferably 0.5 to 5 mm, preferably 0.5 to 1.5 mm, in particular 1 mm are introduced. For a shape deviating from a round shape, the largest dimension should be given as a measure. In the case of a slot shape, the longitudinal extent can significantly exceed the specified numerical values. In this case, it is preferable to keep the width of the slot within the specified limits.

Moreover, it is preferred that the holes in a, preferably regular grid with a grid of 2 to 40 mm, preferably 2 to 4 mm, in particular 3 mm. The pitch is to be understood as the respective center distance to the next adjacent hole. In a slot shape, the pitch corresponds to the axial distance of the slots to each other.

Furthermore, it is preferred that the cover layer is provided before or after the processing described above with a color layer, in particular with a lacquer layer. Because this allows the surface to be personalized. The exterior of a sound-absorbing panel provided with the cover layer thereby becomes independent of the material used.

The technical problem indicated above is also solved by a cover layer for laminating a support plate with a coating, with an adhesive layer which is partially activated and connected to the coating, in that the coating and the adhesive layer are provided with mutually aligned holes Holes in the coating and the holes in the adhesive layer have substantially the same cross-sectional area.

The further preferred embodiments of the cover layer are explained in more detail in the following description of exemplary embodiments.

The above-mentioned technical problem is solved according to a second teaching of the invention by a method for producing a sheet-like panel with sound-absorbing properties, in which channels are introduced into a carrier plate having a first side of the carrier plate with a second side of the Connecting support plate, wherein the first side of the support plate is provided with grooves and in which the grooves and the channels are arranged to each other, that at least a part of the channels are connected to at least one groove, and in which the grooves aligned in a first direction are, wherein the first direction at an angle of greater than 10 °, preferably at an angle greater than 30 °, in particular at an angle of 45 ° to each one of the side edges of the carrier plate. In each case, the more acute angle to one of the side edges is decisive, the other side edge of the angle is naturally greater.

By selecting the angular range of the course of the grooves with respect to the side edges ensures that the grooves extend at a minimum angle to the side edge in a conventional rectangular shape of the panels. This ensures that it is ensured in each case with an individual blank of the panel after cutting a strip that the resulting side edge viewed in the cross-sectional area has enough material of the support plate. Thus, the side edge can be reliably and stably provided with a coating, in particular a cover layer, even up to the edge line with the first and second side. As a limit is called 10 °, since at a groove course at an angle of 10 ° sections of carrier plate material that are not occupied by a groove, arise at too acute an angle to the side edge. This would then create the risk that the material can break off. In the specified range greater than 30 °, this risk is further reduced. The exact angle of 45 ° is due to the Symmetry of the resulting groove and channel structure is a particularly preferred embodiment.

The grooves and channels have the function that the sound impinging on the surface is captured and directed, so that a portion of the sound is directed to the sound source side facing away from the panel. The channels concentrate the sound, which then passes through the channels to the other side. For this purpose, the channels are each connected to at least one groove. This means that the volume occupied by the channel overlaps with the volume enclosed by the groove. So there is a fluidic connection between the channel and the respective groove. In other words, in a plan view of the page, the groove and the respective channel overlap at least partially.

The introduction of the grooves is carried out in a conventional manner by cutting knife or cutter. The channels, however, are preferably introduced by drilling, but also by milling in the carrier plate. For suitable materials, laser processing is also possible. All other techniques for introducing such structures can also be used here.

A further preferred embodiment of the method is that the first side of the carrier plate is provided with first grooves, wherein the first grooves are aligned in a first direction, and that the first side of the carrier plate is provided with second grooves, wherein the second grooves in a second direction and wherein the second direction is oriented at an angle to the first direction. The channels, the first grooves and the second grooves are like that arranged to each other, that at least a part of the channels are connected to at least one groove. Preferably, the first direction and / or the second direction at an angle of greater than 30 °, in particular at an angle of 45 ° to each one of the side edges of the carrier plate. It is intended that both directions deviate significantly from the right angle to the side edge.

The material of the carrier plate can be chosen almost arbitrarily. The fundamental condition of the material is that a processing of the surfaces by the introduction of the grooves and channels is possible.

The support plate is preferably made of wood or a wood material, in particular a chipboard, an Oriented Strand Board (OSB), a medium-density fiberboard (MDF), a high-density fiberboard (HDF), a hardboard, a plywood or an inorganic bonded, preferably cement-bonded chipboard.

Likewise, the carrier plate may consist of a plastic or of a plasterboard.

A further preferred embodiment of the carrier plate is that the material of the carrier plate has fire-retardant properties. Especially for interiors in public buildings, such as concert or lecture halls, this property is a necessary measure.

The support plate preferably has a thickness of 5 to 50 mm, in particular 5 to 30, preferably 10 to 20 mm. The thickness is in each case adapted to the acoustic problem to be solved or to the size of the surface to be covered. Since the carrier plate is intended to significantly produce the stability of the sound-absorbing panel, the thickness of the carrier plate has a corresponding importance.

The first grooves and the second grooves are respectively aligned in groups substantially parallel to each other. One can also speak of Nutenscharen. The substantially parallel orientation means that the first and second directions are parallel. If the grooves are formed in a straight line, the direction can be easily determined. In a curvilinear course, however, the direction must be derived from the overall shape. This can be done for example by determining connecting lines between maxima of the curved course. A substantially parallel course can also be given if the directions of two grooves run parallel, but the groove distances vary.

A particularly easy to manufacture construction of the support plate is achieved when the first direction and the second direction are aligned at a right angle to each other.

A further preferred embodiment of the method described is that the second side of the support plate is provided with grooves, wherein the grooves and the channels are arranged to each other, that the channels are connected to at least one groove. Also Here, therefore, the function of the channels and grooves is achieved to absorb the sound, break and forward. Thus, on the second side of the sound is absorbed to a part.

A particular advantage of the panel with a support plate having the described structure with channels and grooves on both sides is that the sound absorbing function is on both sides of the panel. This is the case, for example, in the application as a furniture part or as a door.

Also, the second side of the panel can be provided in the same way as the first page with a single or double groove structure, as has been previously described for the first page. For this purpose, the second side of the carrier plate is provided with third grooves, wherein the third grooves are aligned in a third direction. Possibly. the second side of the carrier plate is provided with fourth grooves, wherein the fourth grooves are aligned in a fourth direction and wherein the fourth direction is aligned at an angle to the third direction. The third grooves, possibly the fourth grooves and the channels are arranged to each other, that at least a part of the channels is connected to at least one groove.

Here, too, the grooves are preferably aligned substantially parallel to each other and the third direction and the fourth direction are aligned at a right angle to each other.

Although not absolutely necessary, it is also advantageous here if the third direction and / or the fourth direction at an angle of greater than 10 °, preferably at an angle of greater than 30 °, in particular at an angle of 45 ° to each one of the side edges of the carrier plate run. The reason is the same as described above, the new side edges resulting from a blank should have as much material as possible of the carrier plate in cross-section, so that a cover layer applied thereto can be fastened better and more stably.

The arrangement of the channels in relation to the grooves is generally sufficient if at least a part of the channels is in contact with one of the grooves. However, it is preferred that at least a part of the channels is introduced so that the channels are each connected to two grooves. In a preferred manner, at least a part of the grooves is introduced in such a way that a channel is arranged on at least part of the crossing regions between in each case two grooves. Thus, these channels are connected to two grooves and thus can effectively pass the sound.

It has further proven to be advantageous that the channels are introduced with a diameter which is greater than the width of the grooves. Thus, it is ensured, in particular in the crossing regions of two grooves, that the entire base area disposed in the intersection region of two grooves is covered by the channel and no reflections occur at the intersecting surface. Preferred diameters of the channels are less than 12 mm, in particular less than 8, preferably less than 6 mm. The shape of the channels can be round, square or in any curvilinear shape.

Another preferred embodiment of the groove shape is that the grooves are at least partially introduced with a varying depth and / or with a varying width. Likewise, the grooves can be formed rectangular or trapezoidal in cross section. Furthermore, the grooves may have a width of 2 to 10 mm, in particular 3 to 5 mm, preferably with a width of 4 mm and with a depth of 0.5 to 5 mm, in particular 1 to 3 mm, preferably with a depth of 1.5 mm are introduced. The various shape variations of the grooves further improve the acoustic quality of the panel, as the varying shapes of the grooves promote the absorption of sound energy.

A further preferred embodiment of the panel is that at least one of the two sides is provided with a color layer. This ensures a uniform appearance, even if - as will be explained below - a cover layer is applied to the carrier plate.

For in a particularly preferred manner, the first side of the carrier plate is provided with a cover layer which is provided with a plurality of holes. It is advisable to use a cover layer of the type described above according to the first teaching of the present invention. Because with this cover layer, the holes are largely free, so that the sound can penetrate through the holes in the underlying groove and channel structure and can be absorbed.

For the application of the cover layer, the adhesive layer of the cover layer is activated and bonded to the support plate. This can be done with thermoplastic adhesives using pressure and heat.

For a contact adhesive, the surfaces must be pressed together after applying, so that the adhesive effect occurs.

In the case of multicomponent adhesives, it is advisable to provide the cover layer with at least one component and the side of the support plate to be laminated with at least one other component. Then, the various components are brought into contact with each other under the application of pressure, the adhesive effect occurs.

In the case of a microencapsulated adhesive system, in turn, the cover layer is pressed against the support plate in order to at least partially burst open the microcapsules by the forces that occur, so that the previously encapsulated adhesive comes into effect.

The acoustic properties of the panel are influenced by how well the cover layer can interact with the groove and channel structure of the support plate. Therefore, it is further preferred to align the cover layer so that at least a part of the holes is connected to one of the grooves or a channel. This optimizes the sound transmission through the cover layer to the carrier plate.

Depending on the thickness of the carrier plate and the forces occurring in the temperature and humidity fluctuations through the cover layer, it is advantageous if the second side of the carrier plate is provided with a Gegenzugschicht. Furthermore, if the counteracting layer is formed as a cover layer with a plurality of holes, wherein the covering layer has been produced in particular according to a method described above, then the same structure results on both sides of the panel. This has the advantage that the panel is provided on both sides with a cover layer and is usable on both sides. An application, for example, as a door or as a furniture part is improved.

It is generally advantageous if the cover layer arranged on the second side is open to the outside through a hole structure, since the sound trapped by the panel can thus emerge again. In addition, a completely symmetrical construction of the panel is well suited to prevent or at least minimize distortion of the panel due to mechanical stresses.

In turn, it is advantageous if at least one of the side edges of the carrier plate is provided with a cover layer, in particular produced by a method described above.

In addition, the acoustic properties of the panel are further improved if a fleece is arranged within the construction already described. The nonwoven may be between the cover layer and the support plate and / or between the counteracting layer and Carrier plate and / or on the side facing away from the carrier plate of the Gegenzugschicht be arranged.

Nonwoven is a fabric that is neither woven nor knitted and consists of an irregular arrangement of fibers. In this case, different production methods are used, which solidify this composite after forming a loose union of the fibers.

A fleece is characterized by an increased porosity, so that a sound absorbed therein well distributed and thus can be absorbed. The use of nonwovens in sound-absorbing structures is known per se.

The above-indicated technical problem is also solved according to the invention by a sound-absorbing panel, which has been produced according to the method explained above. The panel with a carrier plate, with channels arranged in the carrier plate, which connect a first side of the carrier plate to a second side of the carrier plate, with grooves arranged in the first side of the carrier plate,
wherein the grooves and the channels are arranged to each other, that at least a part of the channels is connected to at least one groove, characterized in that the grooves are aligned in a first direction, wherein the first direction at an angle of greater than 10 ° , Preferably at an angle greater than 30 °, in particular at an angle of 45 ° to each one of the side edges of the support plate.

Further features are explained in more detail in the description of specific embodiments.

The above-mentioned technical problem is solved according to another teaching of the present invention by a method for producing a sheet-like panel with sound absorbing properties, in which channels are introduced into a carrier plate which connect a first side of the carrier plate to a second side of the carrier plate in that the first side of the carrier plate is provided with grooves and in which the grooves and the channels are arranged relative to each other, that at least a part of the channels are connected to at least one groove. The first side of the carrier plate is provided according to the invention with a covering layer having a plurality of holes.

With this structure it is achieved that on the one hand the design of the surface of the sound-absorbing panel can be chosen almost arbitrarily and that on the other hand, the sound from the environment can be absorbed and absorbed through the holes in the groove and channel structure arranged below. At first it does not depend on a particular orientation of the grooves as in the method described above.

The cover layer can be chosen arbitrarily, provided that they connect to the surface of the support plate, in particular can be glued. In addition to bonding, a purely mechanical connection such as nails, screws or staples is also suitable, provided that a stable construction can be produced therewith.

In particular, a cover layer made in accordance with the first teaching of the present invention and having aligned holes in the coating and adhesive layer having substantially the same cross-sectional area is used.

In addition, one or more of the above-explained method steps for the design of the grooves and channels, their orientation and the materials used can also be used in this teaching of the invention.

The above-indicated technical problem is also solved according to the invention by a sound-absorbing panel, which has been produced according to the method explained above. The panel with a carrier plate, with channels arranged in the carrier plate, which connect a first side of the carrier plate to a second side of the carrier plate, with grooves arranged in the first side of the carrier plate,
wherein the grooves and the channels are arranged to each other so that at least a part of the channels is connected to at least one groove, characterized in that the first side of the support plate is provided with a plurality of holes having cover layer.

Further features and advantages of this embodiment of the invention are also given in the description of specific embodiments.

The above-indicated technical problem according to the invention by a sound-absorbing panel with a support plate, with in the support plate arranged channels which connect a first side of the support plate with a second side of the support plate with arranged in the first side of the support plate grooves, wherein the channels and the grooves are arranged to each other, that at least a part of the channels connected to at least one groove is achieved in that the second side of the support plate is provided with third grooves, wherein the third grooves are aligned in a third direction, wherein the channels and the third grooves are arranged to each other, that at least a part of the channels, each with at least one Groove is connected.

With this construction it is achieved that the sound from the environment can be absorbed and absorbed by the holes in the channel and groove structure arranged on both sides of the carrier plate. At first, neither a special orientation of the grooves nor a covering layer arranged on at least one of the two sides of the carrier plate is important, as in the previously described panels.

Further features and advantages of this embodiment of the invention are also given in the description of specific embodiments.

Fig. 1

ein erstes Ausführungsbeispiel einer erfindungsgemäßen Deckschicht, wobei die Fig. 1a bis 1c den Aufbau im Querschnitt in verschiedenen Stadien der Herstellung zeigen und Fig. 1d eine perspektivische Darstellung eines Ausschnittes der fertigen Deckschicht zeigt,

Fig. 2

ein zweites Ausführungsbeispiel einer erfindungsgemäßen Deckschicht, wobei die Fig. 2a bis 2c den Aufbau im Querschnitt in verschiedenen Stadien der Herstellung zeigen und Fig. 2d eine perspektivische Darstellung eines Ausschnittes der fertigen Deckschicht zeigt,

Fig. 3

ein Ausführungsbeispiel eines erfindungsgemäßen schallabsorbierenden Paneels mit Kanälen und mit Nuten, wobei die Nuten auf der oberen Seite der Trägerplatte angeordnet sind und die in einer Richtung unter ca. 45° zu den Seitenkanten ausgerichtet sind (Fig. 3b),

Fig. 4

das in Fig. 3b dargestellte Paneel mit einer Deckschicht auf der oberen Seite,

Fig. 5

ein Ausführungsbeispiel eines erfindungsgemäßen schallabsorbierenden Paneels mit Kanälen und mit Nuten, wobei die Nuten auf der oberen Seite der Trägerplatte angeordnet sind und die in zwei Richtungen unter jeweils ca. 45° zu den Seitenkanten ausgerichtet sind (Fig. 5b),

Fig. 6

das in Fig. 5b dargestellte Ausführungsbeispiel mit Nuten auf der unteren Seite der Trägerplatte,

Fig. 7

das in Fig. 6 dargestellte Paneel mit jeweils einer Deckschicht auf der oberen Seite und der unteren Seite in einer perspektivischen Darstellung (Fig. 7a) und im Querschnitt (Fig. 7b),

Fig. 8

ein Ausführungsbeispiel eines erfindungsgemäßen schallabsorbierenden Paneels mit Kanälen und mit Nuten, wobei die Nuten auf der oberen Seite der Trägerplatte angeordnet sind und die in zwei Richtungen unter jeweils ca. 90° zu den Seitenkanten ausgerichtet sind (Fig. 8b),

Fig. 9

das in Fig. 8b dargestellte Ausführungsbeispiel mit Nuten auf der unteren Seite der Trägerplatte,

Fig. 10

das in Fig. 9 dargestellte Paneel mit jeweils einer Deckschicht auf der oberen Seite und der unteren Seite,

Fig. 11

eine Anordnung von Kanälen und Nuten in einer Draufsicht,

Fig. 12

zwei Ausgestaltungen verschiedener Nutenformen,

Fig. 13

im Querschnitt in Längsrichtung einer Nut, wobei die Nut eine variierende Nuttiefe aufweist,

Fig. 14

im Querschnitt in Querrichtung der Nuten mit verschiedenen Querschnittsformen und

Fig. 15

im Querschnitt die in Fig. 7b dargestellte Ausführungsform eines Paneels, wobei zusätzlich ein Vlies zwischen den Deckschichten und der Trägerplatte angeordnet ist.

In the following, the teachings of the present invention will be explained in more detail by means of embodiments with reference to the accompanying drawings. In the drawing show

Fig. 1

a first embodiment of a cover layer according to the invention, wherein the Fig. 1a to 1c the structure in cross section in show various stages of the production and Fig. 1d shows a perspective view of a section of the finished cover layer,

Fig. 2

a second embodiment of a cover layer according to the invention, wherein FIGS. 2a to 2c show the construction in cross-section at different stages of production and FIG. 2d shows a perspective view of a section of the finished cover layer,

Fig. 3

An embodiment of a sound-absorbing panel according to the invention with channels and with grooves, wherein the grooves are arranged on the upper side of the support plate and which are aligned in one direction at about 45 ° to the side edges (Fig. 3b),

Fig. 4

the panel shown in Fig. 3b with a cover layer on the upper side,

Fig. 5

An embodiment of a sound-absorbing panel according to the invention with channels and with grooves, wherein the grooves are arranged on the upper side of the support plate and which are aligned in two directions, each about 45 ° to the side edges (Fig. 5b),

Fig. 6

the embodiment shown in Fig. 5b with grooves on the lower side of the carrier plate,

Fig. 7

the panel shown in Fig. 6, each with a cover layer on the upper side and the bottom side in a perspective view (Figure 7a) and in cross-section (Figure 7b),

Fig. 8

An embodiment of a sound-absorbing panel according to the invention with channels and with grooves, wherein the grooves are arranged on the upper side of the support plate and which are aligned in two directions, each about 90 ° to the side edges (Figure 8b),

Fig. 9

the embodiment shown in Fig. 8b with grooves on the lower side of the carrier plate,

Fig. 10

the panel shown in Fig. 9, each with a cover layer on the upper side and the lower side,

Fig. 11

an arrangement of channels and grooves in a plan view,

Fig. 12

two embodiments of different groove shapes,

Fig. 13

in cross-section in the longitudinal direction of a groove, wherein the groove has a varying groove depth,

Fig. 14

in cross section in the transverse direction of the grooves with different cross-sectional shapes and

Fig. 15

in cross section, the embodiment of a panel shown in Fig. 7b, wherein additionally a fleece between the cover layers and the support plate is arranged.

The various embodiments of the present invention will be explained below with reference to exemplary embodiments. In this case, like reference numerals in the various embodiments denote the same elements, even if their shapes and arrangements may differ from each other.

Fig. 1a to 1c show the stepwise production structure of a cover layer 2 according to the invention for laminating a support plate. The cover layer 2 has a coating 4 (FIG. 1 a) and thereupon an applied adhesive layer 6 (FIG. 1 b), the adhesive layer 6 being partially activated and connected to the coating 4. The coating 4 and the adhesive layer 6 are provided with aligned holes 8, wherein the holes 8 in the coating 4 and the holes 8 in the adhesive layer 6 have substantially the same cross-sectional area.

2 shows a second exemplary embodiment of a cover layer 2 according to the invention, in which a material, in particular a wood material, which consists of a layer structure is used as the coating 4. This can be the case in particular if the coating 4 consists of a material whose surface is to be changed. For this purpose, a laminate 10 on the upper side and to compensate for any mechanical stresses occurring a laminate 12 is provided as Gegenzugschicht, as is apparent from Fig. 2a.

FIG. 2 b shows the structure after the application of the adhesive layer, while FIG. 2 c shows the finished structure of the cover layer 2.

The coating 4 has a preferred thickness between 0.25 and 5 mm, but the embodiments are not limited to this range of values.

As can be seen from a comparison between Figs. 1 and 2, the holes 8 may have a freely selectable shape. Fig. 1 shows holes 8 with a round shape, while Fig. 2 shows holes 8 with a slot shape.

The holes 8 have a largest dimension or a diameter of 0.5 to 3 mm, preferably 0.5 to 1.5 mm, in particular 1 mm. However, the configuration of the holes 8 is not limited to these numerical values.

The holes 8 are arranged in a preferably regular grid with a grid dimension of 2 to 40 mm, preferably 2 to 4 mm, in particular 3 mm. On the one hand, this can lead to a regular pattern according to FIG. 1d in the case of round holes, or the slot-shaped holes 8 according to FIG. 2d are arranged at a regular distance from one another.

FIG. 3 shows an exemplary embodiment of a sound-absorbing panel 14. In the present case, the panel 14 has only one support plate 20. Thus, there is no difference in itself between the panel 14 and the support plate 20. However, as in the following description of further embodiments, further elements of the support plate 20 are added, which then together with the support plate 20 form the panel 14, throughout the description, the support plate 20 described as part of the panel 14.

In the carrier plate 20 are arranged in the channels 22 (Fig. 3a). The channels 20 connect an upper first side 24 of the carrier plate 20 to a lower second side 26 of the carrier plate 20.

Furthermore, grooves 28 are arranged in the first side 24 of the carrier plate 20 (FIG. 3b). The grooves 28 and the channels 22 are arranged to each other so that the channels 22 are connected to at least one groove 28.

The grooves 28 extend at an angle of 45 ° to the side edges 30 and 32 of the support plate 20. Thereby, the advantageous effect is achieved that the proportion of grooves on the cross-sectional area of the side edge 30 and 32 remains limited, even if one parallel to the side edges 30 or 32 at any point the panel 14 cuts through, for example, to adapt to a certain size.

As an example of a preferred embodiment of the support plate 20 whose thickness is specified with a range of 5 to 50 mm, in particular 5 to 30, preferably from 10 to 20 mm. These values are not limitative of the invention.

FIG. 5 shows a further exemplary embodiment of a sound-absorbing panel 14. The panel 14 initially has, as before, a support plate 20 in which channels 22 are arranged (FIG. 5a). The channels 20 connect an upper first side 24 of the carrier plate 20 to a lower second side 26 of the carrier plate 20.

In the first side 24 of the support plate 20 first grooves 28 are arranged, wherein the first grooves 28 are aligned in the first direction. In the first side 24 of the support plate 20 second grooves 34 are arranged,
wherein the second grooves 34 are aligned in a second direction and wherein the second direction is oriented at an angle to the first direction. In the present case, these are right angles, but the invention is not limited to a rectangular arrangement of the grooves to each other.

The first grooves 28, the second grooves 34 and the channels 22 are arranged to each other such that the channels 22 are respectively connected to the grooves 28 and 34 in one of the crossing regions.

Furthermore, the first direction and the second direction extend at an angle of 45 ° to the side edges 30 and 32 of the carrier plate 14. This in turn achieves the advantageous effect that the proportion of the grooves on the cross-sectional area of the side edges 30 and 32 remains limited Even if you cut parallel to the side edges 30 or 32 at any point the panel 14, for example, to adapt to a particular size.

As FIGS. 3b and 5b show, the grooves 28 and possibly 34 are aligned substantially parallel to one another. This is an advantageous embodiment, but does not limit the invention.

Fig. 6 shows a further embodiment of a panel 14 according to the invention, the first side 24 is formed in the manner as Fig. 5b shows.

In addition, the second side 26 of the support plate 14 is provided with third grooves 36, the third grooves 36 being aligned in a third direction. In the present case, the second side 26 of the support plate 20 is also provided with fourth grooves 38, wherein the invention is not limited to that the second side 26 is provided with third grooves 36 and fourth grooves 38. The fourth grooves 38 are aligned in a fourth direction, the fourth direction being oriented at an angle to the third direction. The third grooves 36, the fourth grooves 38 and the channels 22 are finally arranged to one another such that the channels 22 are each connected to at least one groove 36 and / or 38.

Also, as shown in FIG. 6, the grooves 36 and the grooves 38 are aligned substantially parallel to each other and the third direction and the fourth direction are aligned at a right angle to each other. In addition, the third direction and the fourth direction are at an angle of 45 ° to the side edges 30 and 32 of the support plate 20th

As can be seen from the illustrations of FIGS. 5b and 6, the channels 22 are arranged so that the channels 22 are each connected to two grooves 28 and 34 or 36 and 38 in the region of the crossing regions. This results in a symmetrical structure of the grooves and channels.

This results in an arrangement of the grooves 36 and 38, which may substantially coincide with the arrangement of the grooves 28 and 34 on the first side.

FIG. 11 shows an example in which the channels 22 and the grooves 28 and 34 are arranged such that each channel 22 is connected to only one groove 28. With this embodiment, a good sound absorption can be achieved.

As can be seen in FIGS. 3b, 5b, 6 and 11, the channels 22 have a diameter which is greater than the width of the grooves 28, 34, 36 and 38. This ensures that, in particular, the channels 22 in the crossing regions of two grooves 28 and 34 cover the entire base area occupied by the intersection region.

It is preferred that the channels 22 have a diameter of less than 12 mm, in particular less than 8, preferably less than 6 mm. These numerical values are examples and do not limit the invention.

Fig. 12a shows that the grooves 28 and 34 have a curvilinear course. Thus, these grooves differ from those in the previously explained figures. Due to the curvilinear course of the grooves 28 and 34, a tuned to certain sound frequencies improved absorption can be achieved. Because, depending on the length of the repetitive shape of the grooves, certain frequencies may be better routed and absorbed in the structure.

In order to determine the direction of grooves with a curvilinear course, for example, to determine the angle of the direction to the side edges or to determine the parallelism of two grooves, it is proposed that at least in sections, a connecting line is applied to the outer mold. In other words, the maxima or else the minima in the course of the groove are connected to each other with straight lines. The direction of the line is then the direction of the curvilinear course.

Fig. 12b shows an example with grooves 28 having a varying width, wherein both edges of the grooves 28 each vary in the same way in opposite directions in their course. This regular shape can also be exploited to better absorb certain frequencies of the sound to be absorbed.

Moreover, in FIGS. 12a and 12b it has been omitted to draw in the channels which are shown in the other embodiments.

In the illustrated embodiments, it is preferred that the grooves have a width of 2 to 10 mm, in particular 3 to 5 mm, preferably with a width of 4 mm. Again, the figures given are not used to limit the invention.

As further shown in FIG. 13 by means of a further exemplary embodiment, the grooves of the previously explained exemplary embodiments, shown here with reference to the groove 28, can have a varying depth. Also hereby obtained a varying over the longitudinal extent of the groove 28 shape, the exact configuration can be adjusted for an adaptation of the absorption properties of the construction. The cross section of FIG. 13 also shows the grooves 28 crossing grooves 34.

Here, too, it is indicated by way of example that the grooves have a depth of 0.5 to 5 mm, in particular 1 to 3 mm, preferably with a depth of 1.5 mm.

FIG. 14 shows a further example of a possible embodiment of the grooves 28. For in principle the cross-section of the grooves can be chosen arbitrarily within the production possibilities. As examples, a rectangular cross-section and two trapezoidal grooves 28 are shown. In addition, curvilinear, round or oval groove cross sections are possible.

4, 7a, 7b, 10 and 15, starting from the previously explained embodiments, a further embodiment of the invention is shown. In these exemplary embodiments, the carrier plates 20 explained above are each provided on at least one side with a cover layer 2, wherein the cover layer 2 has a coating 4 and an adhesive layer 6 and
wherein the cover layer 2 has a plurality of holes 8.

In this case, the cover layer 2 is preferably formed and manufactured as previously shown with reference to FIGS. 1 and 2, but the invention is not limited thereto. Because it comes in the present embodiment to the combination of provided with grooves and channels support plate 20 with a cover layer 2 at. As the cover layer 2 has been produced, is initially irrelevant. Thus, for example, the cover layer can be produced in a conventional manner, ie only by punching the coating with subsequent Adhesive application. It can be accepted that while the holes are closed to a part again.

FIG. 4 now shows the carrier plate 20 shown in FIG. 3b, on the first side of which the cover layer 2 has been glued. In each case, a plurality of holes 8 covers the region of a groove 28 from. This is because the pitch of the holes 8 is smaller than the pitch of the grooves 28.

Fig. 7a shows the carrier plate 20 shown in Fig. 6, which is provided with grooves on both sides 24 and 26 and which is provided on both sides with a cover layer 2. Thus, both sides are provided with a decorative cover layer 2, so that a sound-absorbing panel 14 is formed with double-sided cover layers 2. This panel 14 is particularly suitable for an application in which a panel with sound-absorbing properties can be visible from both sides. This is the case for example with doors or cabinet parts.

Fig. 7b shows the structure described above in cross section. It is clearly visible the layer structure. Likewise, exemplary dimensions have been chosen to represent a ratio of the thickness of the support plate 20 to the depths and spacings of the grooves 28 and thicknesses of the cover layers 2.

Figures 8a and 8b, 9 and 10 show another embodiment of a sound absorbing panel 14. In this example, the grooves 28 and 34 and 36 and 38, respectively, are at right angles to the side edges 30 or 32 aligned. It is therefore dispensed with the above-explained preferred orientation of the grooves just. Instead, the cover layer 2 is attached to and bonded to both sides of the support plate 20 as previously described. It is also possible to provide only one side of the support plate 20 with the grooves 28 extending at right angles to the side edges 30 or 32 and to terminate with a cover layer 2. A further variant of the embodiments explained above is that the grid of the channels 22, so their distribution on the side surface, is designed differently than it is the case in Figs. 3a and 5a.

In all of the above-mentioned cases and combinations thereof, a sound-absorbing panel 14 is obtained, as is apparent from at least one teaching of the invention.

It is further preferred that the cover layer 2 is oriented so that at least a part of the holes 8 is connected to one of the grooves 28, 34, 36 or 38 or to a channel 22. This improves the quality of the sound absorption property. A suitable measure for this purpose is certainly to choose the pitch of the holes smaller than the distances between each two grooves, smaller than the width of the grooves or smaller than the diameter of the channels. Then it is always achieved without much effort that the holes at least partially coincide with the underlying structure of the channels and grooves.

In a likewise preferred further embodiment of the invention, at least one fleece in the above integrated structure described. In particular, a fleece 40 is arranged between a cover layer 2 and the carrier plate 20, as shown in FIG. 15. Likewise, FIG. 15 shows that a fleece 40 is arranged between the lower cover layer 2, the counteracting layer, and the carrier plate 20. Moreover, it is possible for a fleece 40 to be applied to the side of the counteracting layer 2 facing away from the carrier plate 20 (not shown in FIG. 15). Due to the presence of the fleece, the acoustic properties of the panel are further improved, without the need for additional design effort. Because the fleece is firmly arranged between the layers, without a frame construction would be required.

Claims (27)

Method for producing a sound-absorbing panel (14) having a workpiece surface and having a cover layer (2) having a coating (4) and an adhesive layer (6), characterized in that first the cover layer (2) is produced by - First, the coating (4) is applied to the adhesive layer (6), wherein the adhesive layer (6) is partially activated and connected to the coating (4), and - Subsequently, a plurality of holes (8) in the previously prepared composite of coating (4) and adhesive layer (6) is introduced. A method according to claim 1, characterized in that the adhesive layer (6) of the holes (8) provided with the cover layer (2) is glued to the workpiece surface. A method according to claim 1 or 2, characterized in that the workpiece surface is the surface of a carrier plate (22). Method according to one of claims 1 to 3, characterized in that prior to the application of the adhesive layer (6), the coating (4) on both Pages with a laminate (10, 12) is laminated. Method according to one of claims 1 to 4, characterized in that the adhesive layer (6) is applied substantially over the entire surface, in the form of beads or as a nonwoven. Method according to one of claims 1 to 5, characterized in that the adhesive layer (6) is rolled, poured or sprayed. Method according to one of claims 1 to 6, characterized in that the holes (8) by a perforation, by drilling, by needling, by cutting or by a laser machining in the coating (4) and the adhesive layer (6) are introduced. A method according to claim 7, characterized in that the holes (8) in a freely selectable form, in particular as round holes or as slots, in the coating (4) and the adhesive layer (6) are introduced. Method according to one of claims 1 to 8, characterized in that the adhesive layer (6) of the cover layer (2) is activated and then glued to the carrier plate (20). Method according to one of claims 1 to 9, characterized in that the second side (26) of the Support plate (20) is provided with a Gegenzugschicht (2). A method according to claim 10, characterized in that as coating layer (2) a cover layer, in particular produced by a method according to one of claims 1 to 10, is applied. Method according to one of claims 1 to 11, characterized in that at least one of the side edges of the carrier plate (20) is provided with a coating, preferably with a cover layer (2), in particular produced by a method according to one of claims 1 to 10. Method according to one of claims 1 to 12, characterized in that between the cover layer (2) and the carrier plate (20) a fleece (40) is arranged. Method according to one of claims 1 to 13, characterized in that a fleece (40) is arranged between the counteracting layer (2) and the carrier plate (20). Method according to one of Claims 1 to 14, characterized in that a fleece (40) is applied to the side of the counteracting layer (2) remote from the carrier plate (20). Cover layer (2), in particular for laminating a carrier plate (20) of a sound-absorbing panel (14), - With a coating (4) and with an adhesive layer (6), characterized in that the cover layer (2) is produced by a method according to any one of claims 1 to 15. Covering layer (2) according to Claim 16, characterized in that the coating (4) and the adhesive layer (6) are provided with aligned holes (8), the holes (8) in the coating (4) and the holes (8 ) in the adhesive layer (6) have substantially the same cross-sectional area. Covering layer (2) according to claim 16 or 17, characterized in that the coating (4) consists of a wood material, a veneer, a laminate, a natural material or a plastic. Covering layer (2) according to claim 18, characterized in that the laminate consists of at least two layers of paper impregnated with a synthetic resin. Covering layer (2) according to claim 18, characterized in that the wood material consists of a plywood board, a thin chipboard, a hardboard, a medium density fiberboard or a high density fiberboard. Covering layer (2) according to claim 20, characterized in that the coating (4) on both sides with a laminate (10,12) is laminated. Covering layer (2) according to claim 18, characterized in that the natural material consists of leather, of rubber or of a fabric of natural fibers. Covering layer (2) according to claim 18, characterized in that the plastic consists of linoleum or of PVC. Covering layer (2) according to one of Claims 16 to 23, characterized in that the adhesive layer (6) is applied essentially over the entire surface, in the form of beads or as a fleece. Covering layer (2) according to claim 24, characterized in that the adhesive layer (6) consists of a thermoplastic adhesive, in particular a hot melt adhesive, a contact adhesive, a multi-component adhesive or a microencapsulated adhesive system. Covering layer (2) according to one of claims 16 to 25, characterized in that the holes (8) have a freely selectable shape, in particular a round shape or a slot shape. Panel (14) with sound-absorbing properties, - With a workpiece surface, in particular a support plate (20), and with a covering layer (2) having a coating (4) and an adhesive layer (6), characterized in that the panel (14) is made by a method according to any one of claims 1 to 15.

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