Classifications

• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
  • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
  • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
  • E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
  • E04B1/82—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to sound only
  • E04B1/84—Sound-absorbing elements
  • E04B1/86—Sound-absorbing elements slab-shaped
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
  • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
  • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
  • E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
  • E04B1/82—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to sound only
  • E04B1/84—Sound-absorbing elements
  • E04B2001/8457—Solid slabs or blocks
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
  • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
  • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
  • E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
  • E04B1/82—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to sound only
  • E04B1/84—Sound-absorbing elements
  • E04B2001/8457—Solid slabs or blocks
  • E04B2001/8461—Solid slabs or blocks layered

Definitions

• the present invention relates to sound-absorbing panels and in particular relates to a sound-absorbing panel, the size and/or shape of which may be modified so as to be adapted to different needs.
• the present invention also relates to a method for manufacturing such a sound-absorbing panel.
• the room may be acoustically very disturbed since the sound waves produced inside it are amplified with an effect similar to that of an echo.
• Sound-proofing materials have the property that they absorb at least a part of the acoustic energy and reduce the amount of reflected energy.
• EP 2,820,199 in the name of the same Applicant describes a soundabsorbing panel and the associated manufacturing method.
• the panel according to EP 2,820,199 is extremely functional and has resulted in a significant improvement in the sector of sound-absorbing panels. In fact, it has optimum acoustic characteristics as well as being very easy to handle and extremely versatile.
• the panel according to EP 2,820,199 is very light and does not require a support frame like the prior known panels.
• the Applicant provides a plurality of different industrially manufactured sound-absorbing panels in different shapes, with different colors and in different sizes.
• the Applicant provides sound-absorbing panels with a substantially rectangular shape, substantially square shape, or substantially circular, elliptical, trapezoidal or other shape.
• sound-absorbing panels which are made with frames consisting of rigid material, such as wood, extruded aluminum or rigid plastic, or of iron profiles which support the sound-absorbing material, form a perimetral edge and allow the covering fabric to be fixed with metal staples, springs or other retaining systems.
• the perimetral frame is cut to size depending on the needs and assembled to create a support frame.
• US 4,744, 189A describes a removable wall panel.
• the panel is configured to be secured to a wall. It is not envisaged being able to modify the shape and/or size of the panel also because this could result in elimination of the securing points.
• the Applicant has defined the aim of further improving the possibility of satisfying the installation and/or customer requirements in terms of the size and shape of the sound-absorbing panels.
• the Applicant has realized that in certain situations it would be desirable for a customer to have a sound-absorbing panel with a shape different from the standard shape.
• a contractor installing sound-absorbing panels must necessarily make compromises and install standard panels in such a way as to cover the wall in the best possible manner.
• compromises prove to be inefficient from the point of view of the sound-absorbing performance because the design engineer and/or the installation contractor is/are obliged to dispense with the installation of one or more panels, leaving a not insignificant part of the wall completely exposed.
• the technical problem of the present invention is therefore to provide a method for manufacturing a sound-absorbing panel, the size and/or shape of which may be modified, also during installation on-site.
• Another object is to be able to vary also subsequently the inclination of one of the cut edges, for example so as to be able to adapt the panel to a wall which is not perfectly vertical (a typical problem of historic buildings), this not being possible for all those panels which use profiles assembled by means of angular brackets fixed at 90 degrees.
• the present invention provides a soundabsorbing panel comprising a padding layer with a first face, a second face and an edge, a fabric and fastening members for fixing the fabric to the padding layer
• the padding layer comprises a layer of heat-bonded synthetic fibers, wherein the density of the fibers in the proximity of the first face and in the proximity of the second face is greater than the density of the fibers in the central zone of the padding layer
• the fabric is arranged so as to adhere substantially to the first face and to the edge of the padding layer and to form fabric flaps along the second face
• the fastening members are removable fastening members and are configured to fix at least one of the fabric flaps to the padding layer along the second face.
• fastening members could be used again, for example screws.
• Other fastening members for example staples, could be difficult to use again and should more preferably be replaced with similar (or different) fastening members, for example other staples, wherein the fastening members comprise at least one screw.
• Fixing the fabric with a screw offers a number of advantages. Firstly, it is able to ensure a more stable fastening. In fact, screws do not tend to become detached. Furthermore, the length of the screw may be adapted to the thickness of the padding layer. On the other hand, staples or other non-threaded fastening members may become detached more easily and penetrate by a smaller amount compared to screws.
• the screws may have a length which is equal to at least one third of the thickness of the padding layer.
• they have a length which is equal to or greater than half the thickness of the padding layer.
• the length of the shank of the screw may be such as to reach also the layer with a greater density in the proximity of the first face, namely the visible face.
• screws may be unscrewed (using a manual or electric screwdriver) while remaining attached (or “screwed”) to the fabric. In this way, they cannot fall to the ground and get lost, thus facilitating the work of the installation personnel, especially when they must modify the shape and/or size of the panel on-site.
• screws allow the fabric to be tensioned better, also because they may be “directed”, i.e. inclined towards the inside of the panel (slightly further away from the edge) and then straightened while they are being screwed in.
• the fabric is in contact with the head of the screw and therefore, by straightening the screw, the fabric is tensioned.
• the edge is a sharp-cut edge.
• the fastening members do not comprise glue or adhesive.
• the fastening members are mechanical fastening members.
• the absence of glue or adhesive is advantageous because it favors the recycling of the panel at the end of its working life: in fact, it is merely required to separate the padding layer (typically made of polyester) and the fabric (also typically made of polyester) from the metal (typically, in fact, the screws and the staples are made of metal).
• the absence of glue and adhesive is advantageous in that the fire and flame propagation resistance is improved.
• the fastening members are discrete fastening members.
• the fastening members comprise one or more of the following: nails, metal staples, staples made of non-metallic material, snap fasteners, buttons and eyelets or rubber bands.
• At least one fabric flap is fixed with two screws.
• at least one flap is fixed with at least one first screw in the proximity of a first end thereof and a second screw in the proximity of its second end.
• the at least one fabric flap which is fixed with two screws is also fixed with one or more staples, for example arranged between two screws, for example aligned (but also not aligned) with them.
• the fabric is shaped as an open box and comprises a bottom, edges and flaps which extend from the edges.
• the fabric is made by interweaving an elastic texturized yarn and comprises polyester.
• the fact that the fabric has a certain elasticity means that it may be tensioned and made to adhere better to the surfaces. This improves the sound-absorbing performance and results in a uniform response of the panel over the entire visible surface, even without the use of glue or adhesive.
• a method for modifying the shape and/or size of a sound-absorbing panel of the aforementioned type comprising:
• the sound-absorbing panel comprises a first shape and a first size
• the step of fixing again the fabric is carried out using, at least in part, the fastening members with which the fabric was originally fixed to the padding layer or using new/different fastening members.
• new fastening members For example, new screws and/or staples.
• the step of cutting a portion of the padding layer comprises the step of cutting the padding layer with a straight-blade cutting member, for example a cutter knife.
• the method also comprises the step of cutting off the excess fabric.
• the present invention comprises a method for manufacturing a sound-absorbing panel of the aforementioned type, comprising:
• the padding layer comprises a layer of heat-bonded synthetic fibers, wherein the density of the fibers in the proximity of the first face and in the proximity of the second face is greater than the density of the fibers in the central zone of the padding layer (10).
• fastening members comprise at least one screw screwed into the thickness of the padding layer from the second face.
• the step of applying fastening members comprises applying at least one staple and/or other removable fastening members.
• - Fig. 1 shows, by way of example, a portion of a padding layer while it is being partially lined with a fabric according to the present invention
• - Fig. 2 shows, in schematic form, a portion of fabric for lining a padding layer according to the present invention
• FIG. 3 shows, in schematic form, the portion of fabric while it is being fixed to the padding layer according to the invention
• FIG. 4 shows, in schematic form, the portion of fabric fixed to the padding layer according to a method of the present invention
• FIG. 5 shows, in schematic form, a cross-section through the padding layer with the fabric and two screws for fixing the fabric to the padding layer;
• FIG. 5a shows, in schematic form, a further cross-section through the padding layer with the fabric and two screws for fixing the fabric to the padding layer;
• FIG. 5b shows, in schematic form, a further cross-section through the padding layer with the fabric and two screws for fixing the fabric to the padding layer;
• FIG. 6 shows, by way of example, the rear face of a sound-absorbing panel according to the present invention
• Fig. 7 shows, in schematic form, the step during which the fabric is partially removed so as to allow cutting of a part of the padding layer, for example using a cutter knife;
• FIG. 8 shows, in schematic form, the step where the fabric is being fixed again to the rear face of the padding layer.
• a sound-absorbing panel suitable for being modified in terms of its shape and/or its size is described.
• a method for modifying the shape and/or the size of a sound-absorbing panel is also described.
• a sound-absorbing panel according to the present invention may be used on its own or in combination with other sound-absorbing panels in order to form structures suitable for installation in various environments in order to improve the acoustics thereof. They may be used to form walls, partitions, ceilings, false ceilings or the like. They may also be used to form furniture or parts of furniture, such as chairs, tables, sofas, bookshelves or the like.
• the sound-absorbing panel 1 may assume any shape. For example, a rectangular, square, round, regular polygon or irregular polygon shape.
• a padding layer 10 of heat-bonded synthetic fibers, a fabric 20 and fastening devices 31 , 32 for fixing the fabric 20 to the padding layer 10 are provided.
• the padding layer 10 comprises a first face 11 and a second face 12. Viewed in cross-section the padding layer 10 (according to embodiments) has a substantially constant cross-section. See in this connection Figures 5, 5a and 5b.
• the padding layer 10 comprises (or is essentially composed of) heat-bonded synthetic fibers.
• the heat-bonded synthetic fibers comprise polyester fibers.
• the fibers have a diameter of between 20 pm (micron) and 50 pm (micron), preferably a diameter of between 30 pm (micron) and 35 pm (micron).
• the fibers can be used in a temperature range of between -40°C and +80°C.
• the fibers are non-toxic and non-irritants. Furthermore they may be able to be fully recycled.
• the density of the fibers in the proximity of the first face 11 and in the proximity of the second face 12 is greater than the density of the fibers in the central zone 13.
• the greater density of the padding layer 10 in the proximity of the outer faces 11 and 12 makes them more rigid and imparts rigidity to the panel 1.
• the fastening devices 31 , 32 may be firmly fastened in order to fix the fabric 20 to the padding layer 10.
• the padding layer 10 is not delimited by a rigid edge which has a smaller thickness (and therefore a high fiber density and consequently is rigid).
• the padding layer 10 terminates substantially with a sharp-cut edge.
• the expression “sharp-cut” will mean that the padding layer is cut at 90° (as shown in Figure 5) or has a cut otherwise inclined, as shown in Figures 5a and 5b.
• the angle of inclination of the cut may be a few degrees or greater, such as 30°, 45° or 60°. Among the inclined cuts, the preferred angle is 45°.
• a cut is “sharp-cut” irrespective as to any chamfer or rounding along the first face 11 and/or the second face 12.
• the padding layer 10 comprises an edge which has a smaller thickness (with a high fiber density and rigid) along a perimetral section.
• the edge with a smaller thickness may be provided along one or two sides of the panel 1 , in the case where the panel has a polygonal shape.
• the sound-absorbing panel 1 also comprises a fabric 20.
• the fabric 20 is fixed at least to one face (11 or 12) of the padding layer.
• the fabric is fixed only to one face (12) of the padding layer 10.
• the padding layer 10 is substantially symmetrical when viewed in cross-section, and therefore a visible face and an opposite face is not identifiable, the fabric 12 is applied to the padding layer 10 so as to define a visible face and a face opposite thereto.
• the fabric 20 is applied so as to cover completely a first face 11 which, accordingly, is defined as being the visible face, typically exposed to the sound source.
• the fabric 20 is preferably applied so as to cover at least partly the edges 15 of the padding layer 10. More preferably, the fabric 20 is applied so as to cover completely the edges 15 of the padding layer 10 so as to cover and not expose the sections of the padding layer 10.
• the fabric 20 is applied so as to cover, at least in part, the second face 12, namely the face opposite to the face 11 which defines the visible face of the panel 1.
• the fabric 20 is applied so as to cover, substantially entirely, the second face 12, namely the face opposite to the visible face.
• the fabric 20 is not fastened to the first face 11 of the padding layer.
• the fabric 20 is not fastened to the first face 11 with adhesive or the like.
• the fabric 20 is not fastened to the edge 15 of the padding layer 10.
• the fabric 20 is not fastened to the edge 15 of the padding layer 10 with adhesive or the like.
• the fabric 20 is fastened to the padding layer 10 along the second face 12. According to embodiments, the fabric 20 is fastened to the padding layer 10 substantially only along the second face 12, opposite to the first face 11.
• the fabric 20 is fastened to the second face 12 by means of one or more devices such as screws, nails, staples made of metal (or other material), strips of Velcro® or the like or strips of double-sided tape, or a combination thereof.
• the fabric 20 may also be fastened by means of snap fasteners, buttons and eyelets or a combination thereof.
• the fabric may also be fastened by means of rubber bands.
• the fabric 20 is not fastened by means of adhesive or, alternatively, the fabric is not only fastened by means of adhesive.
• the fabric 20 is made of polyester.
• the fabric 20 is made by interweaving an elastic texturized yam with a yam count of 750 dtex along warp and weft.
• the structure may be formed by 1600 threads and 1500 wefts per meter with a crepe weave.
• the weight per square meter may be 300 g.
• the fabric is of the Trevira CS flame-retarding type.
• the fabric has the following properties: - specific strength of between 527 and 1552 [Pa s/m]; and
• the fabric has a specific strength of between 723 and 1213 [Pa s/m] and mass porosity of between 74% and 77%.
• the warp of the fabric comprises between 5 and 70 threads per centimeter.
• the warp of the fabric comprises between 5 and 40 threads per centimeter.
• the warp of the fabric comprises between 15 and 40 threads per centimeter.
• the weft of the fabric comprises between 5 and 70 threads per centimeter.
• the weft of said fabric comprises between 5 and 40 threads per centimeter.
• the weft of said fabric comprises between 12 and 22 threads per centimeter.
• the fabric 20 is arranged so as to adhere to (or be substantially directly facing) the first face 11 and the edges 15 and is folded over onto the second face 12.
• the fabric 20 may be shaped as an open box, namely with a bottom 21 , edges 25 and flaps 22.
• Each flap 22, preferably, is separately fastened to the second face 12.
• each flap 22 is fastened by means of screws 31 and/or metal staples 32.
• a flap 22 may be fastened to the padding layer 10 and also the other layer 22, for example by means of metal staples 32.
• the sound-absorbing panel 1 according to the invention is configured to be modified.
• the shape and/or the size of the sound-absorbing panel 1 according to the present invention may be changed so as to adapt it better to the requirements of the site where it will be installed.
• the modification may be performed before transportation to the installation location or also on-site if the need to modify the panel should arise at that moment (or if it is important to ensure that the panel is modified in the correct manner).
• the person performing the modification must remove the fabric 20 by the amount need to expose the padding layer 10 in the zone where the cut is to be made (broken line 16 in Figure 7).
• the person may remove the screws 31 and then remove the metal staples 32, raising the fabric flap to the height required.
• the padding layer 10 may then be cut.
• the fabric 20 may be repositioned, fastening it to the padding layer 10 in a similar manner to the way in which it was fastened before modification (or in another way).
• the fabric may be fixed again using the same screws 31 which will remain screwed to the fabric and so do not risk falling to the ground and being lost.
• the metal staples which should remain attached to the fabric must be removed and replaced. In Fig. 7 the metal staples 32 have not yet been removed. Obviously, according to the present invention, the screws could be replaced.
• the fabric flap 22 corresponding to the side where the cut was made will be longer. Said flap may be kept longer, as shown in Fig. 8, or may be cut so as to have the same length as the other flaps 22.
• the padding layer may be cut at angle of 90° or may be inclined (i.e. not perpendicular) at a different angle so as form a trapezium-shaped panel. This may be necessary when the wall to which the panel will be fixed does not have level walls.
• the inclination may be only a few degrees, for example less than 5°, or a greater angle, for example 5°, 10° or 15°.
• Cutting of the padding layer 10 may be performed using any suitable tool. For example, it may be performed using a strong cutter knife 40 or straightedge blade.
• Reciprocating blades circular blades or reciprocating circular blades may also be used, provided, preferably, that they do not have teeth.
• the sound-absorbing panel according to the invention may be shaped so as satisfy the specific requirements for its use.
• the panel owing to the variable density and in particular owing to the greater density in the proximity of the outer faces, is sufficiently rigid and self- supporting. No frame is required and therefore modification of the frame is not necessary, as instead the case in the known sound-absorbing panels.
• the length of the screws is preferably proportional to the thickness of the panel. According to embodiments, the screws have a length not smaller than about one third of the panel thickness. According to embodiments, the screws have a length not smaller than about half the panel thickness. According to embodiments, the screws have a length not smaller than about two thirds of the panel thickness.

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• Physics & Mathematics (AREA)
• Acoustics & Sound (AREA)
• Engineering & Computer Science (AREA)
• Architecture (AREA)
• Electromagnetism (AREA)
• Civil Engineering (AREA)
• Structural Engineering (AREA)
• Building Environments (AREA)
• Soundproofing, Sound Blocking, And Sound Damping (AREA)

Applications Claiming Priority (2)

Publications (1)

Family

ID=79019115

Family Applications (1)

Country Status (3)

Family Cites Families (15)

• 2022
  • 2022-09-23 EP EP22790575.9A patent/EP4405533A1/de active Pending
  • 2022-09-23 WO PCT/IB2022/059006 patent/WO2023047343A1/en not_active Ceased
  • 2022-09-23 US US18/691,367 patent/US20240384528A1/en active Pending

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