GB2485165A - A laminated panel for acoustic insulation - Google Patents

A laminated panel for acoustic insulation Download PDF

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Publication number
GB2485165A
GB2485165A GB201018494A GB201018494A GB2485165A GB 2485165 A GB2485165 A GB 2485165A GB 201018494 A GB201018494 A GB 201018494A GB 201018494 A GB201018494 A GB 201018494A GB 2485165 A GB2485165 A GB 2485165A
Authority
GB
United Kingdom
Prior art keywords
resin
laminated board
porous
impregnated
core
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Withdrawn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
GB201018494A
Other versions
GB201018494D0 (en
Inventor
Timothy John Sweatman
Douglas Montague Spinney
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.)
Individual
Original Assignee
Individual
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 Individual filed Critical Individual
Priority to GB201018494A priority Critical patent/GB2485165A/en
Publication of GB201018494D0 publication Critical patent/GB201018494D0/en
Priority to PCT/GB2011/001546 priority patent/WO2012059713A1/en
Publication of GB2485165A publication Critical patent/GB2485165A/en
Withdrawn legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
    • B32B37/146—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers whereby one or more of the layers is a honeycomb structure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form
    • B32B3/10—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material
    • B32B3/12—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material characterised by a layer of regularly- arranged cells, e.g. a honeycomb structure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/10—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the pressing technique, e.g. using action of vacuum or fluid pressure
    • B32B37/1027—Pressing using at least one press band
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • 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
    • 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
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/30—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
    • E04C2/34—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts
    • E04C2/36—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts spaced apart by transversely-placed strip material, e.g. honeycomb panels
    • E04C2/365—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts spaced apart by transversely-placed strip material, e.g. honeycomb panels by honeycomb structures
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B2038/0052—Other operations not otherwise provided for
    • B32B2038/0076—Curing, vulcanising, cross-linking
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/02—Composition of the impregnated, bonded or embedded layer
    • B32B2260/021—Fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/06—Vegetal fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2305/00—Condition, form or state of the layers or laminate
    • B32B2305/10—Fibres of continuous length
    • B32B2305/20—Fibres of continuous length in the form of a non-woven mat
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/10—Properties of the layers or laminate having particular acoustical properties
    • B32B2307/102—Insulating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2607/00—Walls, panels
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/08—Impregnating
    • 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
    • E04B2001/742—Use of special materials; Materials having special structures or shape
    • E04B2001/748—Honeycomb materials
    • 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

Abstract

The laminated board 4 has an acoustically absorbent core material 7 and surfaces of resin-impregnated fibre material 5, 6 wherein one surface 6 is significantly less porous to sound than the other surface 5. The core may be a paper honeycomb and the surfaces may be formed of natural fibers and a sugar based bio-resin. The enhanced acoustic properties may be achieved by sequential curing of the resin in stages which differ on either side of the core and various levels of compression may be applied.

Description

Improved A_coustic Panel This invention relates to a method for the manufacture of acoustic panels with widely variable characteristics, particularly those of sound absorption, thermal insulation and physical stiffness.
Laminated boards employing a wide range of manufacturing techniques and materials are well known, particularly in the building and automotive industries, for heat and sound insulation applications.
These include but are not limited to boards made of natural fibre and bio-resins such as those described by the current inventors in their UK Patent Application Number 1018205.3.
According to the present invention acoustic panel board is made using resin impregnated fibre mat on both sides of a layer of core material such as, but not limited to, paper honeycomb. Enhanced acoustic properties are achieved by sequential curing of the resin in stages which differ on either side of the core material such that one side is acoustically more porous than the other.
Widely variable acoustic properties result from differing thicknesses of the core and impregnated mat, from the types of resin and from the parameters of the curing process and compression applied. The resulting material has many applications such as heat and sound insulation in motor vehicles and acoustic ceiling tiles for buildings.
A specific embodiment of the invention will now be described by way of example with reference to the accompanying drawings in which: Figure 1 shows a typical layer of impregnated fibre mat Figure 2 shows a typical cross section of the current invention Figure 3 shows a diagrammatic view the manufacturing process (1) Figure 1 shows a layer of resin impregnated natural fibre mat I wherein a layer of natural fibre material 2 is impregnated by coating it with resin 3. The resin 3 may be but is not limited to sugar-based bio-resin and depending upon its consistency it is allowed to fully or partially impregnate the layer of fibre mat 2. In some applications the mat 2 is coated on both sides.
With reference to Figure 3 the manufacturing of the acoustic board is achieved in a sequential process 19. In a production line which progresses in the direction of the arrow 27, layers of uncured resin-impregnated fibre mat 20 are applied to both sides of a core 21 of sound absorbing material such as paper honeycomb. This sandwich' is passed into a series of belt rollers to compress and cure the layers. In the first stage one belt 23 is hot and the opposing belts 22 are cold and are arranged to give progressive compression to the layered materials.
As the layered materials emerge from the belt 22 the lower impregnated mat 20 is partially cured but remains uncured at its interface with the core material 21. The upper impregnated mat 20 is not cured.
In the next stage of the process the layered materials pass between two heated roller belts 23 and 24 which fully cure both sides under pressure. The final stage is to pass the laminated board 26 through cold roller belts 25 where it is cooled and held flat under compression.
In a variant of the process similar results can be achieved using a static press or presses such that discrete sheets of material are pressed and heat-cured sequentially as specified in the continuous production line process described above.
With reference to Figure 2 the resulting product 4 is a sheet of laminated board wherein one side of the core material 7 has a hard layer of resin impregnated fibre board 6 which is substantially acoustically reflective and is less porous to sound than the other layer of impregnated fibre board 5 which is acoustically porous or semi-porous. The whole has excellent stiffness and thermal insulation properties as well as acoustic characteristics which can be widely varied by adjusting the thicknesses of the various materials, the compression applied and the phased curing times and temperatures. (2)

Claims (4)

  1. CLAIMS: 1. A laminated board wherein an acoustically absorbent core material has surfaces of resin-impregnated fibre material one being significantly less porous to sound than the other.
  2. 2. A laminated board as in Claim 1 wherein one of the resin impregnated surface layers is cured in a multiplicity of stages to give an acoustically porous or semi-porous surface.
  3. 3. A laminated board as in Claims 1 and 2 wherein the acoustic, thermal, and physical stiffness properties are adjusted according to need by varying the thicknesses of the layers, the pressure applied and the curing times given to each stage of manufacture.
  4. 4. A laminated board substantially as described herein with reference to Figures 1 to 3 attached hereto.
GB201018494A 2010-11-03 2010-11-03 A laminated panel for acoustic insulation Withdrawn GB2485165A (en)

Priority Applications (2)

Application Number Priority Date Filing Date Title
GB201018494A GB2485165A (en) 2010-11-03 2010-11-03 A laminated panel for acoustic insulation
PCT/GB2011/001546 WO2012059713A1 (en) 2010-11-03 2011-11-01 Acoustic composite panels and methods for their manufacture

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
GB201018494A GB2485165A (en) 2010-11-03 2010-11-03 A laminated panel for acoustic insulation

Publications (2)

Publication Number Publication Date
GB201018494D0 GB201018494D0 (en) 2010-12-15
GB2485165A true GB2485165A (en) 2012-05-09

Family

ID=43401668

Family Applications (1)

Application Number Title Priority Date Filing Date
GB201018494A Withdrawn GB2485165A (en) 2010-11-03 2010-11-03 A laminated panel for acoustic insulation

Country Status (2)

Country Link
GB (1) GB2485165A (en)
WO (1) WO2012059713A1 (en)

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2531942A (en) * 2014-10-31 2016-05-04 Ecotechnilin Ltd Process for manufacture of laminated composites
FR3043588A1 (en) * 2015-11-12 2017-05-19 Melodit MULTILAYER ACOUSTIC PANEL

Families Citing this family (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR3019089B1 (en) * 2014-03-25 2017-03-31 Faurecia Automotive Ind METHOD FOR MANUFACTURING A STRUCTURAL PART, IN PARTICULAR FOR A MOTOR VEHICLE, AND CORRESPONDING STRUCTURAL PIECE
FR3106776B1 (en) * 2020-02-05 2021-12-31 Mercier Thibault Acoustic panel with sound absorbing border.
US20220289093A1 (en) * 2021-03-11 2022-09-15 Ford Global Technologies, Llc Load ramp for a vehicle

Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2252075A (en) * 1991-01-22 1992-07-29 Short Brothers Plc Structural cellular component
FR2672324A1 (en) * 1991-02-05 1992-08-07 Sonokell Structural panel for false ceilings or partitions having acoustic insulation properties
JPH04223496A (en) * 1990-12-26 1992-08-13 Nippon Tokushu Toryo Co Ltd Deep drawable lightweight soundproof material
US5518796A (en) * 1993-05-13 1996-05-21 Ciba-Geigy Corporation Near-surface enhancement of honeycomb sandwich structures to improve durability using a foaming fiber-filled adhesive
JPH10212772A (en) * 1997-01-30 1998-08-11 Chubu Electric Power Co Inc Sound absorption and insulation pannel
US5888610A (en) * 1995-06-08 1999-03-30 Aerospatiale Societe Nationale Industrielle Method for producing a panel or the like with structural and acoustic properties and panel obtained by said method
JP2004271918A (en) * 2003-03-07 2004-09-30 Daiwa:Kk High-performance sound absorbing material

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US4131664A (en) * 1977-09-28 1978-12-26 Allen Industries, Inc. Method of making a multiple-density fibrous acoustical panel
JP2934048B2 (en) * 1991-04-18 1999-08-16 川崎重工業株式会社 Foamed phenolic resin composite molding
DE29900621U1 (en) * 1999-01-15 1999-04-08 Haertwich Erwin Ecological lightweight building material in composite construction
DE10033322B4 (en) * 2000-07-03 2005-08-04 HP-chemie Pelzer Ltd. Industrial Estate Method for producing composite elements and composite element
DE10132749A1 (en) * 2001-07-03 2003-01-30 Fraunhofer Ges Forschung Fiber reinforcing material based on duroplastic polymer useful for e.g. automobile internal linings and external parts
US20030162461A1 (en) * 2002-02-22 2003-08-28 Balthes Garry E. Process, composition and coating of laminate material
DE102004015472B4 (en) * 2004-03-26 2010-03-11 Herbert Olbrich Gmbh & Co. Kg Multi-layer molding and method for its production
GB2452235A (en) * 2007-03-05 2009-03-04 Eco Mats Ltd Plant fibre mat and method of making a plant fibre mat
GB2471096A (en) 2009-06-16 2010-12-22 Eco Mats Ltd Laminated composites based on natural materials

Patent Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH04223496A (en) * 1990-12-26 1992-08-13 Nippon Tokushu Toryo Co Ltd Deep drawable lightweight soundproof material
GB2252075A (en) * 1991-01-22 1992-07-29 Short Brothers Plc Structural cellular component
FR2672324A1 (en) * 1991-02-05 1992-08-07 Sonokell Structural panel for false ceilings or partitions having acoustic insulation properties
US5518796A (en) * 1993-05-13 1996-05-21 Ciba-Geigy Corporation Near-surface enhancement of honeycomb sandwich structures to improve durability using a foaming fiber-filled adhesive
US5888610A (en) * 1995-06-08 1999-03-30 Aerospatiale Societe Nationale Industrielle Method for producing a panel or the like with structural and acoustic properties and panel obtained by said method
JPH10212772A (en) * 1997-01-30 1998-08-11 Chubu Electric Power Co Inc Sound absorption and insulation pannel
JP2004271918A (en) * 2003-03-07 2004-09-30 Daiwa:Kk High-performance sound absorbing material

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2531942A (en) * 2014-10-31 2016-05-04 Ecotechnilin Ltd Process for manufacture of laminated composites
FR3043588A1 (en) * 2015-11-12 2017-05-19 Melodit MULTILAYER ACOUSTIC PANEL

Also Published As

Publication number Publication date
WO2012059713A1 (en) 2012-05-10
GB201018494D0 (en) 2010-12-15

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