GB2621015A

GB2621015A - Wall panel

Info

Publication number: GB2621015A
Application number: GB2308410.6A
Authority: GB
Inventors: Brian Kelsey Rogan
Original assignee: Pineapple Contracts ULC
Current assignee: Pineapple Contracts ULC
Priority date: 2023-06-06
Filing date: 2023-06-06
Publication date: 2024-01-31
Also published as: GB202308410D0

Abstract

The panel includes a base 4 including means to secure the base to a surface in use (figs 8A-12), a frame 10 securable to the base, a cover (12, fig 6) formed with at least an outer layer of non-porous material and held in tension across the frame, a spacer 8 extending between the base and the cover to provide an air cavity between the two, and a layer of acoustic absorbent material 6A-D mounted within the cavity such that an air gap is provided between the absorber and the cover to allow vibration of the cover (12, fig 6) when it is impacted by sound waves. The cover (12, fig 6) may comprise a sheet of wipeable material e.g., polyurethane fabric that is suitable for use in clinical, correctional and other public environments.

Description

WALL PANEL

FIELD OF THE INVENTION

The present invention relates to a wall panel. In particular, the invention relates to a wall panel, the construction of which allows it to act as an acoustic absorber. More especially, the invention relates to an acoustic absorption wall panel that is suitable for use in clinical environments.

BACKGROUND TO THE INVENTION

Acoustic absorption panels are typically panels of a porous material that are designed to minimise noise levels and reduce echo through the absorption of sound and the consequent reduction of reverberation time.

When a sound wave encounters an object, it will either reflect off it or be absorbed by the object. When a sound wave is reflected, it will come back to the room -if powerful enough, it will lead to echoes. With sound absorption materials present, the sound waves are absorbed as sound energy is converted into heat when air particles within the absorber are subjected to friction.

The performance of sound absorbing materials is quantified by the Sound Absorption Coefficient (SAC) which ranges from 0 (where there is no sound absorption and the sound waves are reflected off a smooth surface) to 1 (which signifies that all sound waves are absorbed, this is known as the 'perfect absorber').

The sound absorption coefficients of materials are also classed from A to E between a frequency range of 250 to 4000 Hz, as described by EN ISO 11654. Where Class A absorption materials have an SAC of 0.90 to 1, while a Class E absorption material has an SAC of 0.15 to 0.25. This range allows manufacturers to provide users with variability of sound absorption depending on the environment it will be used it.

The classification of acoustic devices provides a convenient measure of performance of sound-absorbing materials enabling comparability, evaluation, specification, research, design optimisation and compliance with regulations. These panels are used in environments where minimising excessive sound and noise pollution is important such as recording studios, classrooms and offices.

Traditional acoustic absorption panels are not suitable for clinical environments which require regular sanitisation because the panels are typically comprised of a porous material such as mineral wools and/or polymeric foam, wrapped in an acoustically transparent and porous fabric. The porous nature of the panels is problematic in clinical environments due to being an ideal location for contaminants to grow and spread diseases. Replacing the porous fabric with a wipeable, non-porous fabric significantly degrades of the sound absorbing performance of the absorber material used because some of the sound waves are reflected off the fabric surface rather than passing through the fabric and this reduces the sound energy available for absorption by the absorbent material behind it.

There is though, a particular need for acoustic absorption panels in clinical environments, such as hospitals and prisons, especially in de-escalation rooms to reduce noise levels that can cause confusion, strain, anxiety, and miscommunication. The structure and design of clinical environments tends not to be conducive to reduced noise levels and loud noises can echo through large areas of the building raising anxiety and stress levels of others in the vicinity.

Acoustic absorption wall panels constructed from a materials suitable for clinical environments are known. One such panel is marketed by the applicant under the brand "Hush Acoustic Tile" is made from a cork material. Whilst the material has acoustic absorption properties, the sound absorption coefficient is low, being a category F. The present invention seeks to provide an acoustic absorption wall panel having a non-porous, wipeable fabric making it suitable for clinical environments, but having an improved construction so not to compromise the acoustic absorption properties of the wall panel.

The present invention also seeks to provide an acoustic absorption wall panel the improved construction of which allows for tuneable resonance to broaden the sound frequency range absorbed by the panel.

STATEMENT OF INVENTION

An acoustic absorption panel, the panel comprising: a base including means to secure the base to a surface in use, a frame securable to the base; a cover formed with at least an outer layer of non-porous material held in tension across the frame; a spacer extending between the base and the cover to provide an air cavity therebetween; a layer of acoustic absorbent material mounted within the cavity such that an air gap is provided between the absorber and the cover to allow vibration of the cover when it is impacted by sound waves.

Preferably, the acoustic absorbent layer is made from mineral wool.

Alternatively, the acoustic absorbent layer is made from a polymeric foam, and more preferably, the acoustic absorbent layer is made from a polyurethane.

Preferably, the base has a raised lip that extends internally around its periphery.

Preferably, a peripheral edge of the acoustic absorbent layer is mounted on the lip such that a gap is provided between acoustic absorbent layer and the base surface.

Preferably, the spacer is generally cross-shaped, having lateral arms extending from a longitudinal arm.

Preferably, the lateral arms extend at an angle of less than 90 degrees to the longitudinal arm.

Preferably, the lateral arms and longitudinal arm meet at a junction that is offset from the centre of the longitudinal arm.

Preferably, each lateral arm is tapered upwardly from its distal end to the junction and the longitudinal arm is tapered upwardly from one end to the junction and is tapered downwardly from the junction to the other end, so to form an apex at the junction.

Preferably, the arms of the spacer act as a geometric divider to separate the air cavity into discrete sections, each section having mounted therein a complimentary-shaped layer of acoustic absorbent material.

Preferably, the cavity sections vary in shape and dimension.

Preferably, the apex of the spacer extends above the acoustic absorbent layer to shape the cover held across the frame.

Preferably, the thickness of the acoustic absorbent layer varies along its length.

Preferably, the acoustic absorbent layer is tapered upwardly towards the apex of the spacer.

Preferably, the cover is stretched across the frame, and behind the base so to provide no visible tag or loose fabric thereby preventing any form of tampering or removal.

Preferably, the base securement means includes a mounting board securable to an outer surface of the base, the mounting board having apertures to receive wall mounted brackets.

BRIEF DESCRIPTION OF DRAWINGS

One embodiment will now be described with reference to the accompanying figures in which: Figure 1 is a perspective view of four wall panels constructed in accordance with the invention; Figure 2 is a perspective view of an acoustic absorption wall panel constructed in accordance with a first embodiment of the invention with the front cover removed,.

Figure 3 is an exploded view of the wall panel of figure 2; Figure 4 is a cross-sectional view of the wall panel from line AA offigure 2; Figure 5 is a perspective view of the base of the wall panel; and Figure 6 is an exploded view of an acoustic absorption wall panel constructed in accordance with a second embodiment of the invention; Figure 7 is an exploded view of the mounting board separated from the wall panel; Figure 8A is a further exploded view of the wall panel connected to the mounting board separated from the wall brackets; Figure 8B is a side perspective view of the wall panel separated from the wall brackets; Figure 9A is a perspective view of the rear of the mounting board highlighting a 'French cleat' mounting system; Figure 9B is a further perspective view of the rear of the mounting board highlighting the bracket member secured to the aperture; Figures 10A and 10B are cross-sectional views of the 'French cleat' mounting system in its disengaged and engaged states, respectively; Figure 11A and 11B are cross-sectional views of the lower portion of the mounting system in its disengaged and engaged states, respectively; and Figure 12 is a further perspective view of the lower mounting portion. DETAILED DESCRIPTION OF THE INVENTION A first embodiment of an acoustic absorption wall panel 2 is shown in the figures 2 to 6.

The acoustic absorption wall panel 2 generally comprises a base 4, an acoustic absorber 6, a spacer 8 and a frame 10. A cover 12 (see figure 6) is stretched across the frame above the other components.

The base 4 is generally rectangular and is made of a suitably rigid material, for example, wood, plastics, or a composite material. The base 4 has a raised strip or lip 14 that extends internally around its periphery.

The raised strip 14 may be formed integral with the surface of the base 4 or may, alternatively be provided as a separate framework 1610 be mounted onto the base 4 (as for example shown in the embodiment of figure 5).

In the embodiment shown the base 4 is separated into discrete sections 16 by the spacer 8, acting as a geometric divider, the strip 14 extending around the internal periphery of each section. The sections 16 are divided further by extensions of the strip 14.

It is envisaged though that the base may not compartmentalised there being just one single rectangular peripheral strip 14.

The acoustic absorber 6 takes the form of a sheet of a suitably porous material. Preferably, the absorber 6 is a mineral wool or a polymeric foam, for example, polyurethane. The material chosen is preferably a high-performing traditional sound absorber. As will be explained, a porous material can be used, as the absorber 6 is internal to the structure and not on the exposed surface (preventing its use in a clinical environment).

The absorber 6 is mounted on the peripheral strips 14 across the base 4 such that a gap is provided between the main body of the absorber 6 and the base surface.

The thickness of the absorber 6 may vary along its length. For example, as can be seen in figure 4, the absorber 6 may be wedge-shaped, tapered upwardly towards the apex of the spacer 8. Preferably the thickness of the absorber 6 is approximately 5mm to lOmm less than the height of the spacer 8 for an air gap of 5mm to 10 mm along its length. By varying the thickness of the absorber 6, all the internal space of the panel provides for absorption to maximise its absorption potential.

The thickness of the absorber may be approximately equal to the height of the distal ends of the spacer 8 but is less than the apex of the spacer 8.

The absorber 6 is divided into sections 6A-6D, each section 6A-6D being accommodated in a respective section 16A-16D on the base 4 divided by the spacer 8. All the sections 6A-6D, when combined form the same shape profile as the base 4 (in the embodiment shown, being rectangular). The absorber sections 6A-6D are dimensioned so to be a snug fit within the respective base section 16A-16D so to extend completely across the base surface.

The spacer 8 is generally cross-shaped with the lateral arms 18 formed at an angle to the longitudinal arm 20 and the junction 22 at which the lateral arms 18 and longitudinal arm 18 meet is offset from the centre of the longitudinal arm 20. This is to provide a visual shape to the panel as will be described below.

Each lateral arm 18 of the spacer 8 is tapered upwardly from its distal end to the junction. The longitudinal arm 20 of the spacer 8 is tapered upwardly from one end to the junction 22 and is the tapered downwardly from the junction 22 to the other distal end.

In the second embodiment shown in figure 6, it can be seen that the distal ends of the lateral and longitudinal arms 18, 20 are connected by a framework 24 which is complementary to the dimension of the base.

The apex of the spacer 8, at least, extends above the absorber to shape the cover 12 stretched over and across the frame 10 of the panel.

As the apex of the spacer 8 is formed at the junction 22 which offset from its centre, the overall structure of the wall panel takes the form of an oblique pyramid, as can be seen in figure 1. 15 The height of the apex ranges from 10 mm to 100 mm.

In an alternative embodiment (not shown) the spacer is formed as a cross-member with lateral arms extending perpendicular to the longitudinal arm. This would form a wall panel of a right pyramid.

In the alternative embodiment described in which the base is not compartmentalised, the absorber may be a single piece of material extending across the base and the spacer may be located over absorber. The spacer may take the form of one or more upstanding members across which the cover is stretched.

The cover 12 comprises a sheet of upholstery which is non-porous and wipeable for use in clinical environments. The cover may be made of an acoustically reflective fabric. Preferably the cover 12 is formed from polyurethane covering fabric. Such a cover 12 is suitable for

S

clinical, corrections and other public environments which usually impose design constraints intended to limit the risk of harm to the service user in the environment. The cover 12 is able to be used in challenging environments that require secure fitting and anti-ligature design and is able to weather the elevated cleaning protocols involving stronger chemicals. Degradation of the usual acoustic absorption performance using such material is avoided by stretching the cover 12 across the frame 10 and the apex of the spacer 8, to ensure the cover is kept under tension and physically displaced from the absorber 6. An airtight cavity is provided within the panel, bounded by the base 4 and the cover 12, in which the absorber 6 sits. This allows free vibration of the cover when impacted by sound waves and the absorber 6 below it acts as a vibration dampening element.

The cover 12 is stretched across the frame, down the sides and behind the base, with no visible tag or loose fabric, preventing any form of tampering or removal.

The panel 2 can be adjusted to absorb frequencies over a wider range of frequency range by varying the type and tension of PU stretched over cavities which in turn can be varied in size.

Providing a number of cavity sections 16A-16D within the structure allows for scattering of sound waves. By varying the elevation of a single point in the framework and creating multiple airtight cavities, an angled reflective geometric surface is created, adding further acoustic benefit as scattering improves room acoustics by creating a more diffuse sound field.

Multiple cavities of different sizes allows for different cavities to absorb sound at different frequencies thereby broadening the frequency range over the entire structure.

Tests by the applicant have found the wall panel 2 of the invention to have a higher absorption coefficient than known panels suitable for use in clinic environments.

To further enhance its use in clinical environments, the panel 2 is constructed with sloped edges to ensure that it is ligature proof.

The wall panel 2 is provided with anti-tamper securing mechanism to secure the panel 2 to a wall.

Figure 7 shows a mounting board 26 which is used to secure the wall panel to a surface, being, in practice, a vertical wall 34. One end of the mounting board 26, the end being the bottom of the board 26 when it is secured to the wall, comprises a substantially rectangular aperture 28 at or near each corner. The apertures 28 have an inwardly extending recessed flange 30. More than two apertures may be provided. Alternatively, a single central aperture may be used. Recessed bores 32 are located at the base of the mounting board 26, which extend though the board 26 and into aperture via flange member 30.

As the front, visual, face of the panel 2 takes the form of an oblique pyramid in the embodiments shown, different orientations of the panels provide a different visual effect. Once the orientation of a particular panel has been selected, the mounting board 26 is secured to outer surface of the base 4 of the panel 2 via tamper proof screws received through screw holes 46 (as shown in figures 9A and 9B).

To secure the wall panel 2 to the wall 34, an upper bracket 36 and two lower brackets 38 are required.

The bottom brackets 38 are L-shaped and are initially secured to the wall 34 in the desired location, to be received within the apertures 28 in the mounting board 26 during securement of the panel 2 to the wall 34, as can be seen in figures 9B and 12.

Tamper-proof screws are then inserted into the recessed bores 32 to secure each bracket 38 within the mounting board 26.

Figures 11A and 11B illustrate the securement mechanism of the lower brackets 38 to the mounting board 26.

The upper bracket 36 forms one half of a "French cleat" mechanism. The other half of the French cleat is formed by a complimentary nesting member 42 located within a recess 44 formed in the back of the mounting board 26.

During securement of the panel 2 to the wall 4, the upper bracket 26 and nesting member 42 abut and lock together to complete the French cleat mechanism 40, as can be seen in figure 9A.

Figures 10A-10B show the French cleat mechanism in its disengaged and engaged states respectively.

Although the tamper-proof and ligature-proof securement mechanism is described for use with a wall panel of the present invention, it will be readily apparent that the securement mechanism could be used to secure any item to the wall, such as a mirror or cabinet for example.

Claims

CLAIMS1. An acoustic absorption panel, the panel comprising: a base including means to secure the base to a surface in use, a frame securable to the base; a cover formed with at least an outer layer of non-porous material held in tension across the frame; a spacer extending between the base and the cover to provide an air cavity therebetween; a layer of acoustic absorbent material mounted within the cavity such that an air gap is provided between the absorber and the cover to allow vibration of the cover when it is impacted by sound waves.
2. A panel according to claim 1, wherein the acoustic absorbent layer is made from mineral wool.
3. A panel according to claim 1, wherein the acoustic absorbent layer is made from a polymeric foam.
4. A panel according to claim 3, wherein the acoustic absorbent layer is made from a polyurethane.
5. A panel according to any preceding claim, wherein the base has a raised lip that extends internally around its periphery.
6 A panel according to claim 5, wherein a peripheral edge of the acoustic absorbent layer is mounted on the lip such that a gap is provided between acoustic absorbent layer and the base surface.
7. A panel according to any preceding claim, wherein the spacer is generally cross-shaped, having lateral arms extending from a longitudinal arm.
8. A panel according to claim 7, wherein the lateral arms extend at an angle of less than 90 degrees to the longitudinal arm.
9. A panel according to claim 8, the lateral arms and longitudinal arm meet at a junction that is offset from the centre of the longitudinal arm.
10. A panel according to claim 9, wherein each lateral arm is tapered upwardly from its distal end to the junction and the longitudinal arm is tapered upwardly from one end to the junction and is tapered downwardly from the junction to the other end, so to form an apex at the junction.
11. A panel according to claim 10, wherein the arms of the spacer act as a geometric divider to separate the air cavity into discrete sections, each section having mounted therein a complimentary-shaped layer of acoustic absorbent material.
12. A panel according to claim 11, wherein the cavity sections vary in shape and dimension.
13. A panel according to any of claims 10 to 12, wherein the apex of the spacer extends above the acoustic absorbent layer to shape the cover held across the frame.
14. A panel according to claim 13, wherein the thickness of the acoustic absorbent layer varies along its length.
15. A panel according to claim 14, wherein the acoustic absorbent layer is tapered upwardly towards the apex of the spacer.
16. A panel according to any preceding claim, wherein the cover is stretched across the frame, and behind the base so to provide no visible tag or loose fabric thereby preventing any form of tampering or removal.
17. A panel according to any preceding claim wherein the base securement means includes a mounting board securable to an outer surface of the base, the mounting board having apertures to receive wall mounted brackets.