RU2716671C2 - Multilayer sound absorbing panel and ceiling system - Google Patents

Abstract

FIELD: ground construction.

SUBSTANCE: sound-absorbing ceiling panel, comprising: a first layer comprising a first main surface and a second main surface, wherein the second main surface of the first layer is formed by a perimeter, second main surface of first layer comprises perimeter area adjacent to perimeter of second main surface of first layer, and central area limited by area of perimeter of second main surface of first layer; second layer comprising first main surface and second main surface, wherein first main surface of second layer is formed by perimeter, first main surface of second layer comprises perimeter area adjacent to perimeter of first main surface of second layer, and central area limited by perimeter area of first main surface of second layer. At that, the second main surface of the first layer is connected to the first main surface of the second layer with an adhesive applied on at least one of the perimeter area of the second main surface of the first layer or the perimeter area of the first main surface of the second layer, wherein each of central area of second main surface of first layer and central area of first main surface of second layer does not contain adhesive, whereby first and second layers are glued to each other with adhesive to form cohesive multilayer panel. Embodiments of ceiling panel and suspended ceiling system are also described.

EFFECT: invention relates to multilayer sound absorbing ceiling panels and ceiling systems comprising multilayer sound-absorbing ceiling panels.

17 cl, 21 dwg

Description

CROSS REFERENCE TO RELATED APPLICATIONS

[ 0001 ] This application claims the priority of the United States Patent Application Serial No. 14 / 643,453, filed March 10, 2015, and the United States Patent Application Serial No. 14 / 643,536, filed March 10, 2015, the entire contents of which are incorporated herein by reference.

FIELD OF THE INVENTION

[ 0002 ] Embodiments of the present invention relate to multilayer sound absorbing ceiling panels, methods for manufacturing multilayer sound absorbing ceiling panels, ceiling systems comprising multilayer sound absorbing ceiling panels, and methods of mounting a ceiling system including sound absorbing ceiling panels.

State of the art

[ 0003 ] In the construction of commercial and residential buildings, ceiling systems of various types have been used to provide the desired acoustic characteristics. Noise absorption between rooms is required for a variety of purposes, including for the confidentiality of negotiations, as well as not to disturb people occupying neighboring rooms. Soundproofing inside a separate room is also required for a variety of purposes, including reducing sound volume levels within one specific space.

[ 0004 ] Previously, attempts have been made to improve noise reduction between adjacent rooms. However, such previous attempts have been directed either to single-layer structures or to multi-layer structures having layers that are connected to each other essentially along the entire interface between the layers. Such previous attempts were not able to resolve the question of how the interface between the layers affects the characteristics of both noise reduction and sound absorption of sound-absorbing ceiling panels. Thus, there is a need for a new multilayer sound-absorbing ceiling panel having an interface that can improve the desired acoustic characteristics.

SUMMARY OF THE INVENTION

[ 0005 ] According to some embodiments, the present invention is directed to a sound absorbing ceiling panel comprising a multilayer structure having a first layer and a second layer. The first layer comprises a first major surface and a second major surface. The second main surface of the first layer is formed by the perimeter. The second major surface of the first layer comprises a perimeter region adjacent to the perimeter of the second major surface of the first layer. The second major surface further comprises a central region defined by the perimeter of the second major surface of the first layer. The second layer comprises a first major surface and a second major surface. The first main surface of the second layer is formed by the perimeter. The first major surface of the second layer comprises a perimeter region adjacent to the perimeter of the first major surface of the second layer. The first major surface of the second layer further comprises a central region defined by the perimeter of the second major surface of the second layer. The second main surface of the first layer is bonded to the first main surface of the second layer by adhesive applied to at least one of the perimeter region of the second main surface of the first layer or the perimeter region of the first main surface of the second layer. Each of the central region of the second major surface of the first layer and the central region of the first major surface of the second layer does not contain adhesive.

[ 0006 ] According to other embodiments, the present invention is directed to a sound absorbing ceiling panel comprising a multilayer structure having a first layer and a second layer. The first layer comprises a first major surface and a second major surface. The second main surface of the first layer is formed by the perimeter. The second major surface of the first layer comprises a perimeter region adjacent to the perimeter of the second major surface of the first layer. The second major surface further comprises a central region defined by the perimeter of the second major surface of the first layer. The second layer comprises a first major surface and a second major surface. The first main surface of the second layer is formed by the perimeter. The first major surface of the second layer comprises a perimeter region adjacent to the perimeter of the first major surface of the second layer. The first major surface of the second layer further comprises a central region defined by the perimeter of the second major surface of the second layer. The second main surface of the first layer is connected to the first main surface of the second layer by a plurality of adhesive strips deposited on at least one of the perimeter region of the second main surface of the first layer or the perimeter region of the first main surface of the second layer. The plurality of adhesive strips together form a closed geometric figure that delimits the central region of the second major surface of the first layer and the central region of the first major surface of the second layer.

[ 0007 ] In other embodiments, the present invention is directed to a sound absorbing ceiling panel comprising a first layer and a second layer. The first layer comprises a first major surface, a second major surface and a side surface extending between the first and second major surfaces of the first layer. The lateral surface of the first layer intersects the second main surface of the first layer with the formation of the upper edge of the first layer. The upper edge of the first layer forms the perimeter of the second main surface. The second main surface comprises a perimeter region adjacent to the perimeter, and a central region bounded by the perimeter region. The upper edge of the first layer contains the first portion of the upper edge, the second portion of the upper edge, the third portion of the upper edge and the fourth portion of the upper edge. The second portion of the upper edge is opposite to the first portion of the upper edge. The third portion of the upper edge is ongoing between the first and second sections of the upper edge. The fourth portion of the upper edge is opposite to the third portion of the upper edge and is ongoing between the first and second sections of the upper edge. The second layer comprises a first major surface, a second major surface and a side surface extending between the first and second major surfaces of the second layer. The second major surface of the first layer is bonded to the first major surface of the second layer of at least the first adhesive strip, the second adhesive strip, the third adhesive strip and the fourth adhesive strip. The first adhesive strip is contiguous and substantially parallel to the first portion of the edge. The second adhesive strip is contiguous and substantially parallel to the second edge portion. The third adhesive strip is contiguous and substantially parallel to the third region of the edge. The fourth adhesive strip is contiguous and substantially parallel to the fourth portion of the edge.

[ 0008 ] According to further embodiments, the present invention is directed to a suspended ceiling system comprising a ceiling crate, an enclosed airspace, an indoor environment, and at least one sound absorbing ceiling panel according to the present invention. The ceiling lathing may contain many first elements and many second elements, the first and second elements intersecting, essentially at a right angle, forming many lattice openings. There is a closed airspace above the ceiling crate. Below the ceiling lathing is the indoor environment. At least one of the sound absorbing ceiling panels of the present invention is installed in one of a plurality of grating openings of the ceiling lathing.

[ 0009 ] In still other embodiments, the present invention is directed to a method of mounting a ceiling system. The method may include step a), where the support crate is installed inside the building's interior so that closed air space is formed above the support crate, and an active indoor environment is formed below the support crate. The supporting crate may contain many intersecting beams, forming many openings. In some embodiments of the present invention, the method further includes step b), in which the first ceiling panel is mounted on a support crate inside the first of the openings. The first ceiling panel may be made of sound-absorbing material, and having an upper main surface and a lower main surface, opposite to the upper main surface of the first ceiling panel. In some embodiments, the upper main surface of the first ceiling panel faces a closed airspace. According to some embodiments, the method further includes, after step b), the first sound damping layer is arranged in a freely movable relationship on top of the upper main surface of the first ceiling panel, thereby forming a first multicomponent panel having a CAC value (reducing sound wave energy) of more 37.

[ 0010 ] In other further embodiments, the present invention is directed to a method of mounting a ceiling system. The method of mounting the ceiling system may include step a), in which the support crate is installed in the interior of the building so that a closed air space is formed above the reference crate and an active indoor environment is formed below the reference crate. The supporting crate may contain many intersecting beams, forming many openings. In some embodiments of the present invention, the method further comprises step b), wherein a first ceiling panel is provided having an upper main surface and a lower main surface opposite to the upper main surface of the first ceiling panel. In some embodiments of the present invention, after step b), the method may further include step c), in which a first soundproofing layer is applied in a freely movable relationship to the upper main surface of the first ceiling panel, thereby forming a multicomponent panel having a CAC value of more than 37 In other embodiments of the present invention, after step c), the method may further include step d), in which the multi-component panel is mounted on the support cage heel inside of the first openings. The upper main surface of the first ceiling panel may face a closed airspace.

[ 0011 ] Further areas of applicability of the present invention will become apparent from the following detailed description. It should be understood that the detailed description and specific examples, while representing a preferred embodiment of the invention, are for purposes of illustration only and are not intended to limit the scope of the invention.

Brief Description of the Drawings

[ 0012 ] Features of exemplary embodiments of the present invention will be described with reference to the following drawings, where like elements are denoted in a similar manner, and in which:

[ 0013 ] FIG. 1 is a perspective view of a ceiling system according to a first embodiment of the present invention;

[ 0014 ] FIG. 2 is a side view of a portion of the ceiling system of FIG. 1 according to the present invention;

[ 0015 ] FIG. 3 is a perspective view of a ceiling panel of the ceiling system of FIG. 1 according to one embodiment of the present invention;

[ 0016 ] FIG. 4 is a side view of the ceiling panel of FIG. 3;

[ 0017 ] FIG. 5 is a sectional view of a ceiling panel drawn along line IV of FIG. 3;

[ 0018 ] FIG. 6 is an exploded perspective view of the ceiling panel of FIG. 3;

[ 0019 ] FIG. 7 is a plan view of a first layer of the ceiling panel of FIG. 3 in accordance with one embodiment of the present invention;

[ 0020 ] FIG. 8 is a top view of a first layer of the ceiling panel of FIG. 3 in accordance with another embodiment of the present invention;

[ 0021 ] FIG. 9 is a top view of a first layer of the ceiling panel of FIG. 3 in accordance with yet another further embodiment of the present invention;

[ 0022 ] FIG. 10 is a plan view of a first layer of the ceiling panel of FIG. 3 in accordance with yet another further embodiment of the present invention;

[ 0023 ] FIG. 11 is a bottom view of a second layer of the ceiling panel of FIG. 3 in accordance with one embodiment of the present invention;

[ 0024 ] FIG. 12 is a perspective view of a support battens of a system according to a second embodiment of the present invention;

[ 0025 ] FIG. 13 is a perspective view of the ceiling system using the support crate of FIG. 12 according to the present invention;

[ 0026 ] FIG. 14 is a perspective view of a multi-component panel of the ceiling system of FIG. 13 according to one embodiment of the present invention;

[ 0027 ] FIG. 15 is an exploded sectional view taken along line XV of FIG. 14;

[ 0028 ] FIG. 16 is a sectional view drawn along line XV of FIG. 14;

[ 0029 ] FIG. 17 is a side view of the support battens of FIG. 12 with ceiling panels mounted in openings according to the present invention;

[ 0030 ] FIG. 18 is a side view of the ceiling system of FIG. 13 in a partially mounted configuration according to the present invention;

[ 0031 ] FIG. 19 is a side view of the ceiling system of FIG. 13 according to one embodiment of the present invention;

[ 0032 ] FIG. 20 is a side view of the ceiling system of FIG. 13 according to yet another embodiment of the present invention; and

[ 0033 ] FIG. 21 is a side view of the ceiling system of FIG. 13 in a partially mounted configuration according to yet another embodiment of the present invention.

[ 0034 ] All of the drawings are schematic and not necessarily drawn to scale. Parts marked with the code number of a position in one figure can be considered as the same parts where they appear in other figures without a numerical designation, for the sake of brevity, unless specifically indicated by a different part number and are described here.

Description of Embodiments

[ 0035 ] The following description of the preferred embodiment (s) is only exemplary in nature and is not intended to in any way limit the invention, its use, or its uses.

The description of illustrative embodiments according to the principles of the present invention is intended to be read in connection with the accompanying drawings, which should be considered as part of the entire written presentation. In the description of embodiments of the invention disclosed herein, any reference to a direction or orientation is for convenience of description only and is not intended to limit the scope of the present invention in any way. Relative position terms such as “lower”, “upper”, “horizontal”, “vertical”, “above”, “under”, “up”, “down”, “upper” and “lower”, and also its derivatives (eg, “horizontally”, “down”, “up”, etc.) should be construed as referring to the orientation as described later or as shown in the figure under discussion. These relative positional terms are for convenience of description only and do not require the device to be executed or to operate in a specific orientation, unless specifically stated otherwise. Terms such as “attached”, “attached”, “connected”, “conjugated”, “interconnected”, and the like, imply a relationship in which structures are fixed or attached to each other either directly or indirectly through intermediate structures, as well as both movable and rigidly fixed attachments or interconnections, unless clearly described otherwise. Moreover, features and advantages of the invention are illustrated by reference to exemplary embodiments. Accordingly, the invention should definitely not be limited to such exemplary embodiments illustrating some possible non-limiting combinations of features that may be present individually or in other combinations of features; wherein the scope of the invention is defined by the appended claims.

[ 0036 ] Numerous ideas of the invention are described herein and are distinguished from each other using headings in the following description. More specifically, figures 1-11 relate to the first concept of the invention, and figures 12-21 relate to the second concept of the invention. The first and second concepts of the invention should be considered separately from each other. It is possible that there may be conflicting formulations or terms used in the description of the first and second concepts of the invention. For example, it is possible that in the description of the first concept of the invention, a specific term can be applied having one meaning or definition, and that in the description of the second concept of the invention the same term can be used having different meaning or definition. In the case of such a contradictory formulation, reference should be made to the disclosure of the relevant concept of the invention under discussion. Similarly, a description section describing a particular claimed idea of the invention should be used to interpret the claimed wording when necessary.

I. Ceiling panel having adhesive bonded layers

[ 0037 ] As shown in Figures 1 and 2, one embodiment of the present invention is directed to a ceiling system 1 comprising a ceiling crate 5 and at least one sound-absorbing ceiling panel 20. Closed air space 2 may be present above ceiling crate 5. Closed air space 2 is a space that is present above the sound-absorbing ceiling panels 20 and above the ceiling crate 5, and below the ceiling or subfloor 4 located above the adjacent interfloor roofing in the building. The enclosed airspace 2 creates a place for technical communications laid through the building, for example, heating, ventilation and air conditioning (HVAC), plumbing, data lines, etc. Below the sound-absorbing ceiling panels 20 and below the ceiling crate 5 may be the environment 3 in the room. The environment 3 in the room is the space occupied by the occupants of the room, for example, the environments 3 in the room in the office building would be the space occupied by desks, office workers, computers, etc. The combination of ceiling lathing 5 and sound-absorbing ceiling panels 20 can act as an acoustic and aesthetic screen between the indoor environment 3 and the enclosed airspace 2, as well as the soundproof layer for noise that occurs in the indoor environment 3, as discussed here.

[ 0038 ] The ceiling lath 5 may comprise a plurality of first elements 6 extending parallel to each other. In some embodiments, the ceiling lath 5 may further comprise a plurality of second elements 7 that are extending parallel to each other. The plurality of first elements 6 may intersect the plurality of second elements 7 to form a lattice structure having a plurality of lattice openings 8. In some embodiments, the plurality of first elements 6 intersect the plurality of second elements 7 substantially at right angles, thereby forming rectangular lattice openings 8. Rectangular grating openings 8 may be square or any other shape that has aesthetic or functional significance.

[ 0039 ] As shown in FIG. 2, each of the plurality of first elements 6 and each of the plurality of second elements 7 may comprise T-shaped slats having a horizontal shelf 10 and a rib 11. Closed airspace 2 is located above the T-shaped slats and surrounding indoor environment 3 is located below the T-rails.

[ 0040 ] The ceiling system 1 according to the present invention comprises at least one sound-absorbing ceiling panel 20 that is mounted on the ceiling crate 5 inside one of the plurality of grating openings 8. The ceiling system 1 may include a plurality of sound-absorbing ceiling panels 20 mounted on the ceiling crate 5, each of the plurality of sound-absorbing ceiling panels 20 being laid inside one of the plurality of grating openings 8. In some embodiments, the implementation is something other than sound absorption ceiling panels 20 (for example, lighting fixtures or a vent channel outlet) can be mounted on the ceiling crate 5 inside at least one of the grating openings 8 (not shown).

[ 0041 ] As illustrated by figures 3-6, the sound absorbing ceiling panel 20 may comprise a first layer 100 and a second layer 200. In some embodiments of the present invention, the sound absorbing ceiling panel 20 may further comprise a plaster canvas 300. As shown in FIG. 2, the sound absorbing ceiling panel 20 can be installed on the ceiling lath 5 of the ceiling system 1 so that the first layer 100 of the sound absorbing ceiling panel 20 is adjacent to the indoor environment 3, and the second layer 200 is adjacent to the enclosed airspace 2.

[ 0042 ] As shown in figures 4-6, the first layer 100 of the sound-absorbing ceiling panel 20 comprises a first main surface 101 and a second main surface 102. The first layer 100 further comprises a side surface 103 extending between the first main surface 101 and the second main surface 102. The side surface 103 of the first layer 100 intersects the first main surface 101 of the first layer with the formation of the lower edge 107 of the first layer 100. The side surface 103 of the first layer 100 intersects the second main surface 102 of the first layer with the lower edge 104 of the first layer 100.

[ 0043 ] In some embodiments of the present invention, the side surface 103 of the first layer 100 may include a stepped profile having an upper side surface 103b and a lower side surface 103a. The lower side surface 103a of the first layer intersects the first main surface 101 of the first layer 100 to form the lower edge 107 of the first layer 100. The upper side surface 103b of the first layer intersects the second main surface 102 of the first layer 100 to form the upper edge 104.

[ 0044 ] The intermediate surface 108 is extending between the lower side surface 103a and the upper side surface 103b in a direction that is substantially perpendicular to the side surface 103, the upper side surface 103a and the lower side surface 103b of the first layer 100. In some embodiments, the intermediate surface 108 is oriented in the same direction as the first major surface 101 of the first layer 100. In other embodiments, the intermediate surface 108 is oriented in the direction NIJ at an angle to the first major surface 101.

[ 0045 ] The stepped profile comprises a combination of an upper side surface 103b, an intermediate surface 108, and a lower side surface 103a. According to this embodiment, the second main surface 102 of the first layer 100 has an area that is larger than the area of the first main surface 101 of the first layer 100. In some embodiments, the surface area of the second main surface 102 of the first layer is equal to the sum of the area of the first main surface 102 and the area the intermediate surface 108 of the first layer 100. As shown in figure 2, after the sound-absorbing ceiling panel 20 has been mounted on the ceiling crate 5, the intermediate surface 108 p the first layer 100 may adjoin at least a portion of the upper surface of the horizontal shelf 10 of at least one of the first elements 6 or the second element 7 of the ceiling crate 5. The interface between the intermediate surface 108 of the first layer and the upper surface of the horizontal shelf 10 allows you to create support for the sound-absorbing ceiling panel 10 in fully assembled position.

[ 0046 ] As shown in Figs. the second main surface 102. The second main surface 102 of the first layer 100 may further comprise a central region 106, which is limited by the perimeter region 105 of the second main surface 102 of the first layer 100. Figures 6-10 show non-limiting embodiments a dashed border 170 between the central region 106 and the perimeter region 105 of the first layer 100. In figures 6-10, the dashed border 170 is rectangular; however, the present invention is not limited to the shape of the dashed border 170 having any particular shape (e.g., polygon, circle, ellipse, non-geometric shapes, etc.).

[ 0047 ] The upper edge 104 of the first layer 100 comprises a first upper edge portion 120, a second upper edge portion 121, a third upper edge portion 122 and a fourth upper edge portion 123. The second upper edge portion 121 is opposite the first upper edge portion 120, and the fourth upper edge portion 123 is opposite the third upper edge portion 122. The third upper edge portion 122 is ongoing between the first upper edge portion 120 and the second upper edge portion 121. The fourth upper edge portion 123 is ongoing between the first upper edge portion 120 and the second upper edge portion 121.

[ 0048 ] In some embodiments, the third upper edge portion 122 extends perpendicularly to both of the first upper edge portion 120 and the second upper edge portion 121. In some embodiments, the fourth upper edge portion 123 extends substantially perpendicular to both of the first upper edge portion 120 and the second upper edge portion 121. In some embodiments, the first upper edge portion 120 extends substantially parallel to the second upper edge portion 121.

[ 0049 ] In some embodiments, the step profile of the first layer 100 may be present on each of the side surfaces 103 of the first layer 100. In other embodiments, the step profile may be present on only two opposite side surfaces 103 of the first layer 100. For example, the side surfaces 103 of the first layer 100, which form a first upper edge portion 120 and a second upper edge portion 121, may include a stepped profile, while the side surfaces 103 of the first layer that form the third portion to 122 of the upper edge and the fourth section 123 of the upper edge do not contain a stepped profile. In one preferred embodiment, the first layer 100 is closer to the sound source, for example, to the environment 3 in the room.

[ 0050 ] In some embodiments, the first layer 100 may consist of fiberglass, mineral felt (such as rock wool, slag, or a combination thereof), synthetic polymers (such as foamed melamine, foamed polyurethane, or a combination thereof), mineral wool, silicate cotton wool, or combinations thereof. In some embodiments, the first layer 100 is made of fiberglass. In some embodiments, the first layer 100 advantageously provides a sound absorption function, and preferred materials for performing the sound absorption function for the first layer 100 include fiberglass. The first layer provides an NRC (Noise Reduction Coefficient) of the ceiling of 0.7 or more, preferably 0.9 or more. NRC is further described below. In some non-limiting embodiments of the present invention, the first layer may be selected from Optima ^™ and Lyra ^™ fiberglass cladding panels manufactured by Armstrong (Armstrong World Industries, Inc.) —for example, Lyra 8372 or Optima 3251.

[ 0051 ] As shown in figures 3-6, the second layer 200 comprises a first main surface 201 and a second main surface 202. The second layer 200 may further comprise a side surface 203 extending between the first main surface 201 of the second layer 200 and the second main surface 202 of the second layer 200. The lateral surface 203 of the second layer 200 intersects the second major surface 202 of the second layer 200 to form the upper edge 204 of the second layer 200. The lateral surface 203 of the second layer 200 intersects the first major surface 201 of the second c oya to form the bottom edge 207 of the second layer 200.

[ 0052 ] As shown in figures 3 and 6, the upper edge 204 of the second layer 200 forms the perimeter of the second main surface 202 of the second layer 200. As shown in figure 11, the lower edge 207 of the second layer 200 forms the perimeter of the first main surface 201 of the second layer 200. Lower the edge 207 of the second layer 200 comprises a first lower edge portion 220, a second lower edge portion 221, a third lower edge portion 222 and a fourth lower edge portion 223. The second lower edge portion 221 is opposite the first lower edge portion 220, and the fourth lower edge portion 223 is opposite the third lower edge portion 222. The third lower edge portion 222 is ongoing between the first lower edge portion 220 and the second lower edge portion 221. The fourth lower edge portion 223 is ongoing between the first lower edge portion 220 and the second lower edge portion 221.

[ 0053 ] As shown in figures 4-6, the side surface 203 of the second layer 200 may further comprise an upper side surface 203b and a lower side surface 203a. The upper side surface 203b of the second layer 200 intersects with the second main surface 202 of the second layer 200, forming the upper edge 204 of the second layer 200. The lower side surface 203a of the second layer 200 intersects with the first main surface 201 of the second layer 200 to form the lower edge 207 of the second layer 200.

[ 0054 ] In some embodiments, the upper side surface 203b of the second layer 200 is in the same plane as the lower side surface 203a of the second layer 200 so that the area of the second main surface 202 of the second layer 200 is equal to the area of the first main surface 201 of the second layer. In some embodiments, the upper side surface 203b of the second layer 200 is slanted inwardly at an angle of 30, 45, or 60 degrees with respect to the lower side surface 203a of the second layer so that the area of the second main surface 202 of the second layer 200 is smaller than the area of the first main surface 201 of the second layer . In a preferred embodiment, the second layer 200 faces the opposite side of the sound source, that is, faces the enclosed airspace 2.

[ 0055 ] In some embodiments, the second layer 200 may comprise fiberglass, mineral felt (such as rock wool, slag, or a combination thereof), synthetic polymers (such as foamed melamine, foamed polyurethane, or a combination thereof), mineral wool, silica wool , gypsum, or combinations thereof. In some embodiments, the second layer 200 is made of mineral felt. In some embodiments, the second layer 200 advantageously provides a sound attenuation function, and preferred materials for performing the sound attenuation function for the second layer 200 include mineral felt. The second layer 200 provides a CAC (Ceiling Attenuation Class) of at least 35, preferably at least 40. CAC is further described below. In some non-limiting embodiments of the present invention, the second layer may be selected from the cladding panels School Zone ^TM and Calla ^TM Armstrong manufactured - for example, School Zone 1810.

[ 0056 ] As shown in FIG. 5, the sound absorbing ceiling panel 20 is formed by arranging the first main surface 201 of the second layer 200 adjacent to the second main surface 102 of the first layer 100, thereby creating an interface between the first layer 100 and the second layer 200. More specifically, the surface A partition exists between the first main surface 201 of the second layer and the second main surface 102 of the first layer 100.

[ 0057 ] The first layer 100 can be attached to the second layer 200 of adhesive 50. More specifically, the second main surface 102 of the first layer 100 can be connected to the first main surface 201 of the second layer 200 of adhesive 50 to create cohesively bonded first and second layers 100, 200 with the formation of a cohesive multilayer material. The second main surface 102 of the first layer 100 can be connected to the first main surface 201 of the second layer 200 of adhesive 50 so that the perimeter and upper edge 104 of the first layer 100 are aligned with the perimeter and lower edge 207 of the second layer 200. In other embodiments, the first layer 100 can be attached to the second layer 200 by a mechanical connecting element.

[ 0058 ] In some embodiments, the second main surface 102 of the first layer 100 and the first main surface 201 of the second layer 200 may be bonded with adhesive 50 so that the first upper edge 120 of the first layer 100 is flush with the first lower edge 220 of the second layer 200; the second upper edge 121 of the first layer 100 is flush with the second lower edge 221 of the second layer 200; a third upper edge 122 of the first layer 100 is flush with the fourth lower edge 223 of the second layer; and the fourth upper edge 123 of the first layer 100 is aligned with the third lower edge 222 of the second layer 200.

[ 0059 ] In some embodiments, the first layer 100 and the second layer 200 may be connected so that the perimeter and upper edge 104 of the first layer 100 are not aligned with the perimeter and lower edge 207 of the second layer 200 (not shown). More specifically, the first upper edge 120 of the first layer 100 may extend obliquely to the first lower edge 220 of the second layer 200. The second upper edge 121 of the first layer 100 may extend obliquely to the second lower edge 221 of the second layer 200. The third upper edge 122 of the first layer may extend obliquely to the fourth lower edge 223 of the second layer 200. The fourth upper edge 123 of the first layer may extend obliquely to the third lower edge 222 of the second layer 200.

[ 0060 ] According to another embodiment of the present invention, the area of the first main surface 201 of the second layer 200 may be larger than the area of the second main surface 102 of the first layer 100, thereby leaving at least a portion of the first main surface 201 of the second layer 200 open (not pictured). The exposed portion of the first main surface 201 of the second layer 200 creates a step between the side surface 103 of the first layer 100 and the side surface 203 of the second layer 200. According to this embodiment, the perimeter of the first layer 100 is smaller than the perimeter of the second layer 200. A portion of the first main surface 201 of the second layer 200, which remains open by a step between the side surfaces 103, 104, may adjoin a portion of the upper surface of the horizontal shelf 10 of the first and second elements 6, 7 after sound absorption the ceiling panel 20 is mounted on the ceiling crate 5, like the intermediate surface 108 of the first layer 100, can abut the horizontal shelf 10 of the first and second elements 6, 7 of the ceiling crate 5. According to this embodiment, the first layer 100 has a side surface 103, which may comprise or may not contain a stepped profile of the lower side surface 103a, the intermediate surface 108 and the upper side surface 103b. In other embodiments, the implementation of the area of the first main surface 201 of the second layer 200 may be smaller than the area of the second main surface 102 of the first layer 100.

[ 0061 ] Each of the side surfaces 103 of the first layer 100 can extend in the same plane with each of the side surfaces 203 of the second layer 200. More specifically, each of the sections 103b of the upper edge of the first layer 100 can be located in the same plane with each of the sections 203a of the lower the edges of the second layer 100.

[ 0062 ] Adhesive 50 may be applied to at least one of the perimeter region 105 of the second main surface 102 of the first layer 100 or the perimeter region 205 of the first main surface 201 of the second layer 200. The Central region 106 of the second main surface 102 of the first layer is essentially not contains no adhesive 50 that would connect the center region 106 of the second major surface 102 of the first layer to the first major surface 201 of the second layer 200. The central region 206 of the first major surface 201 of the second layer 200 essentially does not contain any an adhesive that would connect the center region 206 of the first major surface 201 of the second layer 200 to the second major surface 102 of the first layer 100.

[ 0063 ] In some embodiments, the central region 106 of the second major surface 102 of the first layer 100 is in free-motion contact with the first major surface 201 of the second layer 200. In some embodiments, the central region 206 of the first major surface 201 of second layer 200 is in free-motion contact with the second the main surface 102 of the first layer 100. The interface between the first main surface 201 of the second layer 200 and the second main surface 102 of the first layer 100 essentially does not contain ive within the central region 106 of the first layer and the central region 206 of the second layer.

[ 0064 ] In some embodiments, the first layer 100 and the second layer 200 are connected by a mechanical connecting element (eg, needle stitching or clamps), in addition to or alternatively to adhesive 50. In some embodiments, the central region 106 of the first layer 100 is not in physical contact with the central region 206 of the second layer 200.

[ 0065 ] According to the present invention, the adhesive 50 can be any adhesive that provides structural integrity to the multilayer sound-absorbing panel 20 having the first and second layers 100, 200 connected so that the sound-absorbing ceiling panel 20 can be processed without separating the first and second layers 100, 200, for example, even when a certain section or sections of the multilayer sound-absorbing panel 20 is cut for installation. Suitable adhesives include aqueous adhesives and solvent based adhesives, including adhesives based on polyvinyl acetate, urethane, acrylates and polyesters. Adhesives may be a hot melt adhesive, contact adhesive or adhesive for acoustic systems. The adhesive may be applied in the form of dots, continuous strips or discontinuous strips to one or many of the perimeter areas 105, 205 of the first and second layers 100, 200 of the multilayer sound-absorbing panel 20, as is further discussed herein.

[ 0066 ] According to some embodiments of the present invention, the adhesive 50 applied to at least one of the perimeter region 105 of the second main surface 102 of the first layer 100 or the perimeter region 205 of the first main surface 201 of the second layer 200 contains, for example, a plurality of adhesive strips. In other embodiments, the adhesive is applied as a pattern to minimize the contact area between the first and second layers occupied by the applied adhesive. For example, an adhesive is applied as a dot to each of the four corners of the perimeter area of a rectangular panel.

[ 0067 ] As shown in FIGS. 6-10, the plurality of adhesive strips may comprise a first adhesive strip 130, a second adhesive strip 131, a third adhesive strip 132, a fourth adhesive strip 133. Each of the first adhesive strip 130, a second adhesive strip 131, and a third adhesive strips 132 and fourth adhesive strip 133 independently may be a continuous or discontinuous adhesive strip. Each of the first adhesive strip 130, the second adhesive strip 131, the third adhesive strip 132 and the fourth adhesive strip 133 may independently be straight or curved.

[ 0068 ] The first adhesive strip 130 may extend adjacent to the first portion 120 of the upper edge of the first layer 100. The second adhesive strip 131 may extend adjacent to the second portion 121 of the upper edge of the first layer 100. The third adhesive strip 132 may extend adjacent to the third portion 122 of the upper edge the first layer 100. The fourth adhesive strip 133 may extend adjacent to the fourth portion 123 of the upper edge of the first layer 100. According to this embodiment, the first adhesive strip 130, the second adhesive I strip 131, the third adhesive strip 132 and the fourth adhesive strip 133, in each case independently, can extend to the corresponding first portion 120 of the upper edge, second portion 121 of the upper edge, third portion 122 of the upper edge and fourth portion 123 of the upper edge obliquely at an angle or essentially parallel.

[ 0069 ] In non-limiting embodiments, the first adhesive strip 130 may extend adjacent to the first portion 220 of the lower edge of the second layer 200. The second adhesive strip 131 may extend adjacent to the second portion 221 of the lower edge of the second layer 200. The third adhesive strip 132 may extend adjacent to the third portion 222 of the lower the edges of the second layer 200. The fourth adhesive strip 133 may extend adjacent to the fourth portion 223 of the lower edge of the second layer 200. According to this embodiment, the first adhesive strip 130, second the third adhesive strip 131, the third adhesive strip 132 and the fourth adhesive strip 133 can, in each case, independently extend to the respective first portion 220 of the lower edge 220, second portion 221 of the lower edge, third portion 222 of the lower edge and fourth portion 223 of the lower edge obliquely below angle or essentially parallel.

[ 0070 ] As shown in figures 7 and 8, the first adhesive strip 130 may be located at a first distance D ₁ from the first portion 120 of the upper edge of the first layer 100. The second adhesive strip 131 may be located at a second distance D ₂ from the second portion 121 of the upper the edges of the first layer 100. The third adhesive strip 132 may be located at a third distance D ₃ from the third portion 122 of the upper edge of the first layer 100. The fourth adhesive strip 133 may be located at a fourth distance D ₄ from the fourth portion 123 of the upper edge of the first layer 100.

[ 0071 ] In some embodiments, the first distance D ₁ , the second distance D ₂ , the third distance D ₃ , and the fourth distance D ₄ , in each case independently, vary from about 1/8 inch to about 5/8 inch (3.2 -15.9 mm). In some embodiments, the first distance D ₁ , the second distance D ₂ , the third distance D ₃ , and the fourth distance D ₄ , in each case independently, vary from about 1/4 inch to about 1/2 inch (6.35-12, 7 mm). In some embodiments, the first distance D ₁ , the second distance D ₂ , the third distance D ₃ , and the fourth distance D ₄ are about 3/8 inch (9.5 mm).

[ 0072 ] The first adhesive strip 130 may be located at a fifth distance D ₅ from the dashed border 170 of the central region 106. The second adhesive strip 131 may be located at the sixth distance D ₆ from the dashed border 170 of the central region 106. The third adhesive strip 132 may be located at a seventh distance D ₇ from the dashed border 170 of the central region 106. A fourth adhesive strip 133 can be located at an eighth distance D ₈ from the dashed border 170 of the central region 106.

[ 0073 ] In some embodiments, the fifth distance D ₅ , the sixth distance D ₆ , the seventh distance D ₇ and the eighth distance D ₈ , in each case independently, vary from about 0 inches to about 5/8 inches (15.9 mm). In some embodiments, the fifth distance D ₅ , the sixth distance D ₆ , the seventh distance D ₇ and the eighth distance D ₈ , in each case independently, vary from about 1/8 inch to about 1/2 inch (3.2-12.7 mm). In some embodiments, the fifth distance D ₅ , the sixth distance D ₆ , the seventh distance D ₇ and the eighth distance D ₈ are about 0 inches or about 3/8 inches (9.5 mm).

[ 0074 ] According to embodiments, when the fifth distance D ₅ , the sixth distance D ₆ , the seventh distance D ₇ and the eighth distance D ₈ are independently 0 inches, the central region 106 is directly bounded by at least one of the first adhesive strip 130, the second adhesive strips 131, a third adhesive strip 132 and a fourth adhesive strip 133.

[ 0075 ] The first adhesive strip 130, the second adhesive strip 131, the third adhesive strip 132 and the fourth adhesive strip 133 may, in each case, be independently applied to at least one of the first major surface 201 of the second layer 200 or the second major surface 102 of the first layer 100 with a width of from about 1/4 inch to about 1/2 inch (6.35-12.7 mm). The first adhesive strip 130, the second adhesive strip 131, the third adhesive strip 132 and the fourth adhesive strip 133 can in each case be applied to at least one of the first main surface 201 of the second layer 200 or the second main surface 102 of the first layer 100 with a width of about 3 / 8 inches (9.5 mm).

[ 0076 ] Depending on the width of the first, second, third and fourth adhesive strips 130, 131, 132 and 133, and the first, second, third, fourth, fifth, sixth, seventh and eighth distances D ₁ , D ₂ , D ₃ , D ₄ , D ₅ , D ₆ , D ₇ and D ₈ , the central region 106 of the first layer 100 can occupy between about 70% to about 99% of the surface area of the second main surface 102 of the first layer; the same percentage of the surface area is applicable to the central region 206 the second layer 200. In some embodiments, the implementation of the Central region 106 of the first layer 100 may occupy the inter from about 85% to about 95%, for example, about 95%, the surface area of the second main surface 102 of the first layer 100, the same percentage of the surface area is applicable to the central region 206 of the second layer 200.

[ 0077 ] The first adhesive strip 130, the second adhesive strip 131, the third adhesive strip 132 and the fourth adhesive strip 132 can in each case be applied to at least one of the first major surface 201 of the second layer 200 or the second major surface 102 of the first layer 100 s thickness from about 0.01 inches to about 0.25 inches (0.25-6.35 mm). The first adhesive strip 130, the second adhesive strip 131, the third adhesive strip 132 and the fourth adhesive strip 132 may, in each case, be independently applied to at least one of the first main surface 201 of the second layer 200 or the second main surface 102 of the first layer 100 s about 0.03 inches thick (0.76 mm).

[ 0078 ] In some embodiments, the adhesive 50 is applied to at least one of the corners of the perimeter region 105 of the second main surface 102 of the first layer 100 or the perimeter region 205 of the first main surface 201 of the second layer 200.

[ 0079 ] The first, second, third, fourth, fifth, sixth, seventh and eighth distances D ₁ , D ₂ , D ₃ , D ₄ , D ₅ , D ₆ , D ₇ and D ₈ described in relation to the central region 106 of the second the main surface 102 of the first layer 100, are also applicable to the Central region 206 of the first main surface 201 of the second layer 200.

[ 0080 ] In some embodiments, the adhesive 50 is applied to at least one of the first major surface 201 of the second layer 200 or the second major surface 102 of the first layer 100 so that a total of about 10 g to about 10 g are present in the sound absorbing ceiling panel 20 30 g of adhesive 50. In some embodiments of the present invention, adhesive 50 is applied to at least one of the first main surface 201 of the second layer 200 or the second main surface 102 of the first layer 100 so that in the sound-absorbing ceiling of the panel 25, a total of about 15 g to about 30 g of adhesive 50 is present. In some embodiments of the present invention, adhesive 50 is applied to at least one of the first main surface 201 of the second layer 200 or the second main surface 102 of the first layer 100 so that generally applied about 20 g.

[ 0081 ] As demonstrated by the non-limiting embodiments of FIGS. 7 and 8, the first adhesive strip 130, the second adhesive strip 131, the third adhesive strip 132 and the fourth adhesive strip 133 in each case can be a continuous adhesive strip that together defines and forms a closed a geometric figure that defines a central region 106 of a second major surface 102 of the first layer 100.

[ 0082 ] As demonstrated by the non-limiting embodiment of FIG. 9, the first adhesive strip 130, the second adhesive strip 131, the third adhesive strip 132 and the fourth adhesive strip 133 may in each case be a continuous adhesive strip in which the first adhesive strip 130, the second adhesive strip 131, third adhesive strip 132 and fourth adhesive strip 133 of this embodiment are in each case discontinuous with respect to each other

[ 0083 ] As demonstrated by the non-limiting embodiment of FIG. 10, the first adhesive strip 130, the second adhesive strip 131, the third adhesive strip 132 and the fourth adhesive strip 133 may intersect in each case, however, each of the first adhesive strip 130, the second adhesive strip 131, the third adhesive strip 132 and the fourth adhesive strip 133 may be a discontinuous adhesive strip.

[ 0084 ] In one embodiment, shown in FIG. 7, the length of the first adhesive strip 130 may be equal to the length of the first upper edge portion 120, the length of the second adhesive strip 131 may be equal to the length of the second upper edge portion 121, the length of the third adhesive strip 132 may be equal to the length of the third portion 122 of the upper edge, and the length of the fourth adhesive strip 130 may be equal to the length of the fourth portion 123 of the upper edge. In this embodiment, the first adhesive strip 130 and the third adhesive strip 132 overlap, the third adhesive strip 132 and the second adhesive strip 131 overlap, the second adhesive strip 131 and the fourth adhesive strip 133 overlap, and the fourth adhesive strip 133 and the first adhesive strip 130 overlap.

[ 0085 ] In one embodiment, shown in figure 8, the first adhesive strip 130 may have a length that is less than the length of the first section 120 of the upper edge, the second adhesive strip 131 may have a length that is less than the length of the second section 120 of the upper edge, the third adhesive strip 132 may have a length that is less than the length of the third upper edge portion 122, and the fourth adhesive strip 130 may have a length that is shorter than the length of the fourth upper edge portion 123. In this embodiment, each of the first adhesive strip 130, the second adhesive strip 131, the third adhesive strip 132 and the fourth adhesive strip 133 are contacted to form a closed geometric shape.

[ 0086 ] Adhesive 50 may be applied to the first main surface 201 of the second layer using the same method, the central region 106 of the first layer corresponding to the central region 206 of the second layer 200; the dashed border 170 of the first layer corresponds to the dashed border 270 of the second layer 270; the first, second, third and fourth sections 220, 221, 222 and 223 of the lower edge of the second layer 200 correspond to the first, second, third and fourth sections 120, 121, 122 and 123 of the upper edge of the first layer 100; and the first, second, third and fourth adhesive strips 130, 131, 132 and 133 can be applied adjacent to the corresponding first, second, third and fourth sections 220, 221, 222 and 223 of the lower edge of the second layer 200.

[ 0087 ] In some embodiments of the present invention, sound absorbing ceiling panels 20 according to the present invention can be formed using a continuous process that comprises passing a first layer 100 along a conveyor along a longitudinal direction, the second main surface 102 of the first layer 100 being open upward. When the first layer 100 is passed along the machine direction, the second main surface 102 is passed under the first adhesive block, which simultaneously applies the first adhesive strip 130 and the second adhesive strip (not shown). Then, the first layer 100 can be rotated 90 degrees and passed along the machine direction under the second adhesive block, which simultaneously applies the third adhesive strip 132 and the fourth adhesive strip 133 (not shown). The continuous process is also suitable for applying a first adhesive strip 130, a second adhesive strip 131, a third adhesive strip 132 and a fourth adhesive strip 133 on a first face 201 of the second layer 200.

[ 0088 ] After applying the first adhesive strip 130, the second adhesive strip 131, the third adhesive strip 132 and the fourth adhesive strip 133 to at least one of the second main surface 102 of the first layer 100 and the first main surface 201 of the second layer 200, the second main surface 102 the first layer 100 is connected to the first main surface 201 of the second layer 100.

[ 0089 ] Pressure may be applied to at least one of the second main surface 202 of the second layer 200 or the first main surface 101 of the first layer between the first and second layers 100. Heat may also be applied to the first layer 100 and the second layer 200 to ensure proper adhesive bonding between the first layer 100 and the second layer 200. Optionally, a plaster canvas 300 may later be applied to the first main surface 101 of the first layer 100.

[ 0090 ] In non-limiting embodiments, the ceiling panel 20 may be round, oval or polygonal, for example, rectangular (including square and non-square shapes), or triangular. According to these embodiments, the first layer 100 and the second layer 200 together occupy the entire ceiling panel 20. In some embodiments, the polygonal ceiling panels 20 may have rounded or sharp corners.

[ 0091 ] According to some embodiments, the ceiling panel 20 is substantially rectangular, the term “substantially rectangular” means a shape having four edges and four vertices. Each vertex forms an angle ranging from 88 to 92 degrees, alternatively about 90 degrees. Four edges either have the same length (square), or have a first pair of edges that are parallel to each other and extend to the first length, and a second pair of edges that are parallel to each other and have a second length, with the first and second lengths not equal (non-square) . In some embodiments, the first pair of edges comprises a first upper edge portion 120 and a second upper edge portion 121, and a second pair of edges comprises a third upper edge portion 122 and a fourth upper edge portion 123.

[ 0092 ] In some embodiments, the ceiling panel 20 is rectangular, with the first pair of edges and the second pair of edges in each case having a length of 2 feet (0.61 m). In some embodiments, the ceiling panel 20 has an overall thickness ranging from about 1.25 inches to about 2 inches (31.7-50.8 mm), alternatively about 1.75 inches (44.5 mm).

[ 0093 ] The sound absorbing ceiling panel according to the present invention exhibits certain acoustic performance characteristics. More specifically, the American Society for Testing and Materials (ASTM) has developed test method E1414 to standardize the measurement of airborne sound attenuation between environments 3 in rooms that share a common enclosed airspace 2. The indicator derived from this measurement standard , is known as ceiling sound attenuation class (CAC). Ceiling materials and systems with high CAC values have a greater ability to reduce the transmission of sound through closed airspace 2, that is, the function of attenuation of sound.

[ 0094 ] Another important characteristic of materials of a sound-absorbing ceiling panel is the ability to reduce the amount of reflected sound in a room. One measurement of this ability is an estimate of Noise Reduction Ratio (NRC) as described in ASTM C423 Test Method. This estimate is the average value of sound absorption coefficients in four third octave frequency bands (250, 500, 1000 and 2000 Hz), where, for example, a system with an NRC value of 0.90 has an absorption capacity of approximately 90% of an ideal absorber. A higher NRC value indicates that the material provides better sound absorption and reduces sound reflection - the sound absorption function.

[ 0095 ] Previous attempts to develop a ceiling panel having elevated CAC values (that is, a desirable reduction in sound transmission through enclosed airspace 2) have been associated with a simultaneous reduction in sound absorption (NRC), which has resulted in an increased amount of sound reflected within a given environment 3 indoors. It was found that using the sound-absorbing ceiling panel 20 according to the present invention, an increase in the CAC characteristic can be achieved without significantly losing the NRC characteristic.

[ 0096 ] More specifically, by bonding together the first layer 100 and the second layer 200 using an adhesive 50 that is applied only to at least one of the perimeter regions 105, 205 of the first layer 100 or the second layer 200, at the same time as By preserving the central regions 106, 206 of the first layer 100 and the second layer 200 substantially free of adhesive 50, it was found that the resulting sound-absorbing ceiling panel 20 will exhibit a clear improvement in CAC performance, while avoiding a significant deleterious change in character NRC. According to the present invention, the apparent change in the NRC characteristic is a loss of NRC value less than or equal to (≤) 0.05.

[ 0097 ] More specifically, the sound absorbing ceiling panel 20 according to the present invention has a CAC value of 35 or more, preferably 40 or more, and an NRC value of 0.7 or more, preferably 0.9 or more. The first layer 100 may have an NRC value of at least 0.80, alternatively at least 0.90. The second layer 100 may have an NRC value of at least 0.65, and a CAC value of at least 35.

[ 0098 ] In some embodiments, the sound absorbing ceiling panel 20 according to the present invention is formed using a second layer 200, which has a greater CAC value than the CAC value of the first layer 100. The second layer 200 may also have an NRC value that is less than the NRC value the first layer 200. The first layer 100 may be a sound-absorbing layer that absorbs sound within a separate indoor environment 3. The second layer 200 may be a noise suppressing layer that provides sound insulation between adjacent environments 3 in rooms that share a closed airspace 2.

[ 0099 ] According to the present invention, when the sound absorbing ceiling panel 20 has been correctly mounted in the ceiling lath 5 of the ceiling system 1, the second main surface 202 of the second layer 200 faces the enclosed air space 2 of the ceiling system 1.

[ 00100 ] The invention will be described in more detail by way of specific examples. The following examples are provided for illustrative purposes, and are not intended to limit the invention in any way.

Examples

[ 00101 ] Examples were made using a first layer consisting of fiberglass measuring 24 inches × 24 inches × 1 inch (610 mm × 610 mm × 25.4 mm). Examples were made using a second layer consisting of mineral felt measuring 24 inches × 24 inches × 0.75 inches (610 mm × 610 mm × 19 mm). The first and second layers have the following acoustic characteristics:

Fiberglass first layer Mineral Felt Second Layer NRC value 0.95 NRC value 0.70 SAS value No data SAS value 40

[ 00102 ] For the purpose of the present invention, each of the individual fiberglass ceiling panels has the same initial acoustic characteristic. For the purpose of this invention, each of the individual sound attenuating layers of mineral felt has the same initial acoustic characteristic.

[ 00103 ] Examples 1 and 2 were made by gluing together the first and second layers using polyvinyl acetate as an adhesive. The adhesive was applied inside the perimeter of the first layer in the form of the first, second, third and fourth adhesive strips. Each of the adhesive strips was adjacent to the corresponding first, second, third, and fourth upper edges of the first layer at a displacement distance of 3/8 inch (9.5 mm). Each adhesive strip was applied with a width of 3/8 inch (9.5 mm). In each of Examples 1 and 2, a total of 20 g of adhesive was used. The central regions in Examples 1 and 2 were substantially free of adhesive. Each of the central regions of the first and second layers in each case had dimensions of about 22.5 inches × 22.5 inches (571.5 × 571.5 mm) (506.25 square inches) (3266.12 cm ² ), occupying about 88% of the surface area of each of the second major surface of the first layer and the first major surface of the second layer. The final thickness of the entire sound-absorbing ceiling panel as a whole is shown in the table below.

[ 00104 ] Comparative Example 1 was made by uniformly applying eight parallel lines of polyvinyl acetate adhesive to the first major surface of the first layer — that is, through the center region of the first layer. In Comparative Example 1, a total of 20 g of adhesive was used. Comparative Examples 2 and 3 were made by drawing sixteen lines in a checkerboard pattern along the entire first main surface of the first layer — that is, the entire central region of the first layer. In each of Comparative Examples 2 and 3, a total of 20 g of adhesive was used. The final thicknesses of the comparative sound-absorbing ceiling panels are indicated in the table below.

Table 1

Thickness (inches) Adhesive application NRC ΔNRC with Comparative Example 1 САС Example 1 1.75 Perimeter (20 g) 0.95 0.05 (slightly) 43 Example 2 1.75 Perimeter (20 g) 0.95 0.05 (slightly) 43 Comparative Example 1 1.76 8 parallel lines (20 g) 1.00 - 40 Comparative Example 2 1.77 16 lines staggered (40 g) 1.00 - 40 Comparative Example 3 1.78 16 lines staggered (40 g) 1.00 - 39

[ 00105 ] As shown in Table 1, application of the adhesive according to the present invention leads to a noticeable improvement in CAC performance with only a slight decrease in NRC by five hundredths. Thus, the application of the adhesive according to the present invention allows to improve the performance of the CAC without significant adverse effects on the performance of NRC.

[ 00106 ] Moreover, the application of the adhesive according to the present invention unexpectedly results in an improved CAC characteristic with an overall thickness of the ceiling panel. The CAC characteristic is a measure of sound insulation between adjacent indoor environments - as a rule, it is expected that when the thickness of the barrier between adjacent indoor environments is reduced, the same happens with the CAC. Thus, applying the adhesive according to the present invention can improve the performance of the CAC, while at the same time reducing the volume required for such a ceiling panel.

II. Ceiling system with ceiling panels and free-moving sound dampening layers

[ 00107 ] As shown in Figures 12 and 13, this embodiment of the present invention is directed to a ceiling system 1001 comprising a support crate 1005 and at least one multi-component panel 1020. Closed air space 1002 may be located above the support crate 1005. Closed air space 1002 represents the space that is located above the multi-component panels 1020 and above the supporting battens 1005, and below the ceiling or subfloor 1004 located above the adjacent floor in the building. The enclosed airspace 1002 provides a place for technical communications laid through the building, for example, heating, ventilation and air conditioning (HVAC) systems, plumbing systems, data lines, etc. Below the multicomponent panels 1020 and below the support crate 1005, there may be an indoor environment 1003. The indoor environment 1003 is the space occupied by the occupants, for example, the indoor environment 1003 in the office building would be the space occupied by desks, office workers, computers, etc. The combination of support crate 1005 and multicomponent panels 1020 can act as an acoustic, thermal, and aesthetic screen between the indoor environment 1003 and the enclosed airspace 1002, as well as the sound insulation layer for noise that occurs in the indoor environment 1003, as discussed here .

[ 00108 ] The support crate 1005 may comprise a plurality of first beams 1006 extending parallel to each other. In some embodiments, the support crate 1005 may further comprise a plurality of second beams 1007 that extend parallel to each other. The plurality of first beams 1006 may intersect with the plurality of second beams 1007 to form a lattice structure having a plurality of lattice openings 1008. In some embodiments, the plurality of first beams 1006 intersect with the plurality of second beams 1007 substantially at right angles, thereby forming rectangular lattice openings 1008. Rectangular grating openings 1008 may be square or any other shape that has aesthetic or functional significance.

[ 00109 ] As shown in Figures 17-21, each of the plurality of first beams 1006 and each of the plurality of second beams 1007 may comprise T-rails having a horizontal shelf 1010 and a rib 1011. A closed airspace 1002 is located above the T-rails, and the indoor environment 1003 is below the T-rails.

[ 00110 ] The ceiling system 1001 according to the present invention comprises at least one multicomponent panel 1020 that is mounted inside the grating openings 1008 of the supporting crate 1005. The ceiling system 1001 may include many multicomponent panels 1020 mounted on the supporting crate 1005, each of which is a plurality of multicomponent panels 1020 is stacked inside one of a plurality of grill openings 1008. In some embodiments, implementation is something other than multicomponent panels 1020 (e.g., lighting arm round or vent terminal) may be mounted on the supporting battening 1005 within at least one of the lattice openings 1008 (not shown).

[ 00111 ] As illustrated by figures 14 and 16, the multi-component panel 1020 may include a ceiling panel 1100 and a sound dampening layer 1200. In some embodiments of the present invention, the multi-component panel 1020 may further comprise a plaster canvas (not shown). As shown by figures 19 and 21, the multi-component panel 1020 can be installed on the support crate 1005 of the ceiling system 1001 so that the ceiling panel 1100 of the multi-component panel 1020 is adjacent to the indoor environment 1003, and the acoustic layer 1200 is adjacent to the enclosed airspace 1002.

[ 00112 ] As shown in FIG. 15, the ceiling panel 1100 includes a lower main surface 1101 and an upper main surface 1102. The lower main surface 1101 of the ceiling panel 1100 is opposite to the upper main surface 1102 of the ceiling panel 1100. The first layer 1100 further comprises a side surface 1103 extending between the lower main surface 1101 and the upper main surface 1102.

[ 00113 ] The ceiling panel 1100 may have an overall length and width. In some embodiments, the length of the ceiling panel 1100 may be 12, 18, 24, 30, 48, 60, 72, or 96 inches (30.5, 45.7, 61, 76.2, 122, 152.4, 182.9 , 243.8 cm). In some embodiments, the width of the ceiling panel 1100 may be 4, 6, 12, 18, 20, 24, 30, or 48 inches (10.2, 15.2, 30.5, 45.7, 50.8, 61, 76 , 2, 122 cm).

[ 00114 ] The upper main surface 1102 of the ceiling panel 1100 may have a length and a width. The lower main surface 1101 of the ceiling panel 1100 may have a length and a width. In some embodiments, each of the length and width values of the upper main surface 1102 and the lower main surface 1101 of the ceiling panel 1100 may have combined length and width values of the ceiling panel. In some embodiments, the length of the upper major surface 1102 and the length of the lower major surface 1101 are equal. In some embodiments, the width of the upper major surface 1102 and the width of the lower major surface 1101 are equal. In some embodiments, the length of the upper main surface 1102 is greater than the length of the lower main surface 1101. In some embodiments, the width of the upper main surface 1102 is greater than the width of the lower main surface 1101.

[ 00115 ] In some embodiments, the side surface 1103 of the ceiling panel 1100 may include a stepped profile having an upper side surface 1103b and a lower side surface 1103a. Between the lower side surface 1103a and the upper side surface 1103b, the intermediate surface 1108 extends in a direction that is substantially perpendicular to the side surface 1103, the upper side surface 1103a and the lower side surface 1103b of the ceiling panel 1100. In some embodiments, the intermediate surface 1108 is oriented along in the same direction as the lower main surface 1101 of the ceiling panel 1100. In other embodiments, the intermediate surface 1108 is oriented in a directional direction. ju at an angle to the lower main surface 1101.

[ 00116 ] The stepped profile comprises a combination of an upper side surface 1103b, an intermediate surface 1108, and a lower side surface 1103a. According to this embodiment, the upper main surface 1102 of the ceiling panel 1100 has an area that is larger than the area of the lower main surface 1101 of the ceiling panel 1100. In some embodiments, the surface area of the upper main surface 1102 of the first layer 1100 is the sum of the area of the lower main surface 1102 and the area of the intermediate surface 1108 of the ceiling panel 1100. According to this embodiment, at least one of the width and length of the lower main surface 1101 of the ceiling panel and 1100 is less than the length and width of the upper main surface 1102 of the ceiling panel.

[ 00117 ] In some embodiments, the ceiling panel 1100 comprising a stepped profile will have at least one of a length or width of a lower main surface 1101 less than a length or width of an upper main surface 1102 by a value ranging from about 0.5 inches to about 2 inches (1.27-5.08 cm).

[ 00118 ] In some embodiments, the step profile of the ceiling panel 1100 may be present on each of the side surfaces 1103 of the ceiling panel 1100. In other embodiments, the step profile may be present on only two opposite side surfaces 1103 of the ceiling panel 1100. In a preferred embodiment, the ceiling panel 1100 located closer to the sound source, that is, facing the environment 1003 in the room.

[ 00119 ] In some embodiments, the ceiling panel 1100 may consist of fiberglass, mineral felt (such as rock wool, slag, or a combination thereof), synthetic polymers (such as foamed melamine, foamed polyurethane, or a combination thereof), mineral wool, silicate cotton wool, or combinations thereof. In some embodiments, the ceiling panel 1100 is made of fiberglass. In some embodiments, the ceiling panel 1100 is made of a sound absorbing material that advantageously provides a sound absorption function, and preferred materials for performing the sound absorption function for the first layer 1100 include fiberglass. Ceiling panel 1100 provides a ceiling NRC of at least 0.9, preferably at least 0.95. NRC (noise reduction ratio) is further described below. The NRC value of the ceiling panel 1100 is measured before the sound attenuation layer 1200 is located over the ceiling panel 1100, as discussed here. The ceiling panel 1100 has a first stiffness. In some non-limiting embodiments of the present invention, the ceiling panel may be selected from Optima ^™ and Lyra ^™ fiberglass cladding panels manufactured by Armstrong (Armstrong World Industries, Inc.) for example, Lyra 8372 or Optima 3251.

[ 00120 ] As illustrated by figures 15 and 16, the sound damping layer 1200 comprises a lower main surface 1201 and an upper main surface 1202. The lower main surface 1201 of the sound damping layer 1200 is opposite to the upper main surface 1202 of the sound damping layer 1200. The sound damping layer 1200 may further comprise a side surface 1203, extending between the lower main surface 1201 of the soundproof layer 1200 and the upper main surface 1202 of the soundproof layer 1200.

[ 00121 ] The upper main surface 1202 of the sound attenuation layer 1200 may have a length and a width. The lower main surface 1201 of the sound attenuation layer 1200 may have a length and a width. In some embodiments, the length of the upper main surface 1202 and the length of the lower main surface 1201 of the sound attenuation layer 1200 are equal. In some embodiments, the width of the upper main surface 1202 and the width of the lower main surface 1201 of the sound attenuation layer 1200 are equal. In some embodiments, the length of the upper main surface 1202 is less than the length of the lower main surface 1201 of the sound attenuation layer 1200. In some embodiments, the width of the upper main surface 1202 is less than the width of the lower main surface 1201.

[ 00122 ] In some embodiments, the soundproofing layer 1200 may include fiberglass, mineral felt (such as rock wool, slag, or a combination thereof), synthetic polymers (such as foamed melamine, foamed polyurethane, or a combination thereof), mineral wool, silica wool , gypsum, or combinations thereof. In some embodiments, the soundproofing layer 1200 is made of mineral felt. In some embodiments, the sound attenuation layer 1200 advantageously provides a sound attenuation function, and preferred materials for performing the sound attenuation function for the sound attenuator layer 1200 comprise mineral felt.

[ 00123 ] The sound damping layer 1200 provides a ceiling CAC value of at least 37, preferably at least 40, and an NRC value of at least 0.65. CAC (ceiling attenuation class) is further described below. The CAC and NRC values of the sound attenuation layer 1200 are measured until it is located on top of the ceiling panel 1100, as discussed here. The sound damping layer 1200 has a second stiffness. In some embodiments, the first stiffness of the ceiling panel 1100 is greater than the second stiffness of the soundproof layer 1200. In some embodiments, the first stiffness of the ceiling panel 1100 and the second stiffness of the soundproof layer 1200 are equal. In certain nonlimiting embodiments, the ceiling panel may be selected from the facing panels of mineral felt School Zone ^TM and Cortega ^TM manufactured by Armstrong - e.g., School Zone 1810.

[ 00124 ] According to some embodiments, and as shown in FIG. 14, the length of the upper main surface 1102 of the first ceiling panel 1100 is substantially equal to the length of the lower main surface 1201 of the first sound damping layer 1200. In some embodiments, the width of the upper main surface 1102 of the first ceiling panel 1100 is essentially equal to the width of the lower main surface 1201 of the first sound attenuation layer 1200

[ 00125 ] According to some embodiments, the length of the upper main surface 1102 of the first ceiling panel 1100 is greater than the length of the lower main surface 1201 of the first sound damping layer 1200. According to some embodiments, the width of the upper main surface 1102 of the first ceiling panel 1100 is greater than the width the lower main surface 1201 of the first sound damping layer 1200. According to some embodiments, both the length and width of the upper main surface 1102 of the first ceiling panel 1100 are tsya bólshimi than the width of the bottom surface 1201 of the first main layer zvukoglushaschego 1200.

[ 00126 ] According to some embodiments, the length of the upper main surface 1102 of the first ceiling panel 1100 is less than the length of the lower main surface 1201 of the first soundproof layer 1200. According to some embodiments, the width of the upper main surface 1102 of the first ceiling panel 1100 is less than the width the lower main surface 1201 of the first sound damping layer 1200. According to some embodiments, both the length and width of the upper main surface 1102 of the first ceiling panel 1100 are Xia smaller than the width of the bottom surface 1201 of the first main layer zvukoglushaschego 1200.

[ 00127 ] In some non-limiting embodiments, the ceiling system 1001 according to the present invention can be mounted according to the first methodology. The first methodology may include a first step in which a) the support crate 1005 is mounted inside the interior of the building so that closed air space 1002 is formed above the reference crate 1005 and an active indoor environment 1003 is formed below the reference crate 1005. The supporting crate 1005 contains a plurality of intersecting first and second beams 1006, 1007, which form a plurality of lattice openings 1008. The lattice openings 1008 may be formed by sections 1006A of opposing first of intersecting beams (first beams 1006) and sections 1007A of opposing second of intersecting beams (second beams 1007).

[ 00128 ] After step a), step b) follows, where the first ceiling panel 1100A is mounted on the support crate 1005, as shown in FIG. 17. During step b), a second ceiling panel 1100b can also be installed on the support crate 1005 and, optionally, third ceiling panel 1100s. The first ceiling panel 1100 is positioned inside the first of the openings 1008 of the supporting battens 1005 so that the upper main surface 1102 of the first ceiling panel 1100 faces the enclosed airspace 1002, the same applies to the second and third ceiling panels 1100. According to some embodiments, at least one of the ceiling panels 1100 may be located inside the grating aperture 1008 so that the ceiling panel 1100 is limited by sections 1006A, 1007A of the intersecting first and second beams 1006, 1007.

[ 00129 ] As shown in FIG. 17, when the ceiling panel 1100 is mounted on the support crate 1005, at least one of the lower main surface 1101 or the intermediate surface 1108 of the ceiling panel 1100 may abut at least a portion of the upper surface of the horizontal shelf 1010 of at least one of the first element 1006 or the second element 1007 of the supporting crate 1005. The interface between at least one of the lower main surface 1101 or the intermediate surface 1108 of the layer of the ceiling panel 1100 and the upper surface of the horizon of the flange 1010 allows for holding the ceiling panel 1100 in a fully assembled state within the ceiling system 1001.

[ 00130 ] Step b) is followed by step c), in which the first sound damping layer 1200 is arranged in a freely movable relationship over the upper main surface 1102 of the first ceiling panel 1100a, thereby forming a multi-component panel 1020a, as shown in FIG. 18. As shown in FIG. 18 and 19, during step c), at least the second sound attenuation layer 1200b can be positioned in a freely movable relationship over the upper main surface 1102 of the second ceiling panel 1100b, thereby forming a second multicomponent panels 1020b. During step c), the third sound damping layer 1200c can also be arranged in a freely movable relationship over the upper main surface 1102 of the third ceiling panel 1100c, thereby forming a third multicomponent panel 1020c.

[ 00131 ] The multi-component panels 1020, 1020a, 1020b, 1020c have a CAC value greater than 37, and an NRC value of at least 0.95. In some embodiments, at least one of the first, second, or third ceiling panels 1100, 1100a, 1100b, 1100c may be positioned within the grill opening 1008 so that the ceiling panel 1100 and the sound damping layer 1200 are defined by intersecting first and second sections 1006A, 1007A. beams 1006, 1007. The multi-component panels 1020, 1020a, 1020b, 1020c have a CAC value of over 37, and an NRC value of at least 0.95.

[ 00132 ] In some embodiments, implementation of the present invention, the soundproofing layer 1200 may be cut to its final dimensions at the installation site. More specifically, before step b), the present invention may further include providing a sound damping sheet having a length greater than the length of the ceiling panel 1100 (not shown). At least one soundproofing layer 1200 may be cut off from the soundproofing sheet, and at least one soundproofing layer 1200 has a length that is less than substantially equal to or greater than the length of the ceiling panel 1100. Cutting off the soundproofing layers 1200 from the soundproofing sheet before installation of ceiling panels allows you to form a variety of custom-made sound damping layers 1200, which correspond to the diverse forms of ceiling panels 1100, which can be used in the ceiling system 1001. In in some embodiments, the soundproofing layer 1200 may be cut off from the soundproofing sheet after step b), but before step c).

[ 00133 ] In the alternative embodiment shown in FIG. 20, step b) may include mounting the first ceiling panel 1100a and the second ceiling panel 1100b on the support crate 1005 in adjacent first and second grating openings 1008. After the step b) the sound attenuation layer 1200 is positioned in a freely movable relationship over the upper main surface 1102 of both the first and second ceiling panels 1100, 1100a, 1100b. The lower main surface 1201 of the sound attenuation layer 1200 may cover at least one of the sections 1006A, 1007A of the first or second beam 1006, 1007, which is located between adjacent first and second ceiling panels 1100, 1200. The obtained first and second multicomponent panels 1020a, 1020b have a sound attenuation a layer 1200 that creates a continuous structure through at least two openings 1008, optionally three openings 1008, in the support crate 1005. The resulting sound damping layer 1200 may exhibit a CAC value in excess of 37, and an NRC value of at least 0.95.

[ 00134 ] In other non-limiting embodiments, the ceiling system 1001 according to the present invention may conform to a second methodology. The second methodology may include the first step a), where the support crate 1005 is mounted inside the building interior so that closed air space 1002 is formed above the support crate 1005, and an active indoor environment 1002 is formed below the support crate 1005. The supporting crate 1005 contains a plurality of intersecting first and second beams 1006, 1007, which form a plurality of lattice openings 1008. The lattice openings 1008 may be formed by sections 1006A of opposing first of intersecting beams (first beams 1006) and sections 1007A of opposing second of intersecting beams (second beams 1007).

[ 00135 ] Step a) is followed by step b), in which the first ceiling panel 1100 is provided and the first sound damping layer 1100 is formed, as shown in FIG. 15. After step b), step c) is followed, in which the first sound damping layer 1100 is closed in a freely movable the relationship of the upper main surface 1102 of the first ceiling panel 100, thereby forming an uninstalled multi-component panel 1020 having a CAC value greater than 37, as shown in FIG. 16.

[ 00136 ] Steps b) and c) can be repeated many times until the number of multi-component panels 1020 necessary to complete the installation of the ceiling system 1001 is reached. In addition, it is possible that the second soundproofing layer 1200 can be cut to its final size from the soundproofing sheet as discussed above.

[ 00137 ] After step c), step d) follows, wherein at least the first multicomponent panel 1020 is mounted on the support crate 1005, as shown in FIG. 21. The first multicomponent panel 1020 can be positioned inside one of the plurality of openings 1008 so that the upper main surface 1102 of the ceiling panel 1100 faces the enclosed airspace 1002. According to some embodiments, at least the first of the ceiling panels 1100 is located inside the opening 1008 so that the ceiling panel 1100 and sound dampers conductive layer 1200 are limited sections 1006a, 1007A intersecting the first and second beams 1006, 1007.

[ 00138 ] In non-limiting embodiments, step d) may include mounting the multi-component panel 1020b on the support crate 1005 by lowering the multi-component panel 1020b vertically downward from the enclosed airspace 1002 onto the supporting crate 1005. The vertical lowering of the multi-component panel 1020b continues while at least one of the lower main surface 1101 or the intermediate surface 1108 of the ceiling panel 1100 does not abut against the upper surface of the shelf 1010. Using the lowering methodology in the bottom of the multi-component panel 1020b can be brought out essentially one level relative to the support crate 1005 completely during step d). The term "essentially" in this case implies a change in relative orientation by +/- 15 °. During this step, the side surfaces 1203 of the soundproofing layer 1200 do not extend to the support flanges 1010 of the first and second beams 1006, 1007.

[ 00139 ] In other non-limiting embodiments, the multi-component panel 1020c may be lifted vertically up into the support crate 1005 from the indoor environment 1003. To raise the multi-component panel 1020 to the support crate 1005, the multi-component panel 1020c should be temporarily oriented obliquely at an angle with respect to the support crate 1005 so that the side surfaces 1103, 1203 of the ceiling panel 1100 and the silencing layer 1200 are at a distance from the horizontal shelf 1010 of the support crate 1005. How only the side surfaces 1103, 1203 of the ceiling panel 1100 and the sound damping layer 1200 passed the horizontal shelves 1010 of the supporting battens 1005, the multi-component panel 1020 can be reoriented horizontally position relative to the support crate 1005. Then, the multi-component panel 1020 can be lowered vertically until at least one of the lower main surface 1101 or the intermediate surface 1108 of the ceiling panel 1100 abuts against the upper surface of the shelf 1010, as shown in FIG. 21.

[ 00140 ] As shown in FIG. 17, after the ceiling panel 1100 has been installed on the support crate 1005, at least one of the intermediate surface 1108 or the lower main surface of the ceiling panel 1100 may abut at least a portion of the upper surface of the horizontal shelf 1010 at least one of the first element 1006 or the second element 1007 of the supporting crate 1005. The interface between the intermediate surface 1108 of the layer of the ceiling panel 1100 and the upper surface of the horizontal shelf 1010 allows you to support the sweat mammary panel 1100 in the fully assembled condition. Fully mounted, both the ceiling panel 1100 and the sound damping layer 1200 are limited to sections 1006A, 1007A of the intersecting first and second beams 1006, 1007.

[ 00141 ] The term "freely movable," as used in the present invention, refers to an interface that is essentially free of adhesive or mechanical fastening. The term “substantially free of adhesive” means an amount of adhesive that is less than sufficient to impart structural integrity between the ceiling panel 1100 and the sound damping layer 1200. In some embodiments, after the sound damping layer 1200 is freely movable over the top main the surface 1102 of the ceiling panel 1100, the connection between the lower main surface 1201 of the first sound damping layer 1200 and the upper main surface 1102 of the ceiling panel 1100 is minutes contact between the lower major surface 1201 zvukoglushaschego first layer 1200 and an upper major surface of the first ceiling panel 1100 is provided only by the gravitational effect of the first layer 1200 zvukoglushaschego.

[ 00142 ] According to some embodiments, at least one of the multi-component panels 1020 may be located within the grill opening 1008 such that the ceiling panel 1100 and the sound damping layer 1200 are defined by sections 1006A, 1007A of intersecting first and second beams 1006, 1007. As shown in 16, after the sound attenuation layer 1200 was positioned on top of the ceiling panel 1100, a partition surface 1300 with a contact of the surfaces between the lower main surface 1201 of the sound suppress layer 1200 and the upper main surface 110 2 of the ceiling panel 1100. The interface 1300 with the contact of the surfaces may be substantially free of adhesive.

[ 00143 ] According to some embodiments, as shown in FIG. 19, the rib portion 1011 of each of the intersecting beam sections, that is, sections of the plurality of first beams 1006 and sections of the plurality of second beams 1007 (not shown), extends above the interface 1300 with the contact of the surfaces of the multicomponent panels 1020. According to some embodiments, the rib portion 1011 of each of the sections of the intersecting beams, that is, the sections of the plurality of first beams 1006 and the sections of the plurality of second beams 1007, is lower than the partition surface 1300 with k ntaktom multicomponent panel 1020 surfaces (not shown).

[ 00144 ] In non-limiting embodiments, the multi-component panel 1020 may be round, oval or polygonal, for example, rectangular (including square and non-square shapes), or triangular. According to these embodiments, the ceiling panel 1100 and the sound attenuation layer 1200 together occupy the entire multi-component panel 1020. In some embodiments, the polygonal ceiling panels 1020 may have rounded or acute angles.

[ 00145 ] According to some embodiments, the multi-component panel 1020 is substantially rectangular — the term “substantially rectangular” means a shape having four edges and four vertices. Each vertex forms an angle ranging from 88 to 92 degrees, alternatively about 90 degrees. The four side surfaces 1103 either have the same length (square), or have a first pair of edges that are parallel to each other and extend to the first length, and a second pair of edges that are parallel to each other and have a second length, with the first and second lengths not equal ( non-square).

[ 00146 ] In some embodiments, the multi-component panel 1020 is rectangular, with the first pair of edges and the second pair of edges in each case having a length of 2 feet (0.61 m). In some embodiments, the multi-component panel 1020 has a total thickness ranging from about 1.25 inches to about 2 inches (31.7-50.8 mm), alternatively about 1.75 inches (44.5 mm).

[ 00147 ] The multi-component panel 1020 according to the present invention exhibits certain acoustic performance characteristics. More specifically, the American Society for Testing Materials (ASTM) has developed an E1414 test method to standardize the measurement of airborne sound attenuation between environments in rooms that share a common enclosed airspace. The indicator derived from this measurement standard is known as the ceiling attenuation class (CAC). Ceiling materials and systems with high CAC values have a greater ability to reduce the transmission of sound through closed airspace, that is, the function of attenuation of sound.

[ 00148 ] Another important characteristic of materials of a sound-absorbing ceiling panel is its ability to reduce the amount of reflected sound in a room. One measurement of this ability is an estimate of Noise Reduction Ratio (NRC) as described in ASTM C423 Test Method. This estimate is the average value of sound absorption coefficients in four third octave frequency bands (250, 500, 1000 and 2000 Hz), where, for example, a system with an NRC value of 0.90 has an absorption capacity of approximately 90% of an ideal absorber. A higher NRC value indicates that the material provides better sound absorption and reduces sound reflection - the sound absorption function.

[ 00149 ] Previous attempts to develop a sound-absorbing ceiling panel having elevated CAC values (that is, a desirable decrease in sound transmission through a confined airspace) have been associated with a simultaneous reduction in sound absorption (NRC), which caused an increased amount of sound reflected within a given environment in room. It was found that using the multi-component panel 1020 according to the present invention, an increase in the CAC characteristic can be achieved without losing the NRC characteristic.

[ 00150 ] More specifically, when the sound damping layer 1200 is in a free-moving relationship over the upper main surface 1102 of the ceiling panel 1100, it was found that the resulting multicomponent panel 1020 will show a noticeable improvement in the CAC performance, while avoiding the deterioration of the NRC performance.

[ 00151 ] More specifically, the multi-component panel 1020 according to the present invention has a CAC value of at least 37 and an NRC value of at least 0.95. The ceiling panel 1100 may exhibit an NRC value of 0.90 before the soundproof layer is located on top of the ceiling panel 1100. The soundproof layer may have a CAC value of at least 35, and an NRC value of at least 0.65 until it is positioned on top of the ceiling panel 1100.

[ 00152 ] In some embodiments, a multi-component panel 1020 according to the present invention is formed using a sound attenuation layer 1200 that has a greater CAC value than the CAC value of the ceiling panel 1100. The sound attenuation layer 1200 may also have an NRC value that is less than the NRC value of the ceiling panels 1100. The layer of ceiling panel 1100 may be a sound-absorbing layer that absorbs sound within a separate indoor environment 1003. The soundproofing layer 1200 may be a noise suppressing layer that provides sound insulation between adjacent environments 1003 in rooms that share a closed airspace 1002.

[ 00153 ] The invention will be described in more detail by way of specific examples. The following examples are provided for illustrative purposes, and are not intended to limit the invention in any way.

Examples

[ 00154 ] Examples were made using a fiberglass ceiling panel measuring 24 inches × 24 inches × 1 inch (610 mm × 610 mm × 25.4 mm) and consisting of mineral felt soundproofing layer with dimensions of 24 inches × 24 inches × 0.75 inches (610 mm × 610 mm × 19 mm). The ceiling panel and sound damping layers have the following acoustic characteristics:

Fiberglass ceiling panel Sound attenuating mineral felt layer NRC value 0.95 NRC value 0.70 SAS value No data SAS value 40

[ 00155 ] For the purpose of the present invention, each of the individual fiberglass ceiling panels has the same initial acoustic characteristic. For the purpose of this invention, each of the individual sound damping layers of mineral felt has the same initial acoustic characteristic.

[ 00156 ] With respect to Examples 1 and 2, each of the sound damping layers was laid on the upper main surface of the ceiling panel in a freely movable relationship without any adhesive present on the contact interface.

[ 00157 ] With respect to Comparative Example 1, the upper main surface of the ceiling panel and the sound damping layer were glued together using a polyvinyl acetate adhesive. Twenty grams of adhesive were applied in eight parallel lines that were laid diagonally across the top main surface of the ceiling panel.

[ 00158 ] With respect to Comparative Examples 2 and 3, the upper main surface of the ceiling panel and the sound damping layer were glued together using a polyvinyl acetate adhesive. Twenty grams of adhesive were applied in the form of sixteen staggered lines extending over the entire top main surface of the ceiling panel.

[ 00159 ] For the purposes of this invention, the original acoustic characteristics of the Lyra 8361 panel and the Optima 3251 panel are essentially the same.

Table 1

Thickness (inches) Partition surface (amount of adhesive) NRC САС Example 1 1.76 freestanding (0 g) 1,0 44 Example 2 1.75 freestanding (0 g) 1,0 43 Comparative Example 1 1.76 8 parallel lines (20 g) 1.00 40 Comparative Example 2 1.77 16 lines staggered (40 g) 1.00 40 Comparative Example 3 1.78 16 lines staggered (40 g) 1.00 39

[ 00160 ] As shown in Table 1, the location of the sound-attenuating layer in a free-moving relationship over the upper main surface of the ceiling panel results in a marked improvement in CAC performance without sacrificing NRC performance.

[ 00161 ] Furthermore, the arrangement of the soundproofing layer in a freely movable relationship over the upper main surface of the ceiling panel according to the present invention unexpectedly results in an improved CAC characteristic with a reduction in the overall thickness of the ceiling panel. The CAC characteristic is a measure of sound insulation between adjacent indoor environments - as a rule, it is expected that when the thickness of the barrier between adjacent indoor environments is reduced, the same happens with the CAC. Thus, the arrangement of the sound-attenuating layer in a freely movable relationship over the upper main surface of the ceiling panel according to the present invention allows to improve the performance of the CAC, while at the same time reducing the volume required for such a ceiling panel.

[ 00162 ] While the invention has been described with respect to specific examples including currently preferred embodiments of the invention, it will be apparent to those skilled in the art that there are numerous variations and modifications of the above systems and methods. It should be understood that other embodiments may be implemented, and structural and functional modifications may be made without departing from the scope of the present invention. Thus, the spirit and scope of the invention should be construed broadly as set forth in the appended claims.

Claims (39)

1. Sound-absorbing ceiling panel containing: a first layer comprising a first major surface and a second major surface, the second major surface of the first layer being formed by the perimeter, the second major surface of the first layer containing a perimeter region adjacent to the perimeter of the second major surface of the first layer, and a central region bounded by the perimeter of the second major surface of the first layer ; a second layer comprising a first major surface and a second major surface, the first major surface of the second layer being formed by the perimeter, the first major surface of the second layer comprising a perimeter region adjacent to the perimeter of the first major surface of the second layer, and a central region bounded by the perimeter of the first major surface of the second layer ; and moreover, the second main surface of the first layer is connected with the first main surface of the second layer by adhesive applied to at least one of the perimeter region of the second main surface of the first layer or the perimeter region of the first main surface of the second layer, each of which is a central region of the second main surface of the first layer and the central the region of the first main surface of the second layer does not contain adhesive, whereby the first and second layers are glued to each other with adhesive to form a cohesive multilayer Aneli. 2. The sound-absorbing ceiling panel according to claim 1, in which the second layer has a CAC value that is higher than the CAC value of the first layer, and the first layer has an NRC value that is higher than the NRC value of the second layer, the second layer has a CAC value of at least 35, and the first layer has an NRC value of at least 0.7. 3. The sound-absorbing ceiling panel according to claim 1, in which the Central region of the second main surface of the first layer and the Central region of the first main surface of the second layer are in freely movable contact relative to each other. 4. The sound-absorbing ceiling panel according to claim 1, further comprising: a first layer comprising a side surface extending between the first and second main surfaces of the first layer, wherein the side surface of the first layer intersects the second main surface of the first layer to form the upper edge of the first layer, the upper edge of the first layer forming the perimeter of the second main surface of the first layer; a second layer comprising a side surface extending between the first and second main surfaces of the second layer, the side surface of the second layer intersecting the first main surface of the second layer with the formation of the lower edge of the second layer, the lower edge of the second layer forming the perimeter of the first main surface of the second layer; the upper edge of the first layer containing the first portion of the upper edge, the second portion of the upper edge, opposite relative to the first portion of the upper edge, the third portion of the upper edge, continuing between the first and second sections of the upper edge, and the fourth portion of the upper edge, opposite relative to the third portion of the upper edge and continuing between the first and second sections of the upper edge; and adhesive applied to the perimeter region of the second main surface, comprising a first adhesive strip extending adjacent to the first edge portion, a second adhesive strip extending adjacent to the second edge portion, a third adhesive strip extending adjacent to the third edge portion, and a fourth adhesive extending strip the edges. 5. The sound-absorbing ceiling panel according to claim 4, in which the first adhesive strip is located at a first distance from the first portion of the upper edge, the second adhesive strip is at a second distance from the second portion of the upper edge, and the third adhesive strip is located at a third distance from the third portion of the upper edge and the fourth adhesive strip is located at a fourth distance from the fourth portion of the upper edge. 6. The sound-absorbing ceiling panel according to claim 4, in which the first, second, third and fourth adhesive strips together form a closed geometric figure bounding the central region. 7. The sound-absorbing ceiling panel according to claim 1, in which the second main surface of the first layer is connected to the first main surface of the second layer so that the perimeter of the second layer is aligned with the perimeter of the first layer. 8. The sound-absorbing ceiling panel according to claim 1, wherein the central region of the second major surface of the first layer occupies from about 70% to about 99% of the surface area of the second major surface of the first layer. 9. The sound absorbing ceiling panel according to claim 1, wherein the first layer is a fiberglass layer and the second layer is a mineral felt layer. 10. Sound-absorbing ceiling panel containing: a first layer comprising a first major surface and a second major surface, the second major surface of the first layer being formed by the perimeter, the second major surface of the first layer containing a perimeter region adjacent to the perimeter of the second major surface of the first layer, and a central region bounded by the perimeter of the second major surface of the first layer ; a second layer comprising a first major surface and a second major surface, the first major surface of the second layer being formed by the perimeter, the first major surface of the second layer comprising a perimeter region adjacent to the perimeter of the first major surface of the second layer, and a central region bounded by the perimeter of the first major surface of the second layer ; and moreover, the second main surface of the first layer is connected with the first main surface of the second layer by a plurality of adhesive strips deposited on at least one of the perimeter region of the second main surface of the first layer or the perimeter region of the first main surface of the second layer, and the adhesive strips together form a closed geometric figure, which limits the central region of the second major surface of the first layer and the central region of the first major surface of the second layer. 11. The sound absorbing ceiling panel of claim 10, wherein the second layer has a CAC value that is higher than the CAC value of the first layer, and the first layer has an NRC value that is higher than the NRC value of the second layer. 12. The sound-absorbing ceiling panel of claim 10, in which the Central region of the second main surface of the first layer and the Central region of the first main surface of the second layer are in freely movable contact relative to each other. 13. The sound-absorbing ceiling panel of claim 10, further comprising: a first layer comprising a side surface extending between the first and second main surfaces of the first layer, wherein the side surface of the first layer intersects the second main surface of the first layer to form the upper edge of the first layer, the upper edge of the first layer forming the perimeter of the second main surface of the first layer; a second layer comprising a side surface extending between the first and second main surfaces of the second layer, the side surface of the second layer intersecting the first main surface of the second layer with the formation of the lower edge of the second layer, the lower edge of the second layer forming the perimeter of the first main surface of the second layer; the upper edge of the first layer containing the first portion of the upper edge, the second portion of the upper edge, opposite relative to the first portion of the upper edge, the third portion of the upper edge, continuing between the first and second sections of the upper edge, and the fourth portion of the upper edge, opposite relative to the third portion of the upper edge and continuing between the first and second sections of the upper edge; and a plurality of adhesive strips comprising a first adhesive strip extending adjacent to the first edge portion, a second adhesive strip extending adjacent to the second edge portion, a third adhesive strip extending adjacent to the third edge portion, and a fourth adhesive strip extending adjacent to the fourth adjacent portion. 14. The sound-absorbing ceiling panel of claim 13, wherein the first adhesive strip is at a first distance from the first edge portion, the second adhesive strip is at a second distance from the second edge portion, the third adhesive strip is at a third distance from the third edge portion and the fourth adhesive the strip is located at a fourth distance from the fourth portion of the edge. 15. The sound absorbing ceiling panel of claim 13, wherein the central region of the second major surface of the first layer occupies at least 95% of the second major surface of the first layer. 16. Sound absorbing ceiling panel containing: a first layer comprising a first major surface, a second major surface and a side surface extending between the first and second major surfaces of the first layer, the side surface of the first layer intersecting the second major surface of the first layer to form the upper edge of the first layer, the upper edge of the first layer forming the perimeter a second main surface, the second main surface comprising a perimeter region adjacent to the perimeter and a central region bounded by the perimeter region; the upper edge of the first layer containing the first portion of the upper edge, the second portion of the upper edge, opposite relative to the first portion of the upper edge, the third portion of the upper edge, continuing between the first and second sections of the upper edge, and the fourth portion of the upper edge, opposite relative to the third portion of the upper edge and continuing between the first and second sections of the upper edge; a second layer comprising a first major surface, a second major surface and a side surface extending between the first and second major surfaces of the second layer; and moreover, the second main surface of the first layer is connected with the first main surface of the second layer of at least the first adhesive strip, continuing adjacent and essentially parallel to the first portion of the edge, the second adhesive strip, continuing adjacent and essentially parallel to the second portion of the edge, the third adhesive a strip extending adjacent and substantially parallel to the third region of the edge, and a fourth adhesive strip extending adjacent and substantially parallel to the fourth region of the edge. 17. A false ceiling system comprising: a ceiling lath comprising a plurality of first elements and a plurality of second elements, the first and second elements intersecting each other to form a plurality of lattice openings; closed airspace above the ceiling lathing; the environment in the room below the ceiling crate; and for each of the grating openings, a sound-absorbing ceiling panel according to any one of claims 1 to 16, mounted on the ceiling crate and located inside the grating opening.

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