US20130206501A1 - Ceiling panels made from corrugated cardboard - Google Patents
Ceiling panels made from corrugated cardboard Download PDFInfo
- Publication number
- US20130206501A1 US20130206501A1 US13/371,886 US201213371886A US2013206501A1 US 20130206501 A1 US20130206501 A1 US 20130206501A1 US 201213371886 A US201213371886 A US 201213371886A US 2013206501 A1 US2013206501 A1 US 2013206501A1
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- United States
- Prior art keywords
- core
- flutes
- corrugated
- foot
- panel
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- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B9/00—Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation
- E04B9/001—Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation characterised by provisions for heat or sound insulation
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B9/00—Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation
- E04B9/04—Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation comprising slabs, panels, sheets or the like
- E04B9/045—Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation comprising slabs, panels, sheets or the like being laminated
Definitions
- the invention relates to building products and, in particular, to acoustical ceiling tile.
- Suspended ceilings customarily comprise a suspended metal grid and panels or tiles closing the spaces between the grid elements.
- the panels are constructed with selected materials and/or surface treatments to absorb sound.
- the ability of a panel to absorb sound is conventionally reported as its Noise Reduction Coefficient or NRC.
- NRC can range between 0 (no absorption) and 1 (full absorption) with a rating of 0.5, meaning it absorbs 50% of the sound energy striking it, being required to qualify a panel as “acoustical”.
- panels rated at 0.7 are considered to have good acoustical performance.
- the invention provides a ceiling panel with high level acoustical absorption properties using a core made of ordinary corrugated fiberboard, sometimes called cardboard.
- the core construction consists of numerous narrow strips of corrugated fiberboard laminated together.
- the corrugated board is cut perpendicular to the corrugations or flutes so that the flute openings lie in front and back planes of the panel core corresponding to the geometry of the finished panel.
- the front of the panel is covered with a suitable sheet of acoustically transparent material with proper air flow resistance and the back of the panel is optionally closed with another sheet, preferably with acoustical isolating properties.
- the panel of the invention has the potential to be economically produced, light in weight, and have a high post-consumer recycle content.
- Corrugated fiberboard is typically produced on high speed machines with relatively low energy consumption and with high recycled paper content. Because the inventive panel is largely air space, it is relatively light in weight.
- the disclosed vertical orientation of a flat liner board component of the corrugated fiberboard in the finished panel makes the panel sag resistant and capable of spanning large grid modules.
- the inventive panel can be produced directly from reclaimed corrugated fiberboard since there is no criticality in the uniformity of the flute size, flute alignment, and/or number of walls of the corrugated fiberboard used in a particular panel.
- FIG. 1 is a perspective view of an acoustical panel made in accordance with the present invention
- FIG. 2 is a fragmentary schematic showing of one manner of assembling a core of the inventive panel.
- FIG. 3 is a perspective view of a three-dimensional block from which the inventive panels are cut in an alternative manner of producing a core of the inventive panel.
- FIG. 1 illustrates an example of an acoustical ceiling panel 10 of the invention; the panel is a nominal 2 foot by 2 foot unit and can have a nominal thickness of 1 inch. Dimensions discussed herein will be understood to include industry metric equivalents.
- the panel 10 includes a corrugated fiberboard core 11 , a face sheet 12 , and a backing sheet 13 .
- the core 11 is made by assembling numerous corrugated fiberboard layers 15 side-to-side such that the combined total thickness of the layers is equal to the length of an edge of the panel 10 .
- each layer 15 can comprise a corrugated medium 16 and a single flat liner board 17 , the combination of these elements sometimes being referred to as a single-sided or single face corrugated board.
- the paper compositions and fabrication of corrugated fiberboard is well known to the relevant industry.
- the corrugated medium 16 is a paper, typically, in the United States having a weight of 0.026 lbs./square foot.
- the paper is heated, moistened and formed into a fluted pattern on geared wheels.
- the fluted or corrugated medium 16 is joined to the flat liner board 17 with a starch-based adhesive to form the single face board comprising the layer 15 .
- the liner board stock can have the same weight as the paper of the medium 16 .
- the flutes or corrugations of the medium 16 are essentially entirely curvilinear in cross-section and resemble a sine wave.
- the size of the flutes, designated 19 is ordinarily stated by the number of flutes in a foot length of the corrugated fiberboard.
- ASTM Standard D4727 sets out the following flute sizes, applicable to single face, as well as singlewall, doublewall and triplewall corrugated fiberboard (referred to below).
- Tests have indicated good acoustical properties, with an NRC in the order of 0.70, can be obtained with all of these standard flute sizes.
- the panel construction such as the panel thickness, can be selected to absorb sound at targeted frequencies.
- the thickness of the corrugated fiberboard core can be, as mentioned above, nominally 1 inch.
- FIG. 2 schematically illustrates one method of manufacturing the core 11 .
- Single face stock or board 15 i.e. having only one flat liner board 17 and one corrugated medium 16 , is slit into 1 inch wide strips.
- the length of the strips can be equal to one of the nominal planar dimensions of the finished panel 10 .
- the strips are stacked on each other with their longitudinal slit edges in registration. Glue or adhesive is applied to a side of a strip at the interface between adjacent strips. The stack height is built up until it reaches the nominal planar dimension of the finished panel perpendicular to that represented by the length of the laminated strips.
- FIG. 3 illustrates another method of forming the core 11 .
- Flat rectangular sheets 21 of corrugated fiberboard having at least one planar dimension equal to a nominal planar dimension of the finished panel 10 are stacked to a height equal to the other nominal planar dimension of the panel.
- the sheets are permanently attached to one another with glue or adhesive at their interfaces.
- the result is a block 22 , which in the illustration of FIG. 3 is a cube.
- the block 22 is sliced with a saw along a plane denoted by lines X-X and Y-Y spaced nominally 1 inch from a side of the block to form a core.
- Successive cores 11 are formed by more cuts, each spaced a distance of 1 inch from the preceding cut.
- the flutes 19 of the core 11 extend perpendicularly to its major planar faces.
- the face sheet 12 is an acoustically transparent medium or film, optionally painted with proper air flow resistance that can serve as the appearance side visible to an observer in a room in which the panel 10 is installed.
- the face sheet 12 is adhered to the core 11 with a suitable adhesive.
- the face sheet 12 can be coated with a paint of a type used on the face of conventional ceiling tiles to improve its appearance and/or light reflectance and to obtain overall air flow resistance in a proper range.
- a suitable face sheet 12 is a non-woven fabric such as fiberglass scrim with a caliper of 0.02 inch, basis weight of 125 g/m 2 , and specific air flow resistance of 45.6 Pa.s/m coated with a paint.
- the choice of face sheet 12 with proper air flow resistance was found to be important to the overall acoustical performance of the inventive panel; if the air flow resistance is too low or too high, the acoustical performance is impaired.
- the side of the core 11 opposite the facing sheet 12 is preferably covered with the backing sheet 13 which can be a kraft paper laminated with a metal foil as used in some commercially available ceiling tile products. Other non-foiled paper can be used for the backing sheet 13 .
- the backing sheet 13 can be used to obtain a good CAC (Ceiling Attenuation Class) value.
- a suitable adhesive is used to attach the backing sheet 13 to the core 11 .
- the single face board 15 illustrated most clearly in FIG. 2 is the most efficient corrugated fiberboard style from a material usage standpoint.
- the flat liner board 17 of one board 15 can serve as a liner board of an adjacent single face board when it is adhesively attached thereto.
- singlewall, doublewall and triplewall corrugated fiberboard work satisfactorily and can be used in place of the illustrated single face board 15 .
- the core 11 can be made by reclaiming this used material and converting it directly into a core.
Abstract
Description
- The invention relates to building products and, in particular, to acoustical ceiling tile.
- Suspended ceilings customarily comprise a suspended metal grid and panels or tiles closing the spaces between the grid elements. Normally, the panels are constructed with selected materials and/or surface treatments to absorb sound. The ability of a panel to absorb sound is conventionally reported as its Noise Reduction Coefficient or NRC. NRC can range between 0 (no absorption) and 1 (full absorption) with a rating of 0.5, meaning it absorbs 50% of the sound energy striking it, being required to qualify a panel as “acoustical”. In the industry, panels rated at 0.7 are considered to have good acoustical performance. A need exists for acoustical tiles that achieve excellent NRC values and especially have the ability to absorb sound at target frequencies, have a high post consumer recycle content, resist sagging over time, are relatively light in weight, and are relatively inexpensive to produce.
- The invention provides a ceiling panel with high level acoustical absorption properties using a core made of ordinary corrugated fiberboard, sometimes called cardboard. The core construction consists of numerous narrow strips of corrugated fiberboard laminated together. The corrugated board is cut perpendicular to the corrugations or flutes so that the flute openings lie in front and back planes of the panel core corresponding to the geometry of the finished panel. The front of the panel is covered with a suitable sheet of acoustically transparent material with proper air flow resistance and the back of the panel is optionally closed with another sheet, preferably with acoustical isolating properties.
- In addition to high acoustical performance, the panel of the invention has the potential to be economically produced, light in weight, and have a high post-consumer recycle content. Corrugated fiberboard is typically produced on high speed machines with relatively low energy consumption and with high recycled paper content. Because the inventive panel is largely air space, it is relatively light in weight.
- The disclosed vertical orientation of a flat liner board component of the corrugated fiberboard in the finished panel makes the panel sag resistant and capable of spanning large grid modules. The inventive panel can be produced directly from reclaimed corrugated fiberboard since there is no criticality in the uniformity of the flute size, flute alignment, and/or number of walls of the corrugated fiberboard used in a particular panel.
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FIG. 1 is a perspective view of an acoustical panel made in accordance with the present invention; -
FIG. 2 is a fragmentary schematic showing of one manner of assembling a core of the inventive panel; and -
FIG. 3 is a perspective view of a three-dimensional block from which the inventive panels are cut in an alternative manner of producing a core of the inventive panel. -
FIG. 1 illustrates an example of anacoustical ceiling panel 10 of the invention; the panel is a nominal 2 foot by 2 foot unit and can have a nominal thickness of 1 inch. Dimensions discussed herein will be understood to include industry metric equivalents. Thepanel 10 includes acorrugated fiberboard core 11, aface sheet 12, and abacking sheet 13. Thecore 11 is made by assembling numerouscorrugated fiberboard layers 15 side-to-side such that the combined total thickness of the layers is equal to the length of an edge of thepanel 10. - As shown in
FIG. 2 , eachlayer 15 can comprise acorrugated medium 16 and a singleflat liner board 17, the combination of these elements sometimes being referred to as a single-sided or single face corrugated board. The paper compositions and fabrication of corrugated fiberboard is well known to the relevant industry. Thecorrugated medium 16 is a paper, typically, in the United States having a weight of 0.026 lbs./square foot. The paper is heated, moistened and formed into a fluted pattern on geared wheels. Typically, the fluted orcorrugated medium 16 is joined to theflat liner board 17 with a starch-based adhesive to form the single face board comprising thelayer 15. As is typical, the liner board stock can have the same weight as the paper of themedium 16. The flutes or corrugations of themedium 16 are essentially entirely curvilinear in cross-section and resemble a sine wave. The size of the flutes, designated 19, is ordinarily stated by the number of flutes in a foot length of the corrugated fiberboard. ASTM Standard D4727 sets out the following flute sizes, applicable to single face, as well as singlewall, doublewall and triplewall corrugated fiberboard (referred to below). -
Flute Flute Flutes/ft Flutes/m Height (in.) Height (mm) A-Flute 30 to 39 98 to 128 0.1575 to 0.2210 4.00 to 5.61 B-Flute 45 to 53 147 to 174 0.0787 to 0.1102 2.00 to 2.80 C-Flute 35 to 45 115 to 148 0.1300 to 0.1575 3.30 to 4.00 E-Flute 70 to 98 229 to 321 0.0445 to 0.0550 1.13 to 1.40 - Tests have indicated good acoustical properties, with an NRC in the order of 0.70, can be obtained with all of these standard flute sizes. Moreover, the panel construction, such as the panel thickness, can be selected to absorb sound at targeted frequencies.
- By way of example, the thickness of the corrugated fiberboard core can be, as mentioned above, nominally 1 inch.
FIG. 2 schematically illustrates one method of manufacturing thecore 11. Single face stock orboard 15, i.e. having only oneflat liner board 17 and onecorrugated medium 16, is slit into 1 inch wide strips. The length of the strips can be equal to one of the nominal planar dimensions of the finishedpanel 10. The strips are stacked on each other with their longitudinal slit edges in registration. Glue or adhesive is applied to a side of a strip at the interface between adjacent strips. The stack height is built up until it reaches the nominal planar dimension of the finished panel perpendicular to that represented by the length of the laminated strips. -
FIG. 3 illustrates another method of forming thecore 11. Flatrectangular sheets 21 of corrugated fiberboard having at least one planar dimension equal to a nominal planar dimension of the finishedpanel 10 are stacked to a height equal to the other nominal planar dimension of the panel. The sheets are permanently attached to one another with glue or adhesive at their interfaces. The result is ablock 22, which in the illustration ofFIG. 3 is a cube. Theblock 22 is sliced with a saw along a plane denoted by lines X-X and Y-Y spaced nominally 1 inch from a side of the block to form a core.Successive cores 11 are formed by more cuts, each spaced a distance of 1 inch from the preceding cut. - The
flutes 19 of thecore 11 extend perpendicularly to its major planar faces. Theface sheet 12 is an acoustically transparent medium or film, optionally painted with proper air flow resistance that can serve as the appearance side visible to an observer in a room in which thepanel 10 is installed. Theface sheet 12 is adhered to thecore 11 with a suitable adhesive. Theface sheet 12 can be coated with a paint of a type used on the face of conventional ceiling tiles to improve its appearance and/or light reflectance and to obtain overall air flow resistance in a proper range. An example of asuitable face sheet 12 is a non-woven fabric such as fiberglass scrim with a caliper of 0.02 inch, basis weight of 125 g/m2, and specific air flow resistance of 45.6 Pa.s/m coated with a paint. The choice offace sheet 12 with proper air flow resistance was found to be important to the overall acoustical performance of the inventive panel; if the air flow resistance is too low or too high, the acoustical performance is impaired. - The side of the
core 11 opposite the facingsheet 12 is preferably covered with thebacking sheet 13 which can be a kraft paper laminated with a metal foil as used in some commercially available ceiling tile products. Other non-foiled paper can be used for thebacking sheet 13. Thebacking sheet 13 can be used to obtain a good CAC (Ceiling Attenuation Class) value. A suitable adhesive is used to attach thebacking sheet 13 to thecore 11. - The
single face board 15 illustrated most clearly inFIG. 2 is the most efficient corrugated fiberboard style from a material usage standpoint. As shown inFIG. 2 , theflat liner board 17 of oneboard 15 can serve as a liner board of an adjacent single face board when it is adhesively attached thereto. From an acoustical standpoint, singlewall, doublewall and triplewall corrugated fiberboard work satisfactorily and can be used in place of the illustratedsingle face board 15. It is contemplated that where there is a reliable source of used quality corrugated fiberboard stock is available, the core 11 can be made by reclaiming this used material and converting it directly into a core. Since the standard flute ranges are comparable in acoustical performance in a core construction, it is possible to produce a core with mixed flute sizes and without layer to layer flute registration. This flute size and registration free compatibility can make use of reclaimed corrugated fiberboard stock in the manufacture of theinventive panel 10 more practical. - It should be evident that this disclosure is by way of example and that various changes may be made by adding, modifying or eliminating details without departing from the fair scope of the teaching contained in this disclosure. The invention is therefore not limited to particular details of this disclosure except to the extent that the following claims are necessarily so limited.
Claims (7)
Priority Applications (16)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US13/371,886 US8511429B1 (en) | 2012-02-13 | 2012-02-13 | Ceiling panels made from corrugated cardboard |
TW102101545A TWI591239B (en) | 2012-02-13 | 2013-01-15 | Ceiling panels made from corrugated cardboard |
ARP130100244A AR089821A1 (en) | 2012-02-13 | 2013-01-25 | ACOUSTIC ROOF PANELS MADE FROM WAVED CARTON |
DK13705893.9T DK2815039T3 (en) | 2012-02-13 | 2013-02-11 | Ceiling panels made of corrugated cardboard |
EP13705893.9A EP2815039B1 (en) | 2012-02-13 | 2013-02-11 | Ceiling panels made from corrugated cardboard |
PL13705893T PL2815039T3 (en) | 2012-02-13 | 2013-02-11 | Ceiling panels made from corrugated cardboard |
CN201380007057.8A CN104080985A (en) | 2012-02-13 | 2013-02-11 | Ceiling panels made from corrugated cardboard |
PCT/US2013/025492 WO2013122850A1 (en) | 2012-02-13 | 2013-02-11 | Ceiling panels made from corrugated cardboard |
MX2014009327A MX355229B (en) | 2012-02-13 | 2013-02-11 | Ceiling panels made from corrugated cardboard. |
JP2014556764A JP6453649B2 (en) | 2012-02-13 | 2013-02-11 | Corrugated paper ceiling panels |
CA2863548A CA2863548C (en) | 2012-02-13 | 2013-02-11 | Ceiling panels made from corrugated cardboard |
RU2014134742/03A RU2596234C2 (en) | 2012-02-13 | 2013-02-11 | Ceiling panels made of corrugated cardboard |
UAA201409449A UA114905C2 (en) | 2012-02-13 | 2013-02-11 | Ceiling panels made from corrugated cardboard |
IN7284DEN2014 IN2014DN07284A (en) | 2012-02-13 | 2013-02-11 | |
BR112014019041A BR112014019041A8 (en) | 2012-02-13 | 2013-02-11 | CEILING PANELS MADE OF CORRUGATED CARDBOARD |
ES13705893.9T ES2676822T3 (en) | 2012-02-13 | 2013-02-11 | Roof panels made from corrugated cardboard |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US13/371,886 US8511429B1 (en) | 2012-02-13 | 2012-02-13 | Ceiling panels made from corrugated cardboard |
Publications (2)
Publication Number | Publication Date |
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US20130206501A1 true US20130206501A1 (en) | 2013-08-15 |
US8511429B1 US8511429B1 (en) | 2013-08-20 |
Family
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Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
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US13/371,886 Expired - Fee Related US8511429B1 (en) | 2012-02-13 | 2012-02-13 | Ceiling panels made from corrugated cardboard |
Country Status (16)
Country | Link |
---|---|
US (1) | US8511429B1 (en) |
EP (1) | EP2815039B1 (en) |
JP (1) | JP6453649B2 (en) |
CN (1) | CN104080985A (en) |
AR (1) | AR089821A1 (en) |
BR (1) | BR112014019041A8 (en) |
CA (1) | CA2863548C (en) |
DK (1) | DK2815039T3 (en) |
ES (1) | ES2676822T3 (en) |
IN (1) | IN2014DN07284A (en) |
MX (1) | MX355229B (en) |
PL (1) | PL2815039T3 (en) |
RU (1) | RU2596234C2 (en) |
TW (1) | TWI591239B (en) |
UA (1) | UA114905C2 (en) |
WO (1) | WO2013122850A1 (en) |
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Also Published As
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WO2013122850A1 (en) | 2013-08-22 |
AR089821A1 (en) | 2014-09-17 |
TWI591239B (en) | 2017-07-11 |
JP6453649B2 (en) | 2019-01-16 |
TW201333312A (en) | 2013-08-16 |
RU2596234C2 (en) | 2016-09-10 |
ES2676822T3 (en) | 2018-07-25 |
CA2863548A1 (en) | 2013-08-22 |
PL2815039T3 (en) | 2018-08-31 |
CN104080985A (en) | 2014-10-01 |
JP2015512004A (en) | 2015-04-23 |
UA114905C2 (en) | 2017-08-28 |
DK2815039T3 (en) | 2018-07-23 |
MX2014009327A (en) | 2014-11-12 |
BR112014019041A2 (en) | 2017-06-20 |
EP2815039A1 (en) | 2014-12-24 |
BR112014019041A8 (en) | 2017-07-11 |
RU2014134742A (en) | 2016-04-10 |
MX355229B (en) | 2018-04-10 |
CA2863548C (en) | 2018-09-25 |
IN2014DN07284A (en) | 2015-04-24 |
US8511429B1 (en) | 2013-08-20 |
EP2815039B1 (en) | 2018-04-18 |
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