WO2005094317A2 - Panneau de plafond a revetement fibreux - Google Patents

Panneau de plafond a revetement fibreux Download PDF

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Publication number
WO2005094317A2
WO2005094317A2 PCT/US2005/010397 US2005010397W WO2005094317A2 WO 2005094317 A2 WO2005094317 A2 WO 2005094317A2 US 2005010397 W US2005010397 W US 2005010397W WO 2005094317 A2 WO2005094317 A2 WO 2005094317A2
Authority
WO
WIPO (PCT)
Prior art keywords
panel
face
apertures
fibrous material
sound absorbing
Prior art date
Application number
PCT/US2005/010397
Other languages
English (en)
Other versions
WO2005094317A3 (fr
Inventor
Alan C. Wendt
Gerald L. Koski
Maria Augusta D. Azevedo
Original Assignee
Usg Interiors, Inc.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Usg Interiors, Inc. filed Critical Usg Interiors, Inc.
Priority to MXPA06010459A priority Critical patent/MXPA06010459A/es
Priority to CA002557703A priority patent/CA2557703A1/fr
Priority to JP2007505269A priority patent/JP2007530831A/ja
Priority to EP05729203A priority patent/EP1740784A2/fr
Publication of WO2005094317A2 publication Critical patent/WO2005094317A2/fr
Priority to NO20064873A priority patent/NO20064873L/no
Publication of WO2005094317A3 publication Critical patent/WO2005094317A3/fr

Links

Classifications

    • 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
    • E04B9/0414—Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation comprising slabs, panels, sheets or the like being foldable, curvable or rollable
    • 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
    • E04B9/0464—Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation comprising slabs, panels, sheets or the like having irregularities on the faces, e.g. holes, grooves
    • 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
    • E04B9/0478—Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation comprising slabs, panels, sheets or the like of the tray type
    • 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
    • E04B9/22—Connection of slabs, panels, sheets or the like to the supporting construction
    • E04B9/24—Connection of slabs, panels, sheets or the like to the supporting construction with the slabs, panels, sheets or the like positioned on the upperside of, or held against the underside of the horizontal flanges of the supporting construction or accessory means connected thereto
    • E04B9/241—Connection of slabs, panels, sheets or the like to the supporting construction with the slabs, panels, sheets or the like positioned on the upperside of, or held against the underside of the horizontal flanges of the supporting construction or accessory means connected thereto with the slabs, panels, sheets or the like positioned on the upperside of the horizontal flanges of the supporting construction

Definitions

  • suspended-ceiling systems typically include grid members that provide for oppositely extending ceiling panel support flanges. In these systems, the edges of the ceiling panels are installed by laying them in the panel opening created by the grid members. There are also suspended-ceiling systems that have grid members, which include channels designed to grip the vertically extending edges of metal ceiling panels.
  • ceiling panels are typically installed by snapping the flanges up into the grid member channel, and are generally referred to as "snap-up ceiling panels.”
  • Typical lay-in grid panels are manufactured from slag wool fiber and/or recycled paper and expanded perlite or fiberglass to create light weight aesthetic ceiling panels. Some of these grid panels do not provide durability or sound absorption qualities that are desired for use in commercial, residential and industrial space.
  • the present disclosure satisfies these and other needs and provides further related advantages. Summary The disclosure may be described as a novel and improved suspension ceiling panel that includes enhanced sound deadening qualities and increased durability.
  • the panel comprises a metallic panel substrate including a plurality of apertures of varying sizes.
  • the body is further adapted to be connected to the ceiling grid members.
  • the outer exposed surface of the metallic panel substrate is covered by a non-woven fibrous material that is adhered thereto.
  • the multi- dimensioned apertures formed in the panel substrate in combination with the non- woven fibrous fabric on the lower exposed surface of the panel not only provides the appearance of a traditional acoustical panel but provides desirable sound absorption and resistance to flame spread and smoke generation.
  • FIG. 1 is a perspective view of one type of ceiling system illustrating fibrous faced ceiling panels
  • FIG. 2 is a sectional view of the ceiling system, taken along lines 2-2, illustrating the fibrous faced ceiling panels connected to a grid system
  • FIG. 3 is a top view of the ceiling panel illustrating the spacing and sizes of the perforations
  • FIG. 4 is a top view of the ceiling panel illustrating an alternate perforation pattern
  • FIG. 5 is a perspective view of a ceiling system illustrating the fibrous faced ceiling panels transitioning from a first elevation to a second elevation
  • FIG. 6 is another perspective view of a ceiling system illustrating the fibrous faced ceiling panels transitioning from a first elevation to a second elevation
  • FIG. 7 is a perspective view of a ceiling system illustrating the transition from the fibrous faced ceiling panels to other types of ceiling panels
  • FIG. 8 is a perspective view of a ceiling system illustrating curved fibrous faced ceiling panels.
  • Fig. 1 illustrates a portion of an assembled suspension ceiling incorporating snap-up fibrous faced ceiling panels 10 in accordance with the present disclosure.
  • grid members 12 are interconnected to form a grid structure 13.
  • the grid members 12 are arranged to form openings 14 sized to receive the ceiling panels 10.
  • the grid members 12 are suspended from the building structure by wire hangers 16 or other supporting structures.
  • wire hangers 16 To create the grid structure 13, a row of parallel evenly spaced grid members 12 are suspended by wire hangers 16.
  • Each row of the grid members 12 are spaced apart to accommodate the size of the fibrous faced ceiling panels 10.
  • the grid structure 13 also includes a second set of grid members 18 that are perpendicularly oriented in relation to the first set of grid members 12 to create the opening required for hanging the panels 10.
  • the fibrous faced ceiling panels 10 are normally rectangular, usually square in shape, and are preferably made out of metal.
  • the panels 10 are durable in that they are impact resistant, self-supporting do not sag or fracture when perforated.
  • FIG. 5 and 6 which allow the transition from a first elevation to a second elevation.
  • Figure 7 illustrates a decorative transition panel 55 without the facer material, which can be a low gloss or high gloss, reflective panel.
  • the preferred material used in fabricating the fibrous faced ceiling panels 10 is metal, other materials may be used including gypsum, wood, wood fiber, plastic and other substrate materials that allows perforation while retaining the basic shape and stiffness of the fibrous faced ceiling panels 10.
  • Metal and plastic material, such as polycarbonate are preferred since panels can be molded or stamped to include a desired shape or to form various edge configurations for connection to the grid structure 13.
  • the fibrous faced ceiling panels 10 include an interior face 20 and an exterior face 22.
  • the panels 10 may also include a hinge 24 along a first corner 25 of the panel 10 to permit the panel to be pivoted to an open position with respect to the grid system 13.
  • the panel 10 preferably includes flanges 26 along the edges 58 of the panel 10. While a flanged edge and a hinged edge are disclosed, other edge configurations may be used to secure the panels 10 to the grid system.
  • the fibrous faced ceiling panels 10, as shown in FIG. 1, illustrates the panels 10 connected to the grid structure 13 by use of flanges 26. It is beneficial to use the hinge 24 to support the ceiling panel 10 when all metal ceiling panels become as large as 4 feet by 4 feet, because the panels become awkward to install and remove due to their relatively large size and weight. Further illustrations of the use of a hinge can be found in U.S.
  • FIG. 2 is a cross section of FIG.
  • the grid member in this example 12 is fabricated out of a single piece of die-formed sheet metal.
  • the grid member 12 after fabrication includes a bulb portion 34, a channel 36 and a double layer bridge portion 38 that connects the bulb portion 34 and the channel 36.
  • the overall shape of the grid member 12 is to give the member 12 strength to prevent flexing.
  • apertures are placed along the length of the bridge portion 38 so that wire hangers 16 can be threaded through and wrapped around the bulb portion 34.
  • the bridge portion 38 typically includes slots (not shown) that allow one grid member 12 to be connected to the second grid member 18 to form the grid structure 13.
  • the channel 36 as shown in FIG. 2 is formed by bending the double layers of the bridge portion 38, 90 degrees outward, 90 degrees downward and 90 degrees inward to form a boxed channel 36. Bottom edges 42 are folded over to act as an engagement edge for the flange 26 and a retaining surface for the hinge 24.
  • the hinge 24 is formed in the ceiling panel 10 by die-forming the hinge 24 90 degrees upward to create an upwardly extending leg 43 and then die-forming the edge 90 degrees inward to create an inward lip 44.
  • the inward lip 44 of the hinge 24 rests upon the bottom edge 42 in the channel 36 of the grid member 12.
  • the flange 26, shown in FIG. 2 is formed by die-forming or molding the edge 26 of the ceiling panel 10 upward 90 degrees to form a vertical member 45 and by forming a rib 48.
  • the ceiling panel 10 is retained to the grid structure 13 by forcing rib 48 past the bottom edge 42.
  • the rib 48 is properly positioned within the channel 36 when the rib 48 is resting upon the bottom edge 42.
  • the vertical member 45 biases the rib 48 to prevent the ceiling panel 10 from moving out of position.
  • Figure 2 also illustrates a fibrous facer material 54 adhered to the exterior face 22 of the panel substrate 11 viewable from the environmental area of a building structure.
  • the environmental area of the building structure is defined as the space within a building used by occupants to work or conduct other activities. It is the inhabitable space within a structure. From the environmental area, the fibrous facer material 54 is substantially exposed and viewable by the occupants below.
  • the interior face 20 of the panel 10 is substantially concealed from the environmental area and is not viewable by the occupants below.
  • FIG. 3 is a top view of the fibrous faced ceiling panel 10 that illustrates the positioning of apertures 52 of a first diameter and apertures 53 of a second diameter across the panel 10.
  • the non-woven fibrous facer material 54 on the exterior face 22 of the panel 10 is adapted to cover the entire face 22 of the panel 10 including the apertures 52, 53.
  • the fibrous facer material 54 is applied to the panel 10, only the fibrous facer material 54 is visible from below.
  • the panel substrate 11 or the apertures 52, 53 are not viewable from below.
  • the sound absorption mechanism of the fibrous faced ceiling panels 10 is a combination of resonant absorber sound attenuation due to the resistance in air flow through the pores of the non-woven fibrous facer material 54 and the perforation of the panel 10.
  • three main parameters need to be optimized. This includes the extent of perforation of the panel 10 with apertures 52, the airflow resistance of the fibrous facer material 54 and the plenum height, i.e. the distance between the structure and the ceiling.
  • Figure 4 illustrates a top view of an alternate aperture arrangement wherein the panel 10 includes apertures 52 of a first diameter apertures 53 of a second diameter and apertures 55 of a third diameter.
  • the combination of the three aperture sizes enhances the resistance of sound waves of varying frequency.
  • the apertures 52 shown in figure 1 are all of a uniform size.
  • the extent of the perforation of the panel 10 is partially dependent upon the strength of the selected substrate material and its resistance to mechanical impact and to excessive panel flex.
  • Substrates such as metal and plastic can be extensively perforated, while gypsum board is limited to no more than about 20% of its surface area in order to maintain strength.
  • the substrate is perforated from about 10% to about 35% open area.
  • the percentage of the open area of the face 50 of the panel 10 should be about 30% to about 33% Sound is made up of various frequencies.
  • the substrate panel 11 is perforated with apertures of different diameters. More specifically, two or three different aperture sizes are preferred.
  • the diameter of the apertures in the panel are from about .039 inches to about 0.117 inches to achieve the desired sound deadening qualities.
  • the perforated pattern is a combination of 15/128 of an inch apertures and 3/32 of an inch apertures.
  • the non-woven fibrous facer material 54 is applied to the panel substrate with use of an adhesive.
  • the adhesive utilized to adhere the non-woven fibrous facer material 54 to the ceiling panel 10 is preferably a hot melt adhesive that is substrate compatible.
  • the adhesive must also be compatible with the type of facer material 54 applied to the panel 10. While hot melt adhesive is preferred, it is foreseeable that other types of adhesives, such as spray, brush or roll-on adhesives may be used.
  • the sound absorption qualities of the panel are also varied by the type and amount of the glue used on the fibrous facer material 54.
  • the panel substrate 11 and fibrous facer material 54 are designed to permit molding or stamping of the panel 10 into desired configurations to create flanges 26.
  • Transition panels 57 as shown in Figs. 5 and 6 or curved ceiling panels, as shown in Fig. 8 may also be created by molding or stamping the panel. Transition panels 57 are used to transition from a first ceiling elevation to a second ceiling elevation and can be formed by bending or curving the panels 10.
  • the panel substrate 11 is preferably made from steel, aluminum or polymer.
  • the fibrous facer material 54 used to cover the exterior face 51 of the panel substrate 11 can be of various materials so long as the material does not rip or tear when formed with the panel. Certain materials when tested such as fiberglass tear or crack when the panel 10 is molded to create flanges 26 or other desired shapes.
  • Preferred materials for use as a fibrous face material 54 include polymer mixtures having polyster fibers. Another such usable material is a combination of NYLON6 and Polyethylene.
  • the panel substrate 11, in combination with the fibrous facer material 54 should have an airflow resistance from about 900 mks rayls to about 1050 mks rayls.
  • Specific airflow resistance is the product of the airflow resistance of a specimen and its area. This is equivalent to the air pressure difference across the panel 10 divided by the linear velocity of airflow measured outside the panel 10.
  • the airflow resistance of the fibrous facer material 54 in combination with the perforated panel substrate is critical to the efficiency of the acoustic attenuation process.
  • Airflow resistance of a panel 10 is defined as the ratio of the pressure drop across the material to the velocity of the gas passing through it and can be expressed in cgs rayls (dyne/cm 2 per cm/sec). Determination of flow resistivity is the main property in describing the acoustical performance of any porous material.
  • Every fibrous material has specific flow resistance characteristics based on its manufacturing process or inherent nature.
  • composite materials such as the present panel 10, which is a combination of the fibrous facer material 54 and the perforated panel 10, it is important to understand the individual flow resistance of each component.
  • this optimum airflow resistance is about 900 mgs rayls to about 1050 mks rayls.
  • plenum height 64 behind the panel 10 is limited and therefore the sound absorption performance of the panel 10 is restricted by the short plenum gap, as shown in Fig. 2.
  • a second layer of porous insulation material 56 such as glass fiber, mineral fiber, thermoplastic polymeric fiber, thermosetting polymeric fiber, carbonaceous fiber, milkweed fiber, or foam insulation, (with preference to polyolefin microfiber melt blow products) can be applied to the interior face 20 of the panel 10.
  • the panels 10 are designed with four edges 58 that are adapted to be connected to the grid structure 13.
  • the panels 10 can be connected to the grid structure 13 using various edge configurations.
  • the edges 58 of the panel 10 can include the vertical member 45 and a rib member 48. This allows the panel to be snapped into the bottom edges 42 of the grid members 12 and 18.
  • the panel 10 does not include edges 25 and simply lays into the openings 14 created by the grid structure 13. While the concepts of the present disclosure have been illustrated and described in detail in the drawings and foregoing description, such an illustration and description is to be considered as exemplary and not restrictive in character, it being understood that only the illustrative embodiments have been shown and described and that all changes and modifications that come within the spirit of the disclosure are desired and protected. There are a plurality of advantages that may be inferred from the present disclosure arising from the various features of the apparatus, systems and methods described herein. It will be noted that alternative embodiments of each of the apparatus, systems, and methods of the present disclosure may not include all of the features described yet still benefit from at least some of the inferred advantages of such features. Those of ordinary skill in the art may readily devise their own implementations of an apparatus, system, and method that incorporate one or more of the features of the present disclosure and fall within the spirit and scope of the invention as defined by the appended claims.

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Building Environments (AREA)
  • Roof Covering Using Slabs Or Stiff Sheets (AREA)

Abstract

L'invention concerne un panneau de plafond suspendu, qui possède des qualités de durabilité, d'absorption du son et de sécurité incendie améliorées. Le panneau comprend un corps substrat présentant une pluralité d'ouvertures. Le corps est conçu pour se rattacher aux éléments maillés du plafond. La surface extérieure exposée du corps substrat est couverte d'un matériau fibreux non tissé. Les ouvertures ménagées dans le corps substrat, combinées avec le matériau fibreux non tissé disposé sur la surface inférieure exposée du panneau, présentent l'aspect d'un panneau acoustique classique, mais offrent en même temps des qualités d'absorption du son et de résistance au feu désirables.
PCT/US2005/010397 2004-03-26 2005-03-25 Panneau de plafond a revetement fibreux WO2005094317A2 (fr)

Priority Applications (5)

Application Number Priority Date Filing Date Title
MXPA06010459A MXPA06010459A (es) 2004-03-26 2005-03-25 Panel de cielo raso, con frente fibroso.
CA002557703A CA2557703A1 (fr) 2004-03-26 2005-03-25 Panneau de plafond a revetement fibreux
JP2007505269A JP2007530831A (ja) 2004-03-26 2005-03-25 繊維化粧天井パネル
EP05729203A EP1740784A2 (fr) 2004-03-26 2005-03-25 Panneau de plafond a revetement fibreux
NO20064873A NO20064873L (no) 2004-03-26 2006-10-26 Fiberkledd takpanel

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US10/810,787 2004-03-26
US10/810,787 US20050211500A1 (en) 2004-03-26 2004-03-26 Fibrous faced ceiling panel

Publications (2)

Publication Number Publication Date
WO2005094317A2 true WO2005094317A2 (fr) 2005-10-13
WO2005094317A3 WO2005094317A3 (fr) 2006-11-16

Family

ID=34988445

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US2005/010397 WO2005094317A2 (fr) 2004-03-26 2005-03-25 Panneau de plafond a revetement fibreux

Country Status (9)

Country Link
US (1) US20050211500A1 (fr)
EP (1) EP1740784A2 (fr)
JP (1) JP2007530831A (fr)
CN (1) CN1997799A (fr)
CA (1) CA2557703A1 (fr)
MX (1) MXPA06010459A (fr)
NO (1) NO20064873L (fr)
WO (1) WO2005094317A2 (fr)
ZA (1) ZA200607488B (fr)

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WO2015175733A1 (fr) * 2014-05-16 2015-11-19 Armstrong World Industries, Inc. Panneau de plafond acoustique présentant une esthétique améliorée
US11649630B2 (en) 2017-06-28 2023-05-16 Kvadrat Soft Cells A/S Thermally activated building panel

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US20050211500A1 (en) 2005-09-29
CA2557703A1 (fr) 2005-10-13
EP1740784A2 (fr) 2007-01-10
JP2007530831A (ja) 2007-11-01
ZA200607488B (en) 2008-06-25
CN1997799A (zh) 2007-07-11
MXPA06010459A (es) 2007-01-15
NO20064873L (no) 2006-10-26
WO2005094317A3 (fr) 2006-11-16

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