WO2013028511A2 - Acoustical panels for covering a wall, ceiling, or the like - Google Patents

Acoustical panels for covering a wall, ceiling, or the like Download PDF

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Publication number
WO2013028511A2
WO2013028511A2 PCT/US2012/051329 US2012051329W WO2013028511A2 WO 2013028511 A2 WO2013028511 A2 WO 2013028511A2 US 2012051329 W US2012051329 W US 2012051329W WO 2013028511 A2 WO2013028511 A2 WO 2013028511A2
Authority
WO
WIPO (PCT)
Prior art keywords
panel
film
panel structure
composite panel
perforations
Prior art date
Application number
PCT/US2012/051329
Other languages
French (fr)
Other versions
WO2013028511A3 (en
Inventor
Steven Borchardt
Original Assignee
Acoustic Ceiling Products, L.L.C.
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 Acoustic Ceiling Products, L.L.C. filed Critical Acoustic Ceiling Products, L.L.C.
Publication of WO2013028511A2 publication Critical patent/WO2013028511A2/en
Publication of WO2013028511A3 publication Critical patent/WO2013028511A3/en

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Classifications

    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
    • E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
    • E04B1/82—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to sound only
    • E04B1/84—Sound-absorbing elements
    • E04B1/8409—Sound-absorbing elements sheet-shaped
    • 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
    • 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
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
    • E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
    • E04B1/82—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to sound only
    • E04B1/84—Sound-absorbing elements
    • E04B1/86—Sound-absorbing elements slab-shaped
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
    • E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
    • E04B1/82—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to sound only
    • E04B2001/8263—Mounting of acoustical elements on supporting structure, e.g. framework or wall surface
    • E04B2001/8281—Flat elements mounted parallel to a supporting surface with an acoustically active air gap between the elements and the mounting surface
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
    • E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
    • E04B1/82—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to sound only
    • E04B1/84—Sound-absorbing elements
    • E04B2001/8457—Solid slabs or blocks
    • E04B2001/8461—Solid slabs or blocks layered
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
    • E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
    • E04B1/82—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to sound only
    • E04B1/84—Sound-absorbing elements
    • E04B2001/8457—Solid slabs or blocks
    • E04B2001/8476—Solid slabs or blocks with acoustical cavities, with or without acoustical filling
    • E04B2001/848—Solid slabs or blocks with acoustical cavities, with or without acoustical filling the cavities opening onto the face of the element
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
    • E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
    • E04B1/82—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to sound only
    • E04B1/84—Sound-absorbing elements
    • E04B2001/8457—Solid slabs or blocks
    • E04B2001/8476—Solid slabs or blocks with acoustical cavities, with or without acoustical filling
    • E04B2001/848—Solid slabs or blocks with acoustical cavities, with or without acoustical filling the cavities opening onto the face of the element
    • E04B2001/8495—Solid slabs or blocks with acoustical cavities, with or without acoustical filling the cavities opening onto the face of the element the openings going through from one face to the other face of the element

Definitions

  • the present invention relates to panels, and more particularly to panels for covering a wall, ceiling, or the like.
  • a suspended ceiling system which supports individual ceiling tiles or panels, may be installed.
  • Fiberboard-based panels have high acoustic absorption, but must be replaced regularly when used in high moisture, high stress, or sterile environments.
  • Vinyl or other synthetic panels which are easier to install, do not need to be replaced as regularly as fiberboard- based panels because vinyl or synthetic panels provide enhanced durability from physical stress, are resistant to mold and mildew, and can be easily cleaned and/or sterilized.
  • vinyl or synthetic panels may have reduced acoustic performance and therefore may not provide noise attenuation and comfort as may be desired by building occupants.
  • the present invention provides, in one aspect, a composite panel structure adapted to be supported relative to a mounting surface.
  • the composite panel structure includes a panel having a first surface and a second surface defining therebetween a thickness of the panel.
  • the panel also has a plurality of perforations arranged in a hexagonal pattern and spanning the thickness of the panel. The perforations provide acoustic transparency to the panel.
  • the composite panel structure further includes a film positioned adjacent the first surface of the panel to attenuate sound waves reflected from the panel.
  • FIG. 1 is a schematic side view of a panel in accordance with the invention.
  • FIG. 2 is an enlarged view of the panel of FIG. 1, illustrating a hexagonal perforation pattern in the panel.
  • FIG. 3 is a schematic side view of a composite panel structure in accordance with a first embodiment of the invention.
  • FIG. 4 is an enlarged view of the composite panel structure of FIG. 3, illustrating a hexagonal perforation pattern in a panel of the composite panel structure.
  • FIG. 5 is a schematic side view of a composite panel structure in accordance with a second embodiment of the invention.
  • FIG. 6 is an enlarged view of the composite panel structure of FIG. 5, illustrating a hexagonal perforation pattern in a panel of the composite panel structure.
  • FIG. 7 is a graph illustrating random incidence sound absorption coefficients in a small reverberation room over a range of frequencies for the panel of FIG. 1 and the composite panel structures of FIGS. 3 and 5.
  • FIGS. 1 and 2 illustrate a panel 1 for creating a wall, ceiling, or like structure in the interior of a building.
  • the panel 1 may be used on the exterior of a building.
  • the panel 1 includes a first surface 4 in facing relationship with an upper ceiling structure 8 (or, alternatively, another interior mounting surface within a building) and a second surface 12 facing away from the upper ceiling structure 8.
  • the first surface 4 of the panel and the upper ceiling structure 8 define therebetween an air gap having a length L 0 of about 16 inches.
  • the length L 0 of the air gap may change depending upon the desired acoustical performance of the panel 1.
  • the panel 1 is substantially square having a nominal dimension of 2 feet by 2 feet.
  • the panel 1 may be configured having any of a number of different shapes and dimensions.
  • the first and second surfaces 4, 12 define therebetween a thickness T 0 of about 4 mm.
  • the thickness To of the panel 1 may be greater or less than 4 mm.
  • the panel 1 is rigid and is self-supporting (e.g., within a suspended ceiling system), and is made of a plastic material (e.g., rigid polyvinyl chloride, ABS, high-impact polystyrene, etc.).
  • the panel 1 may be made of a foam or a porous, cellular material (e.g., extremely low-density rigid polyvinyl chloride, low density polystyrene, cellular ABS, etc.).
  • a foam or a porous, cellular material e.g., extremely low-density rigid polyvinyl chloride, low density polystyrene, cellular ABS, etc.
  • the panel 1 also includes a plurality of perforations 16 spanning the thickness To of the panel 1 and arranged in a regular 60° hexagonal pattern 20 such that the panel 1 appears visually opaque from a distance (e.g., 3 feet or more; see FIG. 2).
  • the perforations 16 may occur in a different hexagonal pattern, a non-hexagonal pattern, or an irregular pattern.
  • the hexagonal pattern 20 shown in FIG. 2 has an edge length Eo of 5.5 mm, and the perforations 16 are located at the respective vertices of the hexagonal pattern 20 and in the center of the hexagonal pattern 20.
  • the edge length E 0 may be greater or less than about 5.5 mm depending upon the size of the perforations 16.
  • the diameter Do of the perforations 16 is about 1 mm, and the perforations 16 collectively define an open area within the panel 1 of about 3%.
  • the panel 1 functions to allow acoustic (i.e., sound) waves from an environment to pass through the perforations 16 in the panel 1 and be absorbed rather than be reflected back into the environment, thereby decreasing the noise level and improving the comfort of occupants in the environment.
  • the panel 1 being made of a synthetic material, is unlike fiberboard-based panels in that it allows easy installation of the panels 1 , enhanced durability of the panel 1 from physical stress, resistance to growth of mold and mildew on the panel 1 , and ease of cleaning and/or sterilizing of the panel 1.
  • the panel 1 reduces noise levels and maintains the advantages of a conventional synthetic panel over a fiberboard-based panel.
  • FIG. 3 illustrates a composite panel structure 128 in accordance with a first embodiment of the invention for creating a wall, ceiling, or like structure in the interior of a building, or covering the exterior of a building.
  • the composite panel structure 128 includes a panel 101 and an insulation layer 132 positioned adjacent a first surface 104 of the panel 101.
  • the insulation layer 132 may be coupled to the first surface 104 of the panel 101 (e.g., using an adhesive).
  • the insulation layer 132 includes a first surface 136 in facing relationship with the first surface 104 of the panel 101 and a second surface 140 facing away from the first surface 104 of the panel 101.
  • the first and second surfaces 136, 140 of the insulation layer 132 define therebetween a thickness Ti of about 0.5 inches. Alternatively, the thickness Ti of the insulation layer 132 may be greater or less than 0.5 inches.
  • the insulation layer 132 is made of a porous, polyester insulation material. Alternatively, the insulation layer 132 may be made of any of a number of different insulating materials.
  • the panel 101 includes a plurality of perforations 1 16 spanning the thickness T 3 of the panel 101 , which is substantially similar to the thickness To of the panel 1 , and arranged in a regular 60° hexagonal pattern 120 (FIG. 4).
  • the hexagonal pattern 120 shown in FIG. 4 has an edge length Ei of 10.5 mm.
  • the edge length Ei may be greater or less than about 10.5 mm depending upon the size of the perforations 1 16.
  • the diameter Di of the perforations 1 16 is about 3.8 mm, and the perforations 1 16 collectively define an open area within the panel 101 of about 12%.
  • the composite panel structure 128 functions to allow acoustic (i.e., sound) waves from an environment to pass through the perforations 1 16 in the panel 101 and to encounter the insulation layer 132.
  • the insulation layer 132 absorbs some of the sound waves and reduces the sound waves that are reflected back into the environment, thereby decreasing the noise level and improving the comfort of occupants in the environment.
  • the panel 101 being made of a synthetic material, is unlike fiberboard-based panels in that it allows easy installation of the panels, enhanced durability of the panel from physical stress, resistance to growth of mold and mildew on the panel, and ease of cleaning and/or sterilizing of the panel.
  • the composite panel structure 128 reduces noise levels and maintains the advantages of a
  • FIGS. 5 and 6 illustrate a composite panel structure 228 in accordance with a second embodiment of the invention for creating a wall, ceiling, or like structure in the interior of a building, or covering the exterior of a building.
  • the composite panel structure 228 includes a panel 201 and a film 244 positioned adjacent a first surface 204 of the panel 201.
  • the film 244 includes a first surface 248 in facing relationship with the first surface 204 of the panel 201, and a second surface 252 facing away from the first surface 204 of the panel 201.
  • the first and second surfaces 248, 252 of the film 244 define therebetween a thickness T 2 of about 0.0015 inches.
  • the thickness T 2 of the film 244 may be greater or lesser than 0.0015 inches.
  • the film 244 is made of a plastic material (e.g., polyvinyl chloride).
  • the film 244 may be made from a non-plastic material (e.g., a fabric).
  • the film 244 also includes a plurality of microperforations (not shown) spanning the thickness T 2 of the film 244 and having a diameter between about 100 microns and about 300 microns.
  • the microperforations include a diameter of about 250 microns.
  • the density of the microperforations in the film 244 is between about 20 perforations/cm 2 and about 80 perforations/cm 2 .
  • the density of the microperforations in the film 244 is about 50 perforations/ cm 2 .
  • the panel 201 includes a plurality of perforations 216 spanning the thickness T 4 of the panel 201, which is substantially similar to the thickness T 0 of the panel 1, and arranged in a regular 60° hexagonal pattern 220.
  • the hexagonal pattern 220 shown in FIG. 6 has an edge length E 2 of 13.5 mm. Alternatively, the edge length E 2 may be greater or less than 13.5 mm depending upon the size of the perforations 216.
  • the diameter D 2 of the perforations 216 is about 6.35 mm, and the perforations 216 collectively define an open area within the panel 201 of about 20%.
  • the diameter D 2 of each of the perforations 216 may be between about 4 mm and about 8 mm, and the perforations 216 may collectively define an open area within the panel 201 between about 10% and about 30%.
  • an outer perimeter of the film 244 is adhered via an adhesive to an outer perimeter of the panel 201.
  • the adhesive is applied to about the outer one inch of the perimeter of the panel 201.
  • the remaining interior of the film 244 remains unadhered or unattached to the panel 201.
  • a middle or central portion of the film 244 "pillows-up" when sound waves pass through the perforations 216 in the panel 201, and the sounds waves are captured between the film 244 and the panel 201. Note that the extent to which the film 244 is shown "pillowed-up" in FIG. 5 is exaggerated for purposes of illustration.
  • the sound waves may also diffuse through the microperforations in the film 244 to reduce or attenuate the sound waves that are reflected back into an environment.
  • the outer perimeter of the film 244 may be adhered via an adhesive to an edge surface of the panel 201 having a length equivalent to the thickness T 4 of the panel 201 such that no portion of the film 244 is attached to the first surface 204 of the panel 201.
  • the composite panel structure 228 functions to allow acoustic (i.e., sound) waves from an environment to pass through the perforations 216 in the panel 201 and then encounter the film 244. The sound waves diffuse through the
  • the panel 201 being made of a synthetic material, is unlike fiberboard- based panels in that it allows easy installation of the panels, enhanced durability of the panel from physical stress, resistance to growth of mold and mildew on the panel, and ease of cleaning and/or sterilizing of the panel.
  • perforations 216 in the panel 201 and the film 244, the composite panel structure 228 reduces noise levels and maintains the advantages of a conventional synthetic panel over a fiberboard-based panel.
  • FIG. 7 depicts the random incidence sound absorption coefficient in a small reverberation room over a range of frequencies for the panel 1 shown in FIG. 1, the composite panel structure 128 shown in FIG. 3, and the composite panel structure 228 shown in FIG. 5.
  • Tests were conducted in accordance with ASTM C423-08a with an ASTM E795-00 type "E" mounting at a mounting depth of 16 inches. The test conditions were as follows: the temperature was 73 °F-76 °F, the relative humidity was 86-70%, and the barometric pressure was 969 hPa.
  • the second surface 12, 112, 212 of the respective panels 1, 101, 201 (i.e., the surface that would be facing the environment) faced the acoustic waves.
  • the panel 1 displayed the lowest sound absorption coefficient across a range of frequencies, while the composite panel structure 128 displayed the highest sound absorption coefficient except at higher frequencies.
  • the composite panel structure 228 displayed an intermediate sound absorption coefficient except at higher frequencies, where the structure 228 had a higher sound absorption coefficient than the panel 1 and the structure 128.
  • the data in FIG. 7 indicates that the presence of a film or an insulating layer increases the acoustic absorption performance of a perforated panel.

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Acoustics & Sound (AREA)
  • Building Environments (AREA)

Abstract

A composite panel structure adapted to be supported relative to a mounting surface includes a panel having a first surface and a second surface defining therebetween a thickness of the panel. The panel also has a plurality of perforations arranged in a hexagonal pattern and spanning the thickness of the panel. The perforations provide acoustic transparency to the panel. The composite panel structure further includes a film positioned adjacent the first surface of the panel to attenuate sound waves reflected from the panel.

Description

ACOUSTICAL PANELS FOR COVERING A WALL, CEILING, OR THE LIKE
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to co-pending U.S. Provisional Patent Application
No. 61/525,294 filed August 19, 2011, the entire content of which is incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to panels, and more particularly to panels for covering a wall, ceiling, or the like.
BACKGROUND OF THE INVENTION
[0003] Buildings of all types, including commercial, residential, and public buildings, require ceiling structures of some type to create an appropriate appearance within a building. In some buildings, a suspended ceiling system, which supports individual ceiling tiles or panels, may be installed. Fiberboard-based panels have high acoustic absorption, but must be replaced regularly when used in high moisture, high stress, or sterile environments. Vinyl or other synthetic panels, which are easier to install, do not need to be replaced as regularly as fiberboard- based panels because vinyl or synthetic panels provide enhanced durability from physical stress, are resistant to mold and mildew, and can be easily cleaned and/or sterilized. However, vinyl or synthetic panels may have reduced acoustic performance and therefore may not provide noise attenuation and comfort as may be desired by building occupants.
SUMMARY OF THE INVENTION
[0004] The present invention provides, in one aspect, a composite panel structure adapted to be supported relative to a mounting surface. The composite panel structure includes a panel having a first surface and a second surface defining therebetween a thickness of the panel. The panel also has a plurality of perforations arranged in a hexagonal pattern and spanning the thickness of the panel. The perforations provide acoustic transparency to the panel. The composite panel structure further includes a film positioned adjacent the first surface of the panel to attenuate sound waves reflected from the panel.
[0005] Other features and aspects of the invention will become apparent by consideration of the following detailed description and accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1 is a schematic side view of a panel in accordance with the invention.
[0007] FIG. 2 is an enlarged view of the panel of FIG. 1, illustrating a hexagonal perforation pattern in the panel.
[0008] FIG. 3 is a schematic side view of a composite panel structure in accordance with a first embodiment of the invention.
[0009] FIG. 4 is an enlarged view of the composite panel structure of FIG. 3, illustrating a hexagonal perforation pattern in a panel of the composite panel structure.
[0010] FIG. 5 is a schematic side view of a composite panel structure in accordance with a second embodiment of the invention.
[0011] FIG. 6 is an enlarged view of the composite panel structure of FIG. 5, illustrating a hexagonal perforation pattern in a panel of the composite panel structure.
[0012] FIG. 7 is a graph illustrating random incidence sound absorption coefficients in a small reverberation room over a range of frequencies for the panel of FIG. 1 and the composite panel structures of FIGS. 3 and 5.
[0013] Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. DETAILED DESCRIPTION
[0014] FIGS. 1 and 2 illustrate a panel 1 for creating a wall, ceiling, or like structure in the interior of a building. Alternatively, the panel 1 may be used on the exterior of a building. The panel 1 includes a first surface 4 in facing relationship with an upper ceiling structure 8 (or, alternatively, another interior mounting surface within a building) and a second surface 12 facing away from the upper ceiling structure 8. The first surface 4 of the panel and the upper ceiling structure 8 define therebetween an air gap having a length L0 of about 16 inches. The length L0 of the air gap may change depending upon the desired acoustical performance of the panel 1. In the illustrated construction, the panel 1 is substantially square having a nominal dimension of 2 feet by 2 feet. Alternatively, the panel 1 may be configured having any of a number of different shapes and dimensions. The first and second surfaces 4, 12 define therebetween a thickness T0 of about 4 mm. Alternatively, the thickness To of the panel 1 may be greater or less than 4 mm. The panel 1 is rigid and is self-supporting (e.g., within a suspended ceiling system), and is made of a plastic material (e.g., rigid polyvinyl chloride, ABS, high-impact polystyrene, etc.).
Alternatively, the panel 1 may be made of a foam or a porous, cellular material (e.g., extremely low-density rigid polyvinyl chloride, low density polystyrene, cellular ABS, etc.).
[0015] The panel 1 also includes a plurality of perforations 16 spanning the thickness To of the panel 1 and arranged in a regular 60° hexagonal pattern 20 such that the panel 1 appears visually opaque from a distance (e.g., 3 feet or more; see FIG. 2). Alternatively, the perforations 16 may occur in a different hexagonal pattern, a non-hexagonal pattern, or an irregular pattern. The hexagonal pattern 20 shown in FIG. 2 has an edge length Eo of 5.5 mm, and the perforations 16 are located at the respective vertices of the hexagonal pattern 20 and in the center of the hexagonal pattern 20. Alternatively, the edge length E0 may be greater or less than about 5.5 mm depending upon the size of the perforations 16. In the illustrated construction, the diameter Do of the perforations 16 is about 1 mm, and the perforations 16 collectively define an open area within the panel 1 of about 3%.
[0016] With reference to FIGS. 1 and 2, the panel 1 functions to allow acoustic (i.e., sound) waves from an environment to pass through the perforations 16 in the panel 1 and be absorbed rather than be reflected back into the environment, thereby decreasing the noise level and improving the comfort of occupants in the environment. The panel 1 , being made of a synthetic material, is unlike fiberboard-based panels in that it allows easy installation of the panels 1 , enhanced durability of the panel 1 from physical stress, resistance to growth of mold and mildew on the panel 1 , and ease of cleaning and/or sterilizing of the panel 1. By
incorporating perforations 16, the panel 1 reduces noise levels and maintains the advantages of a conventional synthetic panel over a fiberboard-based panel.
[0017] FIG. 3 illustrates a composite panel structure 128 in accordance with a first embodiment of the invention for creating a wall, ceiling, or like structure in the interior of a building, or covering the exterior of a building. Like components are shown with like reference numerals, plus "100." The composite panel structure 128 includes a panel 101 and an insulation layer 132 positioned adjacent a first surface 104 of the panel 101. Alternatively, the insulation layer 132 may be coupled to the first surface 104 of the panel 101 (e.g., using an adhesive). The insulation layer 132 includes a first surface 136 in facing relationship with the first surface 104 of the panel 101 and a second surface 140 facing away from the first surface 104 of the panel 101. The first and second surfaces 136, 140 of the insulation layer 132 define therebetween a thickness Ti of about 0.5 inches. Alternatively, the thickness Ti of the insulation layer 132 may be greater or less than 0.5 inches. The insulation layer 132 is made of a porous, polyester insulation material. Alternatively, the insulation layer 132 may be made of any of a number of different insulating materials.
[0018] The panel 101 includes a plurality of perforations 1 16 spanning the thickness T3 of the panel 101 , which is substantially similar to the thickness To of the panel 1 , and arranged in a regular 60° hexagonal pattern 120 (FIG. 4). The hexagonal pattern 120 shown in FIG. 4 has an edge length Ei of 10.5 mm. Alternatively, the edge length Ei may be greater or less than about 10.5 mm depending upon the size of the perforations 1 16. In the illustrated construction, the diameter Di of the perforations 1 16 is about 3.8 mm, and the perforations 1 16 collectively define an open area within the panel 101 of about 12%.
[0019] With reference to FIGS. 3 and 4, the composite panel structure 128 functions to allow acoustic (i.e., sound) waves from an environment to pass through the perforations 1 16 in the panel 101 and to encounter the insulation layer 132. The insulation layer 132 absorbs some of the sound waves and reduces the sound waves that are reflected back into the environment, thereby decreasing the noise level and improving the comfort of occupants in the environment. The panel 101, being made of a synthetic material, is unlike fiberboard-based panels in that it allows easy installation of the panels, enhanced durability of the panel from physical stress, resistance to growth of mold and mildew on the panel, and ease of cleaning and/or sterilizing of the panel. By incorporating perforations 116 in the panel 101 and the insulating layer 132, the composite panel structure 128 reduces noise levels and maintains the advantages of a
conventional synthetic panel over a fiberboard-based panel.
[0020] FIGS. 5 and 6 illustrate a composite panel structure 228 in accordance with a second embodiment of the invention for creating a wall, ceiling, or like structure in the interior of a building, or covering the exterior of a building. Like components are shown with like reference numerals, plus "200." The composite panel structure 228 includes a panel 201 and a film 244 positioned adjacent a first surface 204 of the panel 201. The film 244 includes a first surface 248 in facing relationship with the first surface 204 of the panel 201, and a second surface 252 facing away from the first surface 204 of the panel 201. The first and second surfaces 248, 252 of the film 244 define therebetween a thickness T2 of about 0.0015 inches. Alternatively, the thickness T2 of the film 244 may be greater or lesser than 0.0015 inches. The film 244 is made of a plastic material (e.g., polyvinyl chloride). Alternatively, the film 244 may be made from a non-plastic material (e.g., a fabric).
[0021] The film 244 also includes a plurality of microperforations (not shown) spanning the thickness T2 of the film 244 and having a diameter between about 100 microns and about 300 microns. Preferably, the microperforations include a diameter of about 250 microns. The density of the microperforations in the film 244 is between about 20 perforations/cm2 and about 80 perforations/cm2. Preferably, the density of the microperforations in the film 244 is about 50 perforations/ cm2.
[0022] The panel 201 includes a plurality of perforations 216 spanning the thickness T4 of the panel 201, which is substantially similar to the thickness T0 of the panel 1, and arranged in a regular 60° hexagonal pattern 220. The hexagonal pattern 220 shown in FIG. 6 has an edge length E2 of 13.5 mm. Alternatively, the edge length E2 may be greater or less than 13.5 mm depending upon the size of the perforations 216. In the illustrated construction, the diameter D2 of the perforations 216 is about 6.35 mm, and the perforations 216 collectively define an open area within the panel 201 of about 20%. In an alternative construction, the diameter D2 of each of the perforations 216 may be between about 4 mm and about 8 mm, and the perforations 216 may collectively define an open area within the panel 201 between about 10% and about 30%.
[0023] In the composite panel structure 228 of FIG. 5, an outer perimeter of the film 244 is adhered via an adhesive to an outer perimeter of the panel 201. The adhesive is applied to about the outer one inch of the perimeter of the panel 201. The remaining interior of the film 244 remains unadhered or unattached to the panel 201. A middle or central portion of the film 244 "pillows-up" when sound waves pass through the perforations 216 in the panel 201, and the sounds waves are captured between the film 244 and the panel 201. Note that the extent to which the film 244 is shown "pillowed-up" in FIG. 5 is exaggerated for purposes of illustration. The sound waves may also diffuse through the microperforations in the film 244 to reduce or attenuate the sound waves that are reflected back into an environment. In an alternative construction of the structure 228, the outer perimeter of the film 244 may be adhered via an adhesive to an edge surface of the panel 201 having a length equivalent to the thickness T4 of the panel 201 such that no portion of the film 244 is attached to the first surface 204 of the panel 201.
[0024] With reference to FIG. 5, the composite panel structure 228 functions to allow acoustic (i.e., sound) waves from an environment to pass through the perforations 216 in the panel 201 and then encounter the film 244. The sound waves diffuse through the
microperforations in the film 244 to reduce or attenuate the sound waves that are reflected back into an environment, thereby decreasing the noise level and improving the comfort of occupants in the environment. The panel 201 , being made of a synthetic material, is unlike fiberboard- based panels in that it allows easy installation of the panels, enhanced durability of the panel from physical stress, resistance to growth of mold and mildew on the panel, and ease of cleaning and/or sterilizing of the panel. By incorporating perforations 216 in the panel 201 and the film 244, the composite panel structure 228 reduces noise levels and maintains the advantages of a conventional synthetic panel over a fiberboard-based panel. [0025] The graph in FIG. 7 depicts the random incidence sound absorption coefficient in a small reverberation room over a range of frequencies for the panel 1 shown in FIG. 1, the composite panel structure 128 shown in FIG. 3, and the composite panel structure 228 shown in FIG. 5. Tests were conducted in accordance with ASTM C423-08a with an ASTM E795-00 type "E" mounting at a mounting depth of 16 inches. The test conditions were as follows: the temperature was 73 °F-76 °F, the relative humidity was 86-70%, and the barometric pressure was 969 hPa. The second surface 12, 112, 212 of the respective panels 1, 101, 201 (i.e., the surface that would be facing the environment) faced the acoustic waves. The panel 1 displayed the lowest sound absorption coefficient across a range of frequencies, while the composite panel structure 128 displayed the highest sound absorption coefficient except at higher frequencies. The composite panel structure 228 displayed an intermediate sound absorption coefficient except at higher frequencies, where the structure 228 had a higher sound absorption coefficient than the panel 1 and the structure 128. The data in FIG. 7 indicates that the presence of a film or an insulating layer increases the acoustic absorption performance of a perforated panel.
[0026] Various features of the invention are set forth in the following claims.

Claims

CLAIMS What is claimed is:
1. A composite panel structure adapted to be supported relative to a mounting surface, the composite panel structure comprising:
a panel including
a first surface and a second surface defining therebetween a thickness of the panel, and
a plurality of perforations arranged in a hexagonal pattern and spanning the thickness of the panel, the perforations providing acoustic transparency to the panel; and a film positioned adjacent the first surface of the panel to attenuate sound waves reflected from the panel.
2. The composite panel structure of claim 1, wherein the first surface of the panel is in facing relationship with the mounting surface, and wherein the second surface of the panel is facing away from the mounting surface.
3. The composite panel structure of claim 1, wherein the perforations in the panel are arranged in a regular 60 degree hexagonal pattern.
4. The composite panel structure of claim 1, wherein the perforations in the panel have a diameter between about 4 mm and about 8 mm.
5. The composite panel structure of claim 4, wherein the diameter of the perforations is about 6 mm.
6. The composite panel structure of claim 1, wherein the perforations in the panel collectively define an open area within the panel between about 10% and about 30%.
7. The composite panel structure of claim 6, wherein the open area within the panel is about 20%.
8. The composite panel structure of claim 1, wherein the film includes a first surface in facing relationship with the first surface of the panel and a second surface facing away from the first surface of the panel.
9. The composite panel structure of claim 8, wherein the first and second surfaces of the film define therebetween a thickness of the film.
10. The composite panel structure of claim 9, wherein the thickness of the film is about 0.0015 inches.
11. The composite panel structure of claim 9, wherein the film further includes a plurality of microperforations spanning the thickness of the film.
12. The composite panel structure of claim 11, wherein a density of the microperforations in the film is between about 20 perforations/cm2 and about 80 perforations/cm2.
13. The composite panel structure of claim 12, wherein the density of the microperforations in the film is about 50 perforations/cm2.
14. The composite panel structure of claim 11, wherein the microperforations have a diameter between about 100 microns and about 300 microns.
15. The composite panel structure of claim 14, wherein the diameter of the microperforations is about 250 microns.
16. The composite panel structure of claim 1, wherein the panel further includes an outer perimeter, and wherein the film includes an outer perimeter adhered to the outer perimeter of the panel.
17. The composite panel structure of claim 16, wherein the film further includes an interior, and wherein the interior of the film remains unadhered to the panel.
18. The composite panel structure of claim 16, wherein a portion of the film pillows-up when sound waves pass through the perforations in the panel, thereby capturing the sound waves between the film and panel.
19. The composite panel structure of claim 18, wherein the captured sounds waves diffuse through the film to attenuate the sound waves reflected back into an environment surrounding the composite panel structure.
20. The composite panel structure of claim 19, wherein the film further includes
microperforations, and wherein the sounds waves diffuse through the microperforations in the film.
21. The composite panel structure of claim 1, wherein the composite panel structure has a higher sound absorption coefficient than the panel alone in a test in accordance with ASTM C423-08a.
PCT/US2012/051329 2011-08-19 2012-08-17 Acoustical panels for covering a wall, ceiling, or the like WO2013028511A2 (en)

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Publication number Priority date Publication date Assignee Title
CN111232182A (en) * 2020-03-06 2020-06-05 中国商用飞机有限责任公司 Interior trim panel and application thereof
CN113803296A (en) * 2020-06-16 2021-12-17 中国航发商用航空发动机有限责任公司 Aircraft engine, acoustic lining pore plate and manufacturing method of acoustic lining pore plate
US20220148550A1 (en) * 2019-03-04 2022-05-12 Corning Incorporated Micro-perforated panel systems, applications, and methods of making micro-perforated panel systems

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WO1994019171A1 (en) * 1991-02-20 1994-09-01 Indian Head Industries, Inc. Insulating laminate
US5536556A (en) * 1991-02-20 1996-07-16 Indian Head Industries, Inc. Insulating laminate
US20020053484A1 (en) * 2000-09-06 2002-05-09 Atsushi Murakami Sound absorbing structure
US20040020712A1 (en) * 2002-08-02 2004-02-05 C.T.A Acoustics Acoustical insulation laminate with polyolefin layer and process for making
US20110180348A1 (en) * 2008-04-22 2011-07-28 Mari Nonogi Hybrid sound absorbing sheet

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WO1994019171A1 (en) * 1991-02-20 1994-09-01 Indian Head Industries, Inc. Insulating laminate
US5536556A (en) * 1991-02-20 1996-07-16 Indian Head Industries, Inc. Insulating laminate
US20020053484A1 (en) * 2000-09-06 2002-05-09 Atsushi Murakami Sound absorbing structure
US20040020712A1 (en) * 2002-08-02 2004-02-05 C.T.A Acoustics Acoustical insulation laminate with polyolefin layer and process for making
US20110180348A1 (en) * 2008-04-22 2011-07-28 Mari Nonogi Hybrid sound absorbing sheet

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20220148550A1 (en) * 2019-03-04 2022-05-12 Corning Incorporated Micro-perforated panel systems, applications, and methods of making micro-perforated panel systems
CN111232182A (en) * 2020-03-06 2020-06-05 中国商用飞机有限责任公司 Interior trim panel and application thereof
CN113803296A (en) * 2020-06-16 2021-12-17 中国航发商用航空发动机有限责任公司 Aircraft engine, acoustic lining pore plate and manufacturing method of acoustic lining pore plate

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