METHOD FOR MAKING ACOUSTICAL PANELS WITH A THREE-DIMENSIONAL SURFACE

PROCEDE DE FABRICATION DE PANNEAUX ACOUSTIQUES A SURFACE TRIDIMENSIONNELLE

English Abstract

A method for producing acoustical panels with a three-dimensional surface by bonding stacks of design pieces (21-28) to a flat panel (10). A layer of adhesive (30) is applied over the assembly, and then a fabric layer (40) is applied over the assembly to bond the fabric (40) over the panel (10) and design pieces (21- 28).

French Abstract

Un procédé permettant de produire des panneaux acoustiques avec une surface tridimensionnelle par collage de piles déléments de conception (21-28) sur un panneau plat (10). Une couche dadhésif (30) est appliquée sur lensemble, puis une couche de tissu (40) est appliquée par-dessus lensemble pour coller le tissu (40) sur le panneau (10) et les éléments de conception (21- 28).

Claims

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CLAIMS:
1. A method for making an acoustical panel with a three-dimensional surface
comprising.
providing an acoustical panel having a substantially flat surface;
forming design pieces;
attaching the design pieces to the surface of the panel to create three-
dimensional designs;
applying adhesive to the design pieces and surface of the panel;
placing an air-permeable, thin flexible layer over the design pieces and
panel;
placing an air-impermeable layer over the thin flexible layer;
drawing air through the panel to suck the thin flexible layer and air-
impermeable layer against the design pieces and surface of the panel: and
removing the air-impermeable layer, while leaving the thin flexible layer to
bond with the adhesive.
2. The method of claim 1 wherein the thin flexible layer comprises fabric.
3. The method of claim 1 wherein acoustical panel is air-permeable.
4. The method of claim 3 wherein the acoustical panel comprises fiberglass.
5. The method of claim 1 further comprising applying a hardening material
to the
edges of the acoustical panel prior to bonding the thin flexible layer.
6. The method of claim 1 further comprising attaching reinforcing material
to the
edges of the acoustical panel prior to bonding the thin flexible layer.

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7. The
method of claim 1 wherein a plurality of flat design pieces are stacked to
create the three-dimensional design.

Description

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METHOD FOR MAKING ACOUSTICAL PANELS
WITH A THREE-DIMENSIONAL SURFACE
BACKGROUND OF THE INVENTION
Field of the Invention. The present invention relates generally to the field
of acoustical panels. More specifically, the present invention discloses a
method
for making acoustical panels with a three-dimensional surface.
Statement of the Problem. Acoustical panels have been used for many
years in a variety of fields of use. For example, many acoustical panels are
used
in suspended ceilings, or as ceiling panels or wall panels. The exposed
surfaces
of most acoustical panels are substantially flat, although many are texturized
or
perforated on a fine scale to provide an aesthetically-pleasing appearance.
Some acoustical panels have been made with a three-dimensional surface
by molding, embossing or cutting away portions of the panel surface. However,
these techniques have inherent limitations in that only so much material can
be
removed, and the panel thickness can only be reduced to a limited degree
without
jeopardizing the structural properties of the resulting acoustical panel.
Thus, the
range of depth and contour of the three-dimensional surfaces that can be
formed
with such techniques is very limited.
Solution to the Problem. The present invention addresses the
shortcomings of the prior art in this field by employing a process of bonding
design
pieces to the face of a flat panel to build up a desired three-dimensional
pattern,
and then applying a fabric cover layer over the assembly. This approach allows
three-dimensional patterns of virtually any complexity and depth to be created
without jeopardizing the structural properties of the panel.
SUMMARY OF THE INVENTION
This invention provides a method for producing acoustical panels with a
three-dimensional surface by bonding stacks of design pieces to a flat panel,
applying a layer of adhesive over the assembly, and then applying a fabric
layer
over the assembly (e.g., drawn down by suction) to bond the fabric over the
panel
and design pieces.

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These and other advantages, features, and objects of the present invention
will be more readily understood in view of the following detailed description
and
the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention can be more readily understood in conjunction with
the accompanying drawings, in which:
FIG. 1 is a perspective view of a flat acoustical panel 10.
FIG. 2 is a perspective view showing design pieces 21 - 28 for the three-
dimensional surface being marked out.
FIG. 3 is a perspective view showing the design pieces 21 - 28 from FIG. 2
being cut out.
FIG. 4 is a perspective view showing the design pieces 21 - 28 laid out
after cutting.
FIG. 5 is a detail perspective view showing two stacked design pieces 21,
22 abutting the edge of an acoustical panel 10.
FIG. 6 is a perspective view showing the layout of the design being marked
on an acoustical panel 10 for placement of the design pieces 21 -28.
FIG. 7 is an exploded perspective view showing the design pieces 21 - 28
being placed on the acoustical panel 10. The shaded areas represent adhesive
30
placement.
FIG. 8 is a perspective view showing the design pieces bonded to
acoustical panels 10 and 11.
FIG. 9 is a detail perspective view showing hardening of the edges of the
assembled panel (i.e., the shaded area).
FIG. 10 is a perspective view showing the panel 10 in a spray booth being
sprayed with adhesive 30 in preparation for applying fabric to the panels.
FIG. 11 is a perspective view showing the panel 10 placed on a vacuum
table 50 with a fabric layer 40 and an air-impermeable cover layer 45 being
drawn
down by suction down over the acoustical panel 10 and design pieces 21 - 28.
FIG. 12 is a perspective view showing a heat machine 54 placed over the
panel assembly in FIG. 11 to further the curing process.

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FIG. 13 is a detail perspective view of a portion of a finished panel 60
showing the fabric layer 40 folded around the edge of the panel and formed
over
the design pieces.
FIG. 14 is a perspective view of three panels 60 - 62 assembled together
showing how designs 65 can be continuous from one panel to the next.
DETAILED DESCRIPTION OF THE INVENTION
Turning to FIG. 1, a perspective view is provided of a flat acoustical panel
10. This panel 10 serves as the base or substrate for the present invention.
The
panel 10 can be made of any conventional material suitable for its intended
use,
such as fiberglass. Optionally, the acoustical panel 10 should be air-
permeable if
the present method employs suction to apply a fabric layer, as will be
discussed in
detail below.
FIG. 2 is a perspective view showing design pieces 21 - 28 for creating the
three-dimensional surface being marked out on a fiberglass board 20. FIG. 3
shows these design pieces 21 - 28 being cut out. The pieces 21 - 28 are laid
out
after cutting in FIG. 4. The design pieces 21 - 28 are then used in
constructing
raised three-dimensional surfaces on the flat panel 10. The design pieces 21 -
28
can either be placed singly atop the panel 10, or they can be stacked to any
desired height on the panel 10. For example, FIG. 5 shows two design pieces 21
and 22 stacked on a panel 10 to create a three-dimensional surface with a
visual
effect similar to a contour map. It should be understood that the design
pieces can
have any desired thicknesses, dimensions or cross-sectional shapes to create
aesthetically pleasing three-dimensional surfaces.
After the design pieces 21 - 28 have been cut out, their proper placement
can be marked on the panel 10 for assembly. FIG. 6 is a perspective view
showing the layout of the design being marked on a panel 10 for placement of
the
design pieces 21 - 28. The design pieces 21 - 28 are then bonded with adhesive
30 to the panel 10 and to each other as illustrated in FIG. 7 to build up the
desired
three-dimensional surface on the panel 10. This design can extend over
multiple
panels 10, 11. For example, FIG. 8 is a perspective view showing the design
pieces bonded to two acoustical panels 10, 11 to create a continuous three-

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dimensional design. Optionally, the exposed edges of the panel 10 and design
pieces 21 - 28 can be hardened by applying a hardening material 35 (e.g.,
epoxy),
as shown in FIG. 9, to increase structural strength and reduce the risk of
damage
of the edges of the panel assembly. Reinforcing material (e.g., thin sheets of
rigid
paper, cardboard or particle board) can also be bonded or attached to the
edges
of the panel 10 and/or design pieces 21 -28.
Next, the assembled panel 10 and design pieces 21 - 28 are placed in a
spray booth beneath spray nozzles 52 and coated with adhesive 30 as depicted
in
FIG. 10. A thin flexible layer 40 (e.g., fabric) is then applied over the
assembled
panel 10 and design pieces 21 - 28. For example, this step can be done by
moving the panel assembly to a suction table 50 (as shown in FIG. 11), placing
fabric 40 over the assembled panel 10 and design pieces 21 - 28, and then
drawing down the fabric 40 by suction through the panel 10.
Optionally, a layer of air-impermeable flexible material 45 (e.g., a thin
plastic or vinyl sheet) can be temporarily placed over the fabric 40 to assist
in
drawing the fabric 40 into close contact with panel assembly and the adhesive
layer. The air-impermeable layer is then removed, while leaving the fabric
layer 40
in place to bond with the adhesive 30. This temporary air-impermeable layer is
more likely to be needed if the fabric layer 40 is loosely woven or very air-
permeable. FIG. 11 is a perspective view showing the panel assembly placed on
a
suction table 50 with a fabric layer 40 and an air-impermeable cover layer 45
being drawn down by suction down over the panel 10 and design pieces 21 - 28.
FIG. 12 is a perspective view showing a heat machine 54 placed over the
panel assembly in FIG. 11 to further curing of the adhesive 30. This step may
be
optional depending on the adhesive selected. Finally, FIG. 13 is a detail
perspective view of a portion of a finished panel showing the fabric 40 folded
around the edge of the panel and formed over the design pieces to complete the
assembly.
It should be understood that virtually any desired three-dimensional design
can be created on a panel 10 by employing the present invention. The designs
can be limited to a single panel or a particular region of a panel.
Alternatively, FIG.

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14 illustrates a series of panels 60, 61 and 62 assembled together showing
designs 65 that span multiple panels.
The above disclosure sets forth a number of embodiments of the present
invention described in detail with respect to the accompanying drawings. Those
skilled in this art will appreciate that various changes, modifications, other
structural arrangements, and other embodiments could be practiced under the
teachings of the present invention without departing from the scope of this
invention as set forth in the following claims.

Representative Drawing