U.S. patent application number 10/749087 was filed with the patent office on 2005-06-30 for translating an aesthetically pleasing surface on an acoustic substrate to the edge of the finished acoustical product.
Invention is credited to Berdan, Clarke II, Martine, Edward A., Parks, Jerry M., Webster, Philip M..
Application Number | 20050142335 10/749087 |
Document ID | / |
Family ID | 34701012 |
Filed Date | 2005-06-30 |
United States Patent
Application |
20050142335 |
Kind Code |
A1 |
Berdan, Clarke II ; et
al. |
June 30, 2005 |
Translating an aesthetically pleasing surface on an acoustic
substrate to the edge of the finished acoustical product
Abstract
A method for translating a decorative surface of an acoustic
substrate to an edge of the finished acoustical product is
provided. A portion of an acoustical substrate having a decorative
surface on a first side is compressed to form a void having at
least one adjacent region of compressed material having an
increased density. The acoustical substrate is then manipulated to
close the void and place at least a portion of the decorative
surface on a side of the substrate. The manipulation of the
acoustical substrate also places the region of compressed material
at the edges of the acoustical substrate, thereby reinforcing the
edges of the acoustical product. A decorative non-woven acoustic
panel that has at least one peripheral edge with a density greater
than the density of the main body is also provided.
Inventors: |
Berdan, Clarke II;
(Granville, OH) ; Parks, Jerry M.; (Granville,
OH) ; Martine, Edward A.; (Newark, OH) ;
Webster, Philip M.; (Brantford, CA) |
Correspondence
Address: |
OWENS CORNING
2790 COLUMBUS ROAD
GRANVILLE
OH
43023
US
|
Family ID: |
34701012 |
Appl. No.: |
10/749087 |
Filed: |
December 30, 2003 |
Current U.S.
Class: |
428/192 |
Current CPC
Class: |
E04B 1/86 20130101; Y10T
428/24942 20150115; E04B 2001/7687 20130101; E04B 2103/04 20130101;
G10K 11/16 20130101; Y10T 428/24777 20150115; A47B 81/06
20130101 |
Class at
Publication: |
428/192 |
International
Class: |
B32B 023/02 |
Claims
Having thus described the invention, what is claimed is:
1. A decorative acoustic panel comprising: a main body formed of a
first material having a first density; at least one peripheral edge
formed of said first material and having a second density, said
second density being greater than said first density; and a
decorative surface.
2. The acoustic panel according to claim 1, wherein said decorative
surface is positioned on a top surface of said main body and said
at least one peripheral edge.
3. The acoustic panel of claim 1, wherein said main body and said
at least one peripheral edge are formed from an acoustic substrate
formed of a thermoplastic acoustic material.
4. The acoustic panel according to claim 3, wherein said acoustic
material is a matrix of polyester staple and copolyester/polyester
bicomponent fibers.
5. The acoustic panel according to claim 3, wherein said at least
one peripheral edge is formed by compressing portions of said
acoustic substrate to form compressed regions and rotating said
compressed regions.
6. The acoustic panel according to claim 5, wherein said decorative
surface is formed on a second material and is affixed to said
acoustic panel after forming said at least one peripheral edge.
7. The acoustic panel according to claim 5, wherein said decorative
surface is formed on a second material and is affixed to said
acoustic substrate prior to forming said at least one peripheral
edge.
8. The acoustic panel according to claim 5, wherein said decorative
surface is integral with a major surface of said acoustic substrate
and is applied prior to forming said at least one peripheral
edge.
9. The acoustic panel according to claim 5, wherein said decorative
surface is integral with a major surface of said acoustic substrate
and is applied after forming said at least one peripheral edge.
10. An acoustic panel comprising: a main body; and a reinforcing
edge on at least one side of said main body formed by compressing
an adjacent outer region to form a compressed region that is
rotated against said main body to form said reinforcing edge.
11. The acoustic panel of claim 10, wherein said reinforcing edge
is formed on opposing sides of said main body.
12. The acoustic panel of claim 10, wherein each said reinforcing
edge has a first density and said main body has a second density
that is less than said first density.
13. The acoustic panel of claim 12, wherein a side of said main
body and each said reinforcing edge includes a decorative
design.
14. The acoustic panel of claim 13, wherein each said reinforcing
edge is bonded to said main body through an application of heat to
soften and bond adjacent fibers located in said reinforcing edge
and said main body.
15. The acoustic panel of claim 13, wherein at least one of said
reinforcing edges is double folded against said main body.
16. The acoustic panel of claim 13, wherein each said reinforcing
edge extends equidistantly beyond said main body.
17. The acoustic panel of claim 13, wherein at least one of said
reinforcing edges is folded flush with a back surface of said main
body.
18. The acoustic panel of claim 16, wherein said reinforcing edges
are formed on all sides of said main body from corresponding
compressed regions.
19. The acoustic panel of claim 13, wherein reinforcing edge has a
non-linear shape.
20. A method of forming a decorative acoustic panel having a
reinforced edge comprising: compressing a portion of an acoustic
substrate having at least a first side including a decorative
surface and a back side opposing said first side to form a void
with at least one adjacent region of compressed material; and
manipulating said at least one adjacent region of compressed
material to close said void and place said compressed material at
an edge of said acoustical substrate to form a reinforced edge,
said manipulation placing at least a portion of said decorative
surface on a side of said acoustic substrate and forming an
acoustic panel.
21. The method of claim 20, wherein said void is a groove that
includes a fold point and said manipulating step comprises rotating
said region of compressed material about said fold point toward
said back side until said groove is closed.
22. The method of claim 20, further comprising: heating said
acoustic panel to bond adjacent fibers in said acoustic substrate;
and cooling said acoustic panel to maintain a shape of said
acoustic panel.
23. The method of claim 20, further comprising molding said
acoustic panel into a desired shape.
24. The method of claim 20, wherein said acoustic substrate has a
first density and said region of compressed material has a second
density that is higher then said first density.
25. A method of forming a decorative acoustic panel having a
reinforced edge comprising: scoring an acoustical substrate having
a decorative surface on at least a major side along a first score
line to form a first outer region and an inner region, said
acoustical substrate having a back side opposing said major side;
compressing said first outer region to form a first flange; and
rotating said first flange toward a back side of said acoustical
substrate to form a reinforced edge, said rotation placing said
decorative surface on said reinforced edge and forming an acoustic
panel.
26. The method of claim 25, wherein said first flange is rotated
until said first flange is flush with said inner region.
27. The method according to claim 26, further comprising removing a
portion of said first flange at an intersection region of said
first outer region and said inner region to facilitate rotation of
said first flange toward said back side of said acoustical
substrate.
28. The method according to claim 27, wherein said removed portion
is a first notch having a first fold point.
29. The method according to claim 28, wherein said rotating step
comprises rotating said first flange toward said back side about
said first fold point.
30. The method according to claim 25, further comprising removing a
portion of said inner region to form a nesting region to receive
said first flange.
31. The method according to claim 25, wherein said first flange has
a length dimension greater than a width dimension of said
acoustical substrate, and wherein when said first flange is rotated
flush with said inner region, a first portion of said first flange
extends beyond said width dimension of said acoustical
substrate.
32. The method according to claim 31, further comprising rotating
said first portion of said first flange toward said back side until
said first portion is flush with said back side.
33. The method according to claim 25, wherein said first flange has
a length dimension that is equal to a width dimension of said
acoustical substrate.
34. The method according to claim 33, further comprising scoring
said acoustical substrate along a second score to form a second
outer region and compressing said second outer region to form a
second flange.
35. The method according to claim 34, further comprising rotating
said second flange toward said back side of said acoustical
substrate until said second flange is flush with said inner region
and said decorative surface is placed on a second side of said
acoustical substrate.
36. The method according to claim 35, wherein said second flange
has a length dimension greater than a width dimension of said
acoustical substrate, and wherein when said second flange is
rotated flush with said inner region, a second portion of said
second flange extends beyond said width dimension of said
acoustical substrate.
37. The method according to claim 36, further comprising rotating
said second portion of said second flange toward said back side
until said second portion is flush with said back side.
38. The method according to claim 25, wherein said first flange
includes an inner and an outer portion.
39. The method according to claim 38, wherein said rotating step
comprises: rotating said outer portion of said first flange toward
said back side until said outer portion is flush with said inner
portion to form a folded flange; and rotating said folded flange
toward said back side until said folded flange is flush with said
inner region.
40. The method of claim 25, wherein said acoustic substrate has a
first density and said compressed material has a second density
that is higher then said first density.
41. A method of forming an acoustic panel from an acoustic
substrate formed of acoustic material having an upper side
including a decorative surface thereon comprising: compressing a
perimeter region of said acoustic substrate to form a central core
of said acoustic material having a first density and a perimeter
flange of said acoustic material having a second density greater
than said first density, said central core including first, second,
third and fourth sides; sizing said perimeter flange such that said
perimeter flange has a width dimension substantially equal to a
corresponding one of said sides, said perimeter flange having said
decorative surface on an upper side thereof; and folding said
perimeter flange relative to said central core so that said
perimeter flange is positioned with said decorative surface
oriented substantially perpendicularly to said upper side of said
central core, said folded perimeter flange forming a reinforcing
edge for said acoustic panel.
42. The method of claim 41, wherein said compressing step forms
said perimeter flange extending substantially completely around
said central core.
43. The method of claim 42, wherein said sizing step comprises:
removing a corner portion of said perimeter flange adjacent two of
said sides; and repeating said removing step until all corner
portions of said perimeter flange have been removed, leaving
perimeter flange members with a width dimension corresponding to
corresponding said sides of said central core.
44. The method of claim 43, wherein each said perimeter flange
member has a length dimension greater than said thickness of said
central core such that after said folding step said perimeter
flange members extend below said bottom surface of said central
core.
45. The method of claim 44, wherein said perimeter flange members
have identical length dimensions such that after said folding step
said perimeter flange members terminate in a common plane oriented
generally parallel to said bottom surface, said perimeter flange
members defining an open cavity surrounded by said folded perimeter
flange members and terminating against said bottom surface of said
central core.
46. The method of claim 45, further comprising: inserting a frame
member into said open cavity for attachment to said folded
perimeter flange members.
Description
TECHNICAL FIELD AND INDUSTRIAL APPLICABILITY OF THE INVENTION
[0001] The present invention relates generally to acoustic panels
and more particularly to a method for translating a decorative
surface of an acoustic substrate to an edge of the finished
acoustical product. An aesthetically pleasing acoustic panel with
reinforced sides is also provided.
BACKGROUND OF THE INVENTION
[0002] Acoustical sound insulators, such as acoustic panels, are
used in a variety of settings where it is desired to dampen noise
from an external source. For example, acoustic panels are commonly
used in office buildings to attenuate sound generated from the
workplace, such as from telephone conversations or from the
operation of office equipment. Acoustic panels are typically formed
of a sound absorbing core material positioned within a frame and
covered by a material, such as fabric or a painted surface, to make
the front side of the panel aesthetically pleasing. In addition,
when a frame is not used, the edges of the core material are coated
with an adhesive layer and hardened to give strength and rigidity
to the acoustic panel. Often, the fabric material is wrapped around
the sides of the core material and fastened to the back side of the
panel by an adhesive or staples so that the sides of the panel are
also aesthetically pleasing. The fabric material may contain a
decorative design or pattern.
[0003] Although conventional acoustic panels are able to dampen
sound over a wide sound/frequency spectrum and may be aesthetically
pleasing, they are costly to manufacture and difficult to assemble.
To manufacture the acoustic panel, the core material is first
fabricated to the finished panel dimensions. The frame must then be
properly sized so that the core material fits securely inside.
Next, the fabric material is cut to the shape of the finished panel
but with sufficient excess so that the fabric material can be
wrapped around the edges and secured to the back side of the panel.
This excess of fabric material leads to waste and excess cost.
[0004] To assemble the acoustic panel, the core material is placed
into the frame, the fabric material is wrapped around the panel,
and the fabric material is secured to the backside of the panel. In
order to ensure that there are no sags in the fabric material, the
fabric material must be pulled tightly across and around the panel
before securing the fabric material to the panel. In addition, if
the fabric contains a design, the fabric must be placed in the
proper orientation so that the finished assembly of acoustic panels
achieves the desired design. Therefore, the assembly of the
acoustic panel can be time consuming and tedious.
[0005] Thus, there exists a need in the art for an acoustic panel
that contains a decorative surface on both the front of the panel
and the sides of the panel that is easy to manufacture, easy to
assemble, and is inexpensive.
SUMMARY OF THE INVENTION
[0006] An object of the invention is to provide methods for
translating a surface on a front side of an acoustical substrate to
an edge of a finished acoustical product. In one exemplary method,
an acoustical substrate of uncompressed fibrous material having a
first density is provided. The acoustical substrate has at least a
first surface containing a decorative design, a back surface
opposing the first surface, a left edge, and a right edge. The
decorative design may be directly applied to the first surface or a
decorative veil (e.g., a woven or non-woven fabric) may be applied
to the first surface for aesthetic purposes. At least one portion
of the acoustical substrate is compressed to form at least one
compressed region having a second density that is greater than the
first density and at least one groove having a fold point. The
compressed region(s) is then rotated about the fold point toward
the back surface until the groove is closed. The rotation of the
compressed region(s) moves at least a portion of the decorative
surface to at least one side of the final acoustical product. Thus,
the decorative surface may be translated to any one or all four
sides of the final acoustical product. The rotation also places the
compressed region at the edge(s) of the final acoustical product,
which reinforces the side(s) of the final acoustical product. The
final acoustical product may be formed of reinforced edges having
any linear or non-linear shape.
[0007] In another exemplary method, the acoustical substrate is
scored along at least one score line to form at least one outer
region and an inner region. The outer region(s) is then compressed
to form at least a first flange having a density that is higher
than the density of the uncompressed inner region. The flange(s) is
then rotated toward the back side of the acoustical substrate until
the flange(s) is flush with the inner region. The rotation of the
flange(s) moves at least a portion of the decorative surface to at
least one side of the final acoustical product. This rotation also
places the compressed region(s) at the edge(s) of the final
acoustical product, which reinforces the side(s) of the final
acoustical product. If the flange(s) extends beyond the back
surface, the flange(s) may again be folded toward the back surface
until the flange is flush with the back surface. The second
rotation of the flange(s) toward the back surface places at least a
portion of the decorative design on the back surface of the final
acoustical product.
[0008] In an alternative embodiment, at least one flange is formed
of an inner portion and an outer portion. The outer portion of the
flange is then rotated toward the back surface until the outer
portion of the flange is flush with the inner portion of the
flange. The folded flange is then folded toward the back surface
until the folded flange is flush with the inner region, thereby
placing the decorative surface on a side of the final acoustical
product. In addition, because the folded flange contains two layers
of compressed, densified material, the side of the final acoustical
product that contains the folded flange is highly reinforced.
[0009] Another object of the invention is to provide a decorative
non-woven acoustic panel. The acoustic panel includes a main body
of uncompressed fibrous material that has a first density and at
least one peripheral edge formed of compressed fibrous material
having a second density that is greater than the first density. The
decorative surface extends across a major surface and at least one
side of the acoustic panel. The decorative surface may be integral
with the acoustic panel or it may be a separate material, such as a
decorative fabric or veil.
[0010] The acoustic panel may be formed of a self-molding
thermoplastic acoustical material that is lightweight, permeable to
air, and capable of being compressed or molded. Fiber systems that
are heat moldable or which can be repositioned and held in place by
ultrasonics, by an adhesive, or by other commonly used fixation
technologies may be used as the acoustical material. In addition,
the acoustic panel may be formed of a matrix of staple and heat
fusible fibers such as bicomponent fibers. In a preferred
embodiment, the acoustic panel is a matrix of polyester staple and
copolyester/polyester bicomponent fibers where the sheath component
fibers have a lower melting point than the core component fibers
and the staple fibers.
[0011] The present invention further includes an acoustic panel
that has reinforced sides formed of compressed acoustic material
having a first density surrounding a central core formed of
uncompressed acoustic material having a second density. The
reinforced sides of the acoustic panel extend beyond the central
core. The acoustic panel may be attached to a frame for mounting to
a surface.
[0012] The foregoing and other objects, features, and advantages of
the invention will appear more fully hereinafter from a
consideration of the detailed description that follows, in
conjunction with the accompanying sheets of drawings. It is to be
expressly understood, however, that the drawings are for
illustrative purposes and are not to be construed as defining the
limits of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIGS. 1a-1d are schematic illustrations depicting a method
of translating a decorative surface to the edges of a final
acoustical product according to one exemplary embodiment of the
present invention;
[0014] FIGS. 2a-2e are schematic illustrations depicting an
alternative location for the grooves formed by the method depicted
in FIGS. 1a-1d;
[0015] FIGS. 3a-3d are schematic illustrations depicting a second
method for translating a decorative surface to the edges of final
acoustical product according to one exemplary embodiment of the
present invention;
[0016] FIGS. 4a-4b are schematic illustrations depicting an
alternative embodiment of the method of FIGS. 3a-3d in which
notches are cut into the first and second flanges;
[0017] FIGS. 5a-5e are schematic illustrations depicting an
alternate embodiment of the method of FIGS. 3a-3d in which the
second flange is folded twice to provide a highly reinforced
edge;
[0018] FIGS. 6a-6c are schematic illustrations depicting an
alternate embodiment of the method of FIGS. 3a-3d in which the
first and second flanges extend beyond the back surface of the
final acoustical product; and
[0019] FIGS. 7a-7f are schematic illustrations depicting an
alternate embodiment of the method of FIGS. 6a-6c in which four
flanges are formed and folded to form a box-like final acoustical
product.
DETAILED DESCRIPTION AND PREFERRED EMBODIMENTS OF THE INVENTION
[0020] Unless defined otherwise, all technical and scientific terms
used herein have the same meaning as commonly understood by one of
ordinary skill in the art to which the invention belongs. Although
any methods and materials similar or equivalent to those described
herein can be used in the practice or testing of the present
invention, the preferred methods and materials are described
herein. It is to be noted that like numbers found throughout the
figures denote like elements.
[0021] The present invention relates to methods for translating a
decorative surface on a front side of an acoustical substrate to an
edge of the finished acoustical product. One exemplary inventive
method is illustrated in FIGS. 1a-1d. As shown in FIG. 1a, an
acoustical substrate 10 is provided which has a first surface 5, a
back surface 6 opposing the first surface 5, a left edge 7, and a
right edge 8. The first surface 5 includes a left first surface 2,
a central first surface 3, and a right first surface 4. The
acoustical substrate 10 contains a decorative design (not shown) on
the first surface 5 for aesthetic purposes. The decorative design
may be directly applied to the first surface 5. Alternatively, a
decorative veil (not shown) may be positioned on the first surface
5 to provide a design. As used herein, the term "veil" is meant to
include both woven and non-woven fabrics. Although a decorative
design may be located on the first surface 5, a decorative design
or decorative veil may also optionally be located on the back
surface 6.
[0022] The material used to form the acoustical substrate 10 may be
a self-molding thermoplastic acoustical material that is
lightweight, permeable to air and capable of being compressed or
molded, such as by a conventional compression or molding press. For
example, the acoustical substrate 10 may be a matrix of polymer
fibers, such as, but not limited to, polyethylene fibers,
polypropylene fibers, polyester fibers, such as polyethylene
terephthalate (PET) fibers, polyamide fibers, polyphenylene sulfide
(PPS) fibers, polystyrene fibers, polycarbonate fibers, natural
fibers (e.g., cotton and cellulose), inorganic fibers (e.g., glass
fibers), or mixtures thereof. Preferably, the polymer fibers are a
blend polyethylene terephthalate (PET). Other fiber systems that
are heat moldable or which can be repositioned and held in place by
ultrasonics, by an adhesive, or by other commonly used fixation
technologies easily identifiable by one of skill in the art are
considered to be within the purview of this invention. In addition,
the acoustical substrate 10 may have a thickness of from
approximately 0.1 inch-4.0 inches and a density of from
approximately 1 lb/ft.sup.3-10 lb/ft.sup.3. In the inventive
methods discussed below, the compressed regions preferably have a
density of from approximately 7 lbs/ft.sup.3-30 /ft.sup.3. In each
of the inventive embodiments described below, the compressed
regions have a density that is greater than the non-compressed
regions.
[0023] In a preferred embodiment, the acoustical substrate 10 is
formed of a matrix of staple and heat fusible fibers such as
bicomponent fibers. Bicomponent fibers may be formed of two
polymers combined to form fibers having a core of one polymer and a
surrounding sheath of the other polymer. When bicomponent fibers
are used as a component of the acoustic material, the bicomponent
fibers may be present in an amount of from 10-100% of the total
fibers. In the instant invention, the acoustical substrate is
preferably a matrix of polyester staple and copolyester/polyester
bicomponent fibers where the sheath component fibers have a lower
melting point than the core component fibers and the staple
fibers.
[0024] To translate the decorative design located on the first
surface 5 to an edge of the finished acoustical product, at least
one region of the acoustical substrate 10 may be compressed in a
manner such that at least a portion of the first surface 5 can be
folded toward the back surface 6 to place the decorative design
located on the first surface 5 on the edge of the finished product.
In the embodiment depicted in FIG. 1b, portions of the back surface
6 of the acoustical substrate 10 are compressed, such as by a heat
"V" groove molding wheel, to form a first groove 20 and a second
groove 21. As depicted in FIG. 1c, the left portion 24 formed by
first groove 20 contains the left first surface 2, the left edge 7,
and a first inner surface 12. The right portion 25 contains the
right first surface, the right edge 8, and a second inner surface
13. The left and right portions 24, 25 of the acoustical substrate
10 may then folded or rotated about first and second fold points 14
and 15 respectively, as shown from the phantom lines in FIG. 1c, to
collapse first and second grooves 21, 22. FIG. 1d illustrates the
final acoustical product 30 formed once the left portion 24 and the
right portion 25 have been rotated and first and second grooves 20,
21 have been completely collapsed.
[0025] As shown in FIG. 1d, in the final acoustical product 30, the
decorative design located on the left first surface 2 of the
acoustical substrate 10 has been transferred to the left side of
the final acoustical product 30 and the decorative design located
on the right first surface 4 has been transferred to the right side
of the final acoustical product 30. In addition, the left edge 7
and the right edge 8 are now positioned on the back side of the
final acoustical product 30 contiguous with the back surface 6.
[0026] The left and right portions 24, 25 may be held in this
rotated or folded position, and thus the shape of the final
acoustical product 30 maintained, through heat molding. For
example, when bicomponent fibers having a core component and a
sheath component with a melting point less than the melting point
of the core component are used in the acoustical substrate 10, the
final acoustical product 30 may be heated to a temperature
sufficient to soften the sheath but not the core of the fibers. The
softened sheath acts as a binder between adjacent fibers that cause
the fibers to bond together in the shape of the final acoustical
product 30. The final acoustical product 30 is then cooled to set
the shape. In an alternate embodiment, ultrasonics may be used to
provide the bonding energy required to bond the bicomponent fibers
located at the sheath interface together. Alternatively, an
adhesive material can be used to hold the left and right portions
24, 25 in their rotated position and maintain the shape of the
final acoustical product 30. Other conventional bonding methods may
be used to hold the left and right portions 24, 25 in their folded
positions, and would be identifiable by one of ordinary skill in
the art. Due to the compression of the fibers in the acoustical
substrate 10, portions of the acoustical substrate 10 adjacent to
grooves 20, 21 have an increased density. Thus, once the left
portion 24 and the right portion 25 are rotated or folded as shown
in FIG. 1d, the edges or sides of the final acoustical product 30
are reinforced and have an increased strength and a density that is
greater than the density of the inner portion of the final
acoustical product 30.
[0027] Various other locations for compressing the acoustical
substrate 10 and forming a groove or multiple grooves in the
acoustical substrate 10 such that collapsing the groove(s) would
place the decorative surface on at least a portion of a side of the
final acoustical product would be easily identified by one of skill
in the art, and are considered to be within the purview of this
invention. For example, in an alternate embodiment shown in FIGS.
2a-2d, a first groove 31 having a first side 35 is formed on the
left edge 7 of the acoustical substrate 10 and a second groove 32
having a second side 36 is formed on the right edge 8 of the
acoustical substrate 10 by compression (FIG. 2b). The left portion
33 and the right portion 34 of the acoustical substrate 10 are
folded toward the back surface 6, as shown from the phantom lines
in FIG. 2c, until the first groove 31 and the second groove 32 are
collapsed. The intermediate product (not shown) resulting from this
rotation of the left and right portions 33, 34, has a
non-rectangular shape. To form substantially 90.degree. corners as
illustrated in the final acoustical product 37 shown in FIG. 2d, an
external forming device may be used to compress the fibers in the
area of the left first surface 2 and the right first surface 4 and
mold the intermediate product (not shown) to form substantially
90.degree. corners. Alternative shapes, such as, but not limited
to, rounded corners (illustrated in FIG. 2e), may be formed by such
an external forming device or mold by compressing the intermediate
product into the desired shape.
[0028] Once the first and second grooves 31, 32 are completely
collapsed, the decorative design that was positioned on the left
first surface 2 on the first surface 5 of the acoustical substrate
10 is now positioned on the left side of the final acoustical
product 37 and the decorative design that was positioned on the
right first surface 4 on the first surface 5 of the acoustical
substrate 10 is now positioned on the right side of the final
acoustical product 37. It is to be noted that in this embodiment,
the compressed regions (e.g., the areas surrounding first and
second sides 35, 36) are not located at the edges of the final
acoustical product 37. Instead, the compressed regions are
positioned along the back surface 6 of the final acoustical product
37. These compressed regions have a density that is greater than
the density of the uncompressed regions, which results in greater
strength and/or stiffness of the final acoustical product 37.
[0029] The decorative design on the acoustical substrate 10 may be
applied in a planar fashion to the first surface 5 of the
acoustical substrate 10, and may include colors, geometric or
abstract designs or shapes, or other patterns or images. It is to
be understood that the decorative design or the decorative veil may
be added prior to or after the compression and densification of the
acoustical substrate. In addition, the decorative design can be
embossed, such as in a texturizing mold, to give a texture feel to
the acoustical substrate 10. If the decorative design is embossed
prior to the application of the decorative design or after the
application of the design to the acoustical substrate 10 but before
translating the decorative design to the edge of the final
acoustical product, the texturing can be accomplished on a single
plane with a single texturing roll or other similar texturing
device known to those of skill in the art. Moreover, when the
texturing is accomplished on a single plane, the image or design
can be aligned with the texture so that the changes in shape match
with the image changes. On the other hand, if the decorative design
is embossed after the design has been translated to the edges of
the finished acoustical product, each surface containing the design
may be individually embossed.
[0030] Turning now to FIGS. 3a-3d, a second inventive method for
translating a decorative surface of an acoustical substrate to an
edge of the finished acoustical product can be seen. As in the
embodiments discussed above, the acoustical substrate 10 includes a
first surface 5 having a decorative design to make the acoustical
substrate 10 aesthetically pleasing, a back surface 6 opposing the
first surface 5, a left edge 7, and a right edge 8. In addition,
the first surface 5 is formed of a left first surface 2, a central
first surface 3, and a right first surface 4.
[0031] Initially, the acoustical substrate 10 is scored along first
and second score lines 40, 41 respectively to delineate a left
outer region 42, a right outer region 43, and a central region 44
as is shown in FIG. 3a. Preferably, the acoustical substrate 10 is
scored to a depth sufficient to score to the decorative design or
decorative veil located on the first surface 5. However, it is
possible to score a portion of the decorative design or decorative
veil as long as a sufficient number of fibers remain to provide a
strong fold point. By scoring the acoustical substrate 10 to a
depth sufficient to reach the decorative design on the first
surface 5, the radius of curvature of the folded edge may be
reduced, thereby yielding a sharper edge detail in the final
acoustical product. A slitter blade or other similar blade or
cutting technique known by those of skill in the art to score or
sever a material can be used to score the acoustical substrate 10.
Preferably, the blade is less than or equal to {fraction (1/16)} of
an inch in thickness.
[0032] The length of the left outer region 42 (e.g. the distance
extending from left edge 7 to the first score line 40) and the
length of the right outer region 43 (e.g. the distance extending
from the right edge 8 to the second score line 41) may be equal to
or greater than the width of the central region 44 (e.g. the
distance from the first surface 5 to the back surface 6) to place
the decorative design on the entire side of the final acoustical
product 50. However, if only a portion of the side of the final
acoustical product 50 is to contain the decorative design, then the
length of the left outer region 42 and the right outer region 43
may be shorter than the width of the central region 44.
[0033] As illustrated in FIG. 3b, the left outer region 42 and the
right outer region 43 are then compressed, e.g., under heat, to
form a first flange 45 and a second flange 46. Preferably, the left
and right outer regions 42, 43 are compressed to a thickness of
approximately {fraction (1/32)} of an inch to approximately 1/2 of
an inch. Once the compression of the left outer region 42 and the
right outer region 43 is complete, a heated and/or shaped tip may
optionally be used to melt a portion of the fibers in the area
where the first flange 45 and second flange 46 intersects with the
central region 44 (not shown) to make room for the first and second
flanges 45, 46 once they are folded as described below.
Additionally, the fibers in the central region 44 may be softened
to provide a bonding region for the first and second flanges 45, 46
after they are folded. Alternatively, an adhesive may be applied to
the central region 44 to bond the folded flanges to the central
region 44.
[0034] Alternatively, portions of the first and second flanges 45,
46 may be removed or compressed to provide fold points about which
the first and second flanges 45, 46 can rotate or fold. Such an
alternative embodiment is illustrated in FIG. 4a, which depicts a
first notch 48 formed in the first flange 45 and second and third
notches 49, 49a formed in the second flange 46. The first, second,
and third notches 48, 49, 49a may be formed by removing material
from the first and second flanges 45, 46, such as by with a
conventional blade or saw, heat melting the fibers in the first and
second flanges 45, 46, or by compressing the portions of the first
and second flanges 45, 46 at the desired fold points. The first
notch 48, the second notch 49, and the third notch 49a provide
first, second, and third fold points 51, 52, 52a respectively
(shown in FIG. 4a) for the rotation of the first and second flanges
45, 46 toward the back surface 6 (shown in FIG. 4b). The first
flange 45 may be rotated about the first fold point 51 and the
second flange 46 may be rotated about the second and third fold
points 52, 52a as shown in FIG. 4b.
[0035] Turning back to FIGS. 3a-3d, the first and second flanges
45, 46 are then folded toward the back surface 6 (shown from the
phantom lines depicted in FIG. 3b) until the first flange 45 and
the second flange 46 are flush with the central region 44 (not
shown). Once the second flange 46 is flush with the central region
44, the second flange 46 may again be folded toward the back
surface 6, as shown from the phantom lines in FIG. 3c, to form the
final acoustical product 50 (FIG. 3d). The folded first and second
flanges 45, 46 may be bonded to the central region 44 by softening
the sheath fibers through conventional bonding means such as heat
transfer, hot air, or ultrasonics. Alternatively, the first and
second flanges 45, 46 may be affixed to the central region 44 by
any conventional adhesive. A heated tip or other heating device may
optionally be used to shape the folded flanges to provide a crisp
edge to the final acoustical product 50.
[0036] As illustrated in FIG. 3d, the decorative design located on
the left first surface 2 is now positioned on the left side of the
final acoustical product 50 and the design on the right first
surface 4 is now positioned on the right side. In addition, at
least a portion of the decorative design located on the right first
surface 4 is now positioned on the back side of the final
acoustical product 50. Additionally, because the first and second
flanges 45, 46 contain compressed fibers, the first and second
flanges 45, 46 have an increased stiffness and/or superior
strength. As a result, folding the first and second flanges 45, 46
as shown in FIGS. 3c and 3d, the left and right sides and corners
of the final acoustical product 50 are reinforced.
[0037] In an alternate embodiment illustrated in FIGS. 5a-5d, the
acoustical substrate 10 is scored along the first score line 40 and
the second score line 41. As in the embodiment described above with
respect to FIGS. 3a-3d, the left outer region 42 is compressed to
form the first flange 45 and the right outer region 43 is
compressed to form the second flange 46 (shown in FIG. 5b). An
outer portion 46a of the second flange 46 is then folded as shown
in FIG. 5c until the outer portion 46a is flush with an inner
portion 46b and the right edge 8 is facing the central region 44
(e.g., the outer portion 46a is rotated approximately 180.degree.).
The second flange 46 may have a portion of the fibrous material
removed at the intersection of the outer portion 46a and the inner
portion 46b so that the outer portion 46a can be rotated or folded
approximately 180.degree. and be flush with the inner portion 46b.
Alternatively, heat may be applied such as through a heated tip to
soften the fibers at the intersection and facilitate bending the
second flange 46 so that the flange can subsequently be molded to
form a crisp corner.
[0038] The folded flange 53 is then folded (rotated) toward the
back surface 6 (FIG. 5d) until the folded flange 53 is flush with
the central region 44 (FIG. 5e). As with the embodiment described
above in FIGS. 3a-3d, the compressed fibrous material (e.g.,
densified fibrous material) in the first and second flanges 45, 46
strengthens the edges and corners of the final acoustical product
55. Thus, when the first and second flanges 45, 46 are folded as
shown in FIGS. 5d-e, the left side of the final acoustical product
55 is reinforced and the right side of the acoustical product is
highly reinforced due to presence of the two layers of compressed
(densified) fibrous material on the right side. Additionally, the
decorative design on the first surface 5 is transferred to the
sides of the final acoustical product 55. By notching the underside
of the second flange 46, at least a portion of the decorative
design may be transferred to the back side of the final acoustical
product 55.
[0039] In a further alternative embodiment of the method described
in FIGS. 3a-3d, the acoustical substrate 10 is scored with a tool,
such as an abrasion wheel or other similar type cutting mechanism
identifiable to those of skill in the art, that is at least
{fraction (1/16)} of an inch in thickness. Such a tool will remove
fibers from the acoustical substrate 10 along the length of the
score. This method permits the first flange 45 and the second
flange 46 to fold or nest into the areas removed in the central
region 44 by the abrasion wheel (e.g., nesting areas).
[0040] Unlike the embodiment described above in which the backside
of the decorative design may be scored to ensure a crisp folding of
the first and second flanges 45, 46, this inventive embodiment uses
the thicknesses of the first and second flanges 45, 46 and the
nesting areas to force the location of the fold point. However, it
is to be understood that the abrasion wheel may also be used to
score a fold point in the first and second flanges 45, 46. In
addition, the abrasion wheel may be used to remove some of the
fibrous material on the left outer region 42 (e.g., fibrous
material located at the left edge 7 and at the region of the
intersection of the left outer region 42 and the central region 44)
and some of the fibrous material located on the right outer region
43 (e.g., fibrous material located at the right edge 8 and at the
intersection of the right outer region 43 and the central region
44) to compensate for the lateral expansion of the fibrous material
when the left outer portion 42 and the right outer portion 43 are
compressed to form the first and second flanges 45, 46.
[0041] It is sometimes desirable to form an acoustical product that
does not have a decorated surface that ends flush with the back of
the acoustical substrate or the acoustical panel. Acoustic panels
of varying thicknesses ranging from approximately 0.25 inches to
approximately 4.0 inches may be needed to meet the acoustical
requirements, wall or ceiling thickness requirements, or both. In
this regard, FIGS. 6a-6c illustrate an inventive method whereby an
acoustical product is formed that has varying thicknesses.
[0042] Turning to FIG. 6a, an acoustical substrate 10 that includes
a first surface 5 having a decorative design thereon to make the
acoustical substrate 10 aesthetically pleasing, a back surface 6
opposing the first surface 5, a left edge 7, and a right edge 8 is
provided. In addition, the first surface 5 is formed of a left
first surface 2, a central first surface 3, and a right first
surface 4. The acoustical substrate 10 is scored along the first
score line 40 and the second score line 41 to form the left outer
region 42, the right outer region 43, and the central region 44. In
this embodiment, the length of both the left outer region 42 (e.g.,
the distance from the left edge 7 to the first score line 40) and
the right outer region 43 (e.g., the distance from the right edge 8
to the second score line 41) is greater than the width of the
acoustical substrate 10 (e.g. the distance from the first surface 5
to the back surface 6). The length of the left outer region 42 is
preferably equal to the right outer region 43.
[0043] The left outer region 42 and the right outer region 43 are
then compressed, such as by heating the acoustical substrate 10 and
concurrently applying pressure, to form the first flange 45 and the
second flange 46 respectively. Next, the first flange 45 and the
second flange 46 are folded or rotated toward the back surface 6
(shown in FIG. 6b) until they are flush with the central region 44
(shown in FIG. 6c). Because the length of the first and second
flanges 45, 46 is greater than the width of the acoustical
substrate 10, the sides of the final acoustical product 70 extend
below the back surface 6. The distance (D) that the first and
second flanges 45, 46 extend beyond the back surface 6 of the
acoustical substrate 10 represents the distance that the final
acoustical product 70 will be spaced out from the surface upon
which the acoustical panel is mounted. As can be seen in FIG. 6c,
the decorative surface on the left first surface 2, which was
originally on the top surface of the acoustical substrate 10, has
been transferred to the left side of the final acoustical product
70 and the decorative surface on the right first surface 4, which
was originally on the top surface of the acoustical substrate 10,
has been transferred to the right side of the final acoustical
product 70.
[0044] The final acoustical product 70 shown in FIG. 6c may also be
used to form a tuned acoustical absorber. In this exemplary
embodiment (not shown), the central region 44 is compressed to form
a rigid pan. The central region 44 may be compressed evenly across
its length or it may be compressed to varying thicknesses.
Absorbing material may then be added and adhered to the pan, such
as by an adhesive material, prior to mounting the tuned absorber
onto a surface. Suitable examples of the absorbing material
include, but are not limited to, polymer fibers, glass fibers, and
open cell foam plastics. The type and amount of absorbing material
that is added to the pan is dependent upon the desired acoustical
properties of the tuned acoustical absorber. However, it is
preferable that the amount of absorbing material that is added to
the pan results in a thickness that is less than or equal to the
depth of the compression in the pan.
[0045] Although the methods depicted in FIGS. 1a-6c are described
with respect to two regions of the acoustical substrate being
compressed and folded to move the decorative surface to the left
and right sides of the final acoustical product, the acoustical
substrate may be compressed in only one region to place the
decorative surface and the compressed region on one side of the
final acoustical product. Additionally, the acoustical substrate
may be compressed in more than two regions (e.g., three or more) to
place the decorative surface and compressed regions on multiple
sides of the final acoustical product. The placement of the
compressed regions translates the decorative design to a desired
side of the final acoustical product. Thus, according to the
principles of the instant invention, the decorative surface can be
translated to any one or to all of the sides of the final
acoustical product. Similarly, the compressed regions may be
positioned on any one side or all of the sides of the final
acoustical product to reinforce and strengthen the final acoustical
product. Further, the final acoustical product may be formed of
reinforced edges having any linear or non-linear shape. In
addition, the length of the compressed regions relative to the
width of the acoustical substrate and how the compressed regions
are folded (e.g., double folded, folded over to the back side of
the acoustical substrate, etc.) to form the final acoustical
product are chosen depending on the desired shape and application
of the final acoustical product.
[0046] One such example of translating the decorative surface to
all of the sides of the final acoustical product is illustrated in
FIGS. 7a-7f. As shown in FIG. 7a, the acoustical substrate 10
contains the first surface 5, the bottom surface 6 opposing the
first surface 5, the right edge 8, the left edge 7, a front edge 1,
and a rear edge 9 opposing the front edge 1. Perimeter regions of
the acoustical substrate 10 are compressed to form a region of
compressed material 71 (FIG. 2b) having a first density. A core of
uncompressed material 75 (shown in phantom in FIG. 7b) having a
second density that is less than the first density is positioned
substantially at the center of the acoustical substrate 10 and
extends below the compressed region 71. The orientation of the core
75 below compressed region 71 can best be seen in FIG. 7c, which
shows the acoustical substrate of FIG. 7b in elevation.
[0047] Portions 76, 77, 78, 79 of the compressed material 71
positioned around the perimeter are then removed to form the first
flange 45, the second flange 46, a front flange 72, and a rear
flange 73, as illustrated in FIG. 7d. The first, second, front, and
rear flanges 45, 46, 72, 73 are folded toward the back surface 6 as
depicted in FIG. 7d until the flanges 45, 46, 72, 73 are flush with
the core 75, forming a box-like final acoustical product 90 (FIG.
7e). Optionally, the edges of the flanges 45, 46, 72, 73 may be
beveled so that when the flanges 45, 46, 72, 73 are folded and
flush with the core 75, they come together to form a clean corner.
As shown in FIG. 7e, the first, second, front, and rear flanges 45,
46, 72, 73 extend beyond the core 75 when they are completely
folded and form a void 80 that is open at the bottom and surrounded
by the core 75 and the first, second, front, and rear flanges 45,
46, 72, 73.
[0048] The final acoustical product 90 may optionally be attached
to a frame 95 having a base 96 and flanges 97 for mounting the
final acoustical product 90 to a surface, such as a wall. The frame
95 may be positioned such that the flanges 97 are placed into the
void 80. The flanges 97 are then affixed to the first, second,
front, and rear flanges 45, 46, 72, 73, and/or the back surface 6
such as by an adhesive or mechanical fastener. The frame 95 may
then be mounted on a surface by affixing the base 96 to the
surface. The frame 95 may also have an extended region (not shown)
for attaching hardware or securing the frame to a larger structure.
If the extended region is present on the frame 95, a notch (not
shown) is then cut into one or more of the first, second, front,
and rear flanges 45, 46, 72, 73 to accommodate the extended region.
It is to be understood that the frame 95 is depicted for
illustrative purposes and that any suitable frame may be used so
long as the frame 95 is attached to at least one of the first,
second, front, or rear flanges 45, 46, 72, 73 or to the back
surface 6.
[0049] In an alternate embodiment (not shown), two acoustical
products may be attached to a frame. In such an embodiment, a first
acoustical product may be placed over the frame at a first half so
that one half of the frame is covered by the first acoustical
product. A second acoustical product may then be placed over the
second half of the frame such that the two acoustical product abut
each other. The acoustical products may be attached to the frame by
an adhesive or by mechanical fasteners. This embodiment forms a
two-sided final acoustical substrate.
[0050] Due to the compression and folding of the fibers in the
acoustical substrate during the formation of sides of the final
acoustical products, the sides or peripheral edges of the final
acoustical products are reinforced, have increased strength and/or
stiffness, and have densities that are greater than the
non-compressed regions. As a result, the final acoustical products
do not have to have an adhesive applied to the edges or sides to
strengthen and harden the edge; the compressed fibers provide the
requisite strength and/or stiffness for each of the final
acoustical products. Additionally, unlike many conventional
acoustic products, the inventive acoustical products do not need to
be placed into a frame. The final acoustical products may be placed
directly onto a mounting surface. Furthermore, the final acoustical
products may have varying densities throughout its structures due
to the compression and folding of the various portion of the
acoustical substrate. In addition, by compressing the acoustical
substrate and not excising material, thereby minimizing waste
disposal.
[0051] Although the inventive methods described above form final
acoustical products that have substantially square corners, other
shapes may be molded by conventional methods from the final
acoustical products, such as by heat molding. Alternatively, the
acoustical substrate 10 may be scored or cut in locations that
result in edges that have a geometric shape other than square or
rectangular. Such locations are easily determined by those of skill
in the art and are considered to be within the purview of this
invention.
[0052] The invention of this application has been described above
both generically and with regard to specific embodiments. Although
the invention has been set forth in what is believed to be the
preferred embodiments, a wide variety of alternatives known to
those of skill in the art can be selected within the generic
disclosure. The invention is not otherwise limited, except for the
recitation of the claims set forth below.
* * * * *