Methods for controlling aesthetics of nonwoven acoustic structures

Abstract

Disclosed herein is a method for manufacturing an acoustic structure having a predetermined characteristic. The method includes providing a binding material having a first characteristic, intermixing a fibrous material having a second characteristic with the binding material to yield a nonwoven blend, and forming the nonwoven blend to yield an acoustic structure having the predetermined characteristic resulting from the intermixed binding material and fibrous material. The binding material is perceptible up to a first distance from the structure, the fibrous material is perceptible up to a first distance from the structure, the predetermined characteristic is perceptible beyond a second distance from the structure, and the second distance is greater than the first distance.

Description

Cross-Reference to Related Application

[0001] This application is a PCT International Application claiming priority to United States Provisional Patent Application No. 63 / 626,732 filed on January 30, 2024, the disclosure of which is incorporated herein by reference in its entirety. Field of the Disclosure

[0001] The present disclosure relates to methods for manufacturing acoustic building structures, such as ceiling and wall panels, and more particularly to methods for controlling color of nonwoven acoustic building structures. Background

[0002] Building materials, such as acoustics structures, planks, and panels for ceiling and wall systems, are designed to balance interests with respect to aesthetics, material cost, structural integrity, fire safety, acoustics, temperature control, and environmental impact.

[0003] Accordingly, those skilled in the art continue research and development in the field of acoustic building structures. Summary

[0004] This summary is intended merely to introduce a simplified summary of some aspects of one or more implementations of the present disclosure. Further areas of applicability of the present disclosure will become apparent from the detailed description provided hereinafter. This summary is not an extensive overview, nor is it intended to identify key or critical elements of the present teachings, nor to delineate the scope of the disclosure. Rather, its purpose is merely to present one or more concepts in simplified form as a prelude to the detailed description below.

[0005] Applicants have discovered a method for manufacturing an acoustic structure having a predetermined characteristic.

[0006] The method includes providing a binding material having a first characteristic, intermixing a fibrous material having a second characteristic with the binding material to yield a nonwoven blend, and forming the nonwoven blend to yield an acoustic structure having the predetermined characteristic resulting from the intermixed binding material and fibrous material. The binding material is perceptible up to a first distance from the structure, the fibrous material is perceptible up to a first distance from the structure, the predetermined characteristic is perceptible beyond a second distance from the structure, and the second distance is greater than the first distance.

[0007] In one example, the binding material comprises a blend of a first binding fiber having a first color and a second binding fiber having a second color. In one example, the first color is black and the second color is white. In one example, the binding material includes a thermoplastic polymer. In one example, the binding material comprises PET. In one example, the binding material comprises a polymer having a melting temperature lower than the melting temperature of the fibrous material. In one example, the binding material includes a plurality of fibers having an average diameter ranging from about 0.1 pm to about 60 pm. In one example, the binding material is a biocomponent fibrous binder comprising a fiber coated in a sheath. In one example, the sheath has a melting temperature that is lower than the melting temperature of the fibrous binder. In one example, the binding material comprises from about 0 wt.% to about 40 wt. % biocomponent fibrous binder, based on the total dry weight of the binding material.

[0008] In one example, fibrous material comprises a plurality of fibers having an average diameter ranging from about 0.1 pm to about 60 pm. In one example, the fibrous material comprises one or more of natural fibers, organic fibers, and wool. In one example, the fibrous material comprises a first fibrous material having a first fiber characteristic, a second fibrous material having a second fiber characteristic, and a third fibrous material having a third fiber characteristic. In one example, the first fiber characteristic is a first color, the second fiber characteristic is a second color, and the third fiber characteristic is a third color. In one example, the first color is different from the second color and the third color.

[0009] In one example, the predetermined characteristic is different than the first characteristic and the second characteristic.

[0010] In one example, the predetermined characteristic is a color aesthetic. In one example, the first characteristic is a first color aesthetic and the second characteristic is a second color aesthetic.

[0011] In one example, the forming comprises applying the nonwoven blend to a mold and heating the nonwoven blend. In one example, the forming comprises carding and crosslapping the nonwoven blend.

[0012] In one example, the binding material is provided in an amount based upon the predetermined characteristic. In one example, the amount of binding material provided is adjustable based upon the predetermined characteristic. In one example, the fibrous material is provided in an amount based upon the predetermined characteristic. In one example, the amount of fibrous material provided is adjustable based upon the predetermined characteristic.

[0013] In one example, the method includes applying a resin to the acoustic structure after the forming. In one example, the applying comprises foaming a resin and applying the foamed resin to the acoustic structure. In one example, the resin is a clear resin. In one example, the resin is a pigmented resin.

[0014] In another example, the method includes determining an amount of binding material required to fulfill the predetermined characteristic, providing the determined amount of binding material, determining an amount of fibrous material required to fulfill the predetermined characteristic, intermixing the determined amount of fibrous material with the binding material to yield a nonwoven blend, and forming the nonwoven blend to yield the acoustic structure having the predetermined characteristic.

[0015] In one example, the binding material has a first characteristic that is perceptible up to a first distance from the substrate. In one example, the fibrous material has a second characteristic that is perceptible up to a first distance from the substrate. In one example, the predetermined characteristic is perceptible beyond a second distance from the substrate. In one example, the second distance is greater than the first distance. In one example, the predetermined characteristic is different than the first characteristic and the second characteristic. In one example, the predetermined characteristic results from the intermixing of the fibrous material with the binding material. In one example, the first characteristic is a first color aesthetic and the second characteristic is a second color aesthetic.

[0016] In one example, the binding material includes a blend of a first binding fiber having a first color and a second binding fiber having a second color. In one example, the first color is black and the second color is white. In one example, the binding material includes a thermoplastic polymer. In one example, the binding material includes PET. In one example, the binding material includes a polymer having a melting temperature lower than the melting temperature of the fibrous material. In one example, the binding material includes a plurality of fibers having an average diameter ranging from about 0.1 pm to about 60 pm. In one example, the binding material is a biocomponent fibrous binder including a fiber coated in a sheath. In one example, the sheath has a melting temperature that is lower than the melting temperature of the fibrous binder. In one example, the binding material includes from about 0 wt.% to about 40 wt. % biocomponent fibrous binder, based on the total dry weight of the binding material.

[0017] In one example, the determining an amount of binding material required to fulfill the predetermined characteristic includes calculating an amount of the first binding fiber required to fulfill the predetermined characteristic and calculating an amount of the second binding fiber required to fulfill the predetermined characteristic. In one example, the amount of binding material required is adjustable based upon the predetermined characteristic.

[0018] In one example, the fibrous material includes a plurality of fibers having an average diameter ranging from about 0.1 pm to about 60 pm. In one example, the fibrous material includes one or more of natural fibers, organic fibers, and wool. In one example, the fibrous material includes a first fibrous material having a first fiber characteristic, a second fibrous material having a second fiber characteristic, and a third fibrous material having a third fiber characteristic. In one example, the first fiber characteristic is a first color, the second fiber characteristic is a second color, and the third fiber characteristic is a third color. In one example, the first color is different from the second color and the third color.

[0019] In one example, the determining an amount of fibrous material required to fulfill the predetermined characteristic includes calculating an amount of the first fibrous material required to fulfill the predetermined characteristic, calculating an amount of the second fibrous material required to fulfill the predetermined characteristic, and calculating an amount of the third fibrous material required to fulfill the predetermined characteristic. In one example, the amount of fibrous material required is adjustable based upon the predetermined characteristic. In one example, the predetermined characteristic is a color aesthetic.

[0020] In one example, the forming includes applying the nonwoven blend to a mold and heating the nonwoven blend. In one example, the forming includes carding and crosslapping the nonwoven blend. In one example, the forming includes using an airlay technique. In one example, the method includes applying a resin to the acoustic structure after the forming. In one example, the method includes foaming a resin and applying the foamed resin to the acoustic structure. In one example, the resin is a clear resin. In one example, the resin is a pigmented resin.

[0021] Also disclosed is an acoustic structure.

[0022] In one example, the acoustic structure includes a substrate having a first surface opposite a second surface. The substrate includes a binding material having a first characteristic that is perceptible up to a first distance from the substrate and fibrous material having a second characteristic intermixed with the binding material, the second characteristic perceptible up to the first distance from the substrate. The acoustic structure has a predetermined characteristic resulting from the intermixed binding material and fibrous material. The predetermined characteristic is perceptible beyond a second distance from the substrate and the second distance is greater than the first distance.

[0023] In one example, the predetermined characteristic is different from the first characteristic and the second characteristic. In one example, the first characteristic is a first color aesthetic, the second characteristic is a second color aesthetic, and the predetermined characteristic is a third color aesthetic.

[0024] In one example, the binding material includes a blend of black fibers and white fibers. In one example, the binding material includes a thermoplastic polymer. In one example, the binding material includes PET. In one example, the binding material includes a polymer having a melting temperature lower than the melting temperature of the fibrous material. In one example, the binding material includes a plurality of fibers having an average diameter ranging from about 0.1 pm to about 60 pm. In one example, the binding material is a biocomponent fibrous binder including a fiber coated in a sheath. In one example, the sheath has a melting temperature that is lower than the melting temperature of the fibrous binder. In one example, the binding material includes from about 0 wt.% to about 40 wt. % biocomponent fibrous binder, based on the total dry weight of the binding material. In one example, the fibrous material includes a plurality of fibers having an average diameter ranging from about 0.1 pm to about 60 pm.

[0025] In one example, the fibrous material includes one or more of natural fibers, organic fibers, and wool. In another example, the fibrous material includes one or more of hemp, jute, kenaf, flax, sisal, fique, coir, cotton, and wool. In another example, the fibrous material includes a first fibrous material having a first fiber characteristic, a second fibrous material having a second fiber characteristic, and a third fibrous material having a third fiber characteristic. In one example, the first fiber characteristic is a first color, the second fiber characteristic is a second color, and the third fiber characteristic is a third color. In one example, the first color is different from the second color and the third color.

[0026] In one example, the predetermined characteristic is a color aesthetic. In one example, the first characteristic is a first color aesthetic and the second characteristic is a second color aesthetic.

[0027] Further areas of applicability of the present disclosure will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred examples of the disclosure, are intended for purposes of illustration only and are not intended to limit the scope of the disclosure. Description of the Drawings

[0028] The detailed description of the disclosure will be better understood when read in conjunction with the appended drawings. It should be understood, however, that the disclosure is not limited to the precise arrangements and instrumentalities of the examples shown in the drawings.

[0029] Fig. lisa perspective view of an acoustic structure;

[0030] Fig. 2 is a front view of the acoustic structure of Fig. 1;

[0031] Fig, 3 is a side view of the acoustic structure of Fig. 1;

[0032] Fig. 4 is a perspective view of an acoustic system; and

[0033] Fig. 5 is a side view of the acoustic system of Fig. 4. Detailed Description

[0034] For illustrative purposes, the principles of the present disclosure are described by referencing various examples thereof. Although certain examples of the disclosure are specifically described herein, one of ordinary skill in the art will readily recognize that the same principles are equally applicable to, and can be employed in other applications and methods. It is to be understood that the disclosure is not limited in its application to the details of any particular example shown. The terminology used herein is for the purpose of description and not to limit the disclosure, its application, or uses.

[0035] As used herein and in the appended claims, the singular forms “a”, “an”, and “the” include plural references unless the context dictates otherwise. The singular form of any class of the ingredients refers not only to one chemical species within that class, but also to a mixture of those chemical species. The terms “a” (or “an”), “one or more” and “at least one” may be used interchangeably herein. The terms “comprising”, “including”, “containing”, and “having” may be used interchangeably. The term “include” should be interpreted as “include, but are not limited to”. The term “including” should be interpreted as “including, but are not limited to”.

[0036] As used throughout, ranges are used as shorthand for describing each and every value that is within the range. Any value within the range can be selected as the terminus of the range.

[0037] Unless otherwise specified, all percentages and amounts expressed herein and elsewhere in the specification should be understood to refer to percentages by weight of the total composition. Unless otherwise specified, reference to a molecule, or to molecules, being present at a “wt. %” refers to the amount of that molecule, or molecules, present in the composition based on the total weight of the composition. Unless otherwise specified, reference to a molecule, or to molecules, being present “based on the dry weight of the composition” refers to that molecule, or molecules, being present in the composition based on the total weight of the composition in a dry state. The “dry state” refers to solvent being present in the composition at an amount less than 5.0 wt. %, less than about 3.0 wt. %, less than about 1.0 wt. %; preferably less than about 0.5 wt. %, and more preferably less than about 0.25 wt. % of the composition. For example, a composition in the dry state may refer to a composition having about 95% solids, about 98% solids, preferably about 99% solids, or more preferably about 100% solids. By contrast, unless otherwise specified, reference to a molecule, or to molecules, being present “based on the wet weight of the composition” refers to that molecule, or molecules, being present in the composition based on the total weight of the composition which includes at least 5 wt. % of solvent.

[0038] According to the present application, use of the term “about” in conjunction with a numeral value refers to a value that may be + / - 5% of that numeral. As used herein, the term “substantially free” is intended to mean an amount less than about 5.0 wt. %, less than 3.0 wt. %, less than 1.0 wt. %; preferably less than about 0.5 wt. %, and more preferably less than about 0.25 wt. % of the composition.

[0039] Unless defined otherwise, all technical and scientific terms used herein have the same meanings as commonly understood by one of ordinary skill in the art to which this disclosure belongs. All patents, patent applications, publications, and other references cited or referred to herein are incorporated by reference in their entireties for all purposes. In the event of a conflict in a definition in the present disclosure and that of a cited reference, the present disclosure controls.

[0040] In the description of examples disclosed herein, any reference to direction or orientation is merely intended for convenience of description and is not intended in any way to limit the scope of the present disclosure. Relative terms such as "lower," "upper," “horizontal,” “vertical,”, “above,” “below,” “up,” “down,” “top” and “bottom” as well as derivatives thereof (e.g., “horizontally,” “downwardly,” “upwardly,” etc.) should be construed to refer to the orientation as then described or as shown in the drawing (if applicable) under discussion. These relative terms are for convenience of description only and, unless specified otherwise, do not require that the apparatus be constructed or operated in a particular orientation.

[0041] As used herein, terms such as “attached,” “affixed,” “connected,” “coupled,” “interconnected,” and the like refer to a relationship wherein structures are secured or attached to one another either directly or indirectly through intervening structures, as well as both movable or rigid attachments or relationships, unless expressly described otherwise. Accordingly, the disclosure is not limited to such examples illustrating certain combinations of features that may exist alone or in combination with other features.

[0042] The present disclosure relates to methods for controlling a characteristic, such as color, of nonwoven acoustic structures. The nonwoven acoustic structures are comprised of a blend of different fibers having different characteristics provided in amounts that are selectively controllable based on the desired characteristic of the acoustic structures. For example, the blend may include fibers of three, four, or five different colors, such as black, white, magenta, cyan, and yellow added in predetermined amounts that are selectively controllable and adjustable to yield a specific color. The disclosed method advantageously provides a manufacturing method allowing for manufacture of nonwoven acoustic structures having different characteristics, such as colors, without having to change many manufacturing processes or add different dyes to each structure.

[0043] Referring to Fig. 1, disclosed is a structure, such as an acoustic structure 100. The structure may be a ceiling panel, wall panel, blade, or other building or architectural structure. The acoustic structure 100 is comprised of sustainable, nonwoven fibrous materials, such as felt, configured to optimize acoustic properties, fire safety, and aesthetics. The structure 100 has a predetermined characteristic, such as a color aesthetic, that is present throughout the entirety of the structure 100 as described below.

[0044] Referring to Fig. 2, the acoustic structure 100 is characterized by a width Wpranging from about 12 inches to about 96 inches. The acoustic structure 100 is further characterized by a length Lp ranging from about 48 inches to about 120 inches. Referring to Fig. 3, the acoustic structure 100 is further characterized by its thickness tp ranging from about 0.1 inches to about 2 inches.

[0045] The acoustic structure 100 includes a substrate 110 having a first major surface 112 opposite a second major surface 114 and a side surface 113 extending therebetween. The side surface includes a first side 113a, a second side 113b, a third side 113c, and a fourth side 113d. the building attachment hardware 70 may be coupled to the second side surface 113b of acoustic structure 100. In other examples, the building attachment hardware 70 may be coupled to either the first and / or second major surfaces 112, 114 of the acoustic structure 100 at a location immediately adjacent to the second side surface 113b of the acoustic structure 100.

[0046] The substrate 110 includes a binding material having a first characteristic that is perceptible up to a first distance from the substrate and fibrous material having a second characteristic intermixed with the binding material. The second characteristic is also perceptible up to the first distance from the substrate 110. The acoustic structure 100 has a predetermined characteristic resulting from the intermixed binding material and fibrous material. The predetermined characteristic is perceptible beyond a second distance from the substrate 110. In one or more examples, the second distance is greater than the first distance.

[0047] In one or more examples, the predetermined characteristic is different from the first characteristic and the second characteristic. For example, the first characteristic may be a first color aesthetic, the second characteristic may be a second color aesthetic, and the predetermined characteristic may be a third color aesthetic. The predetermined characteristic is present throughout the entire thickness and length of the structure 100, differentiating from structures having coatings to provide aesthetic properties.

[0048] As described above, the acoustic structure 100 is comprised of nonwoven fibrous materials, such as felt, having a first characteristic. The first characteristic may be a color aesthetic or texture aesthetic. In one example, the acoustic structure 100 comprises fibrous material including one or more of natural fibers, organic fibers, and wool. In another example, the fibrous material comprises a plurality of fibers having an average diameter ranging from about 0.1 pm to about 60 pm including all ranges and sub-ranges there-between.

[0049] In one or more examples, the nonwoven fibrous material comprises a blend of a first fibrous material having a first characteristic, a second fibrous material having a second characteristic, and a third fibrous material having a third characteristic. The first fibrous material may have a first color, the second fibrous material may have a second color that is different from the first color, and the third fibrous material may have a third color that is different from the first color and the second color. The amount of first fibrous material, second fibrous material, and third fibrous material is adjustable based upon the predetermined characteristic. For example, the amount of each fibrous material is selected and adjustable to achieve a desired color aesthetic that is visually perceptible to an observer in proximity to the acoustic structure 100.

[0050] In another example, the nonwoven fibrous material comprises a blend of a first fibrous material having a first characteristic, a second fibrous material having a second characteristic, a third fibrous material having a third characteristic, and a fourth fibrous material having a fourth characteristic. The first fibrous material may have a first color, the second fibrous material may have a second color that is different from the first color, the third fibrous material may have a third color that is different from the first color and the second color, and the fourth fibrous material may have a fourth color that is different from the first color, the second color, and the third color. The amount of first fibrous material, second fibrous material, third fibrous material, and fourth fibrous material is adjustable based upon the predetermined characteristic. For example, the amount of each fibrous material is selected and adjustable to achieve a desired color aesthetic that is visually perceptible to an observer in proximity to the acoustic structure 100. The fibrous material may further include a fifth fibrous material having a fifth characteristic.

[0051] The acoustic structure 100 may further include a binding material blended or intermixed with the fibrous material. The binding material may include binding fibers, such as a blend of black fibers and white fibers. In one example, the binding material comprises a thermoplastic polymer. In another example, the binding material comprises PET. In yet another example, the binding material comprises a polymer having a melting temperature lower than the melting temperature of the fibrous material.

[0052] In one or more examples, the binding material includes a fibrous binder coated with a biocomponent sheath. Using a fibrous binder coated with a biocomponent sheath may provide the aesthetic effect of feathering on the acoustic structure 100. The bicomponent sheath may have a melting temperature that is lower than the melting temperature of the fibrous binder. In one or more examples, the binding material comprises from about 0 wt.% to about 40 wt. % fibrous binder coated with a biocomponent sheath- including all ranges and sub-ranges there-between, based on the total dry weight of the binding material.

[0053] In one or more examples, the acoustic structure 100 further includes a resin intermixed with the fibrous material and binding material. The resin may beneficially add mechanical strength, rigidity, fire retardancy, antifungal, and antimicrobial properties to the acoustic structure 100. For example, the resin may include, among other things, fire retardant, insecticide, and fungicide.

[0054] The acoustic structure 100 may be further characterized by its acoustic properties. In one example, the acoustic structure 100 is defined by having a sufficiently high noise reduction coefficient (NRC) rating to be characterized as an acoustic structure 100. NRC is a measure of sound energy absorption of a material. An NRC rating of 0 is a perfect sound reflection material. An NRC rating of 1 is a perfect sound absorption material. In one example, the acoustic structure 100 has an NRC value ranging from about 0.65 to about 0.90.

[0055] The acoustic structure 100 may be further characterized by its flame resistance properties. In one or more examples, the fire resistance is measured by ASTM E-84, and the disclosed structure 100 exhibits a fire resistance performance rating of Class A.

[0056] Referring to Fig. 4 and Fig. 5, the acoustic structure 100 may be part of an acoustic system 10 including more than one acoustic structure 100, or a plurality of acoustic structures. In the acoustic system 10, each acoustic structure 100 may be coupled to a support structure 7, such as a strut 5. The support structure 7 may include one or more parallel struts 5. The support structure 7 may be installed into an interior space 2 by attaching strut attachment hardware 6 directly or indirectly to both the stmts 5 and a structural barrier 4. In the installed state, the acoustic system 10 may comprise the acoustic structure 100 being supported by the struts 5 of the support structure 7 in the interior space 2 by the panel attachment hardware 70.

[0057] In the installed state, each acoustic structure 100 of the plurality of acoustic structures may be horizontally offset by a lateral offset distance Di that is a positive non-zero value. Specifically, the later offset distance Di may be the distance between the first major surface 112 of a first acoustic structure 100 and the second major surface 114 of an adjacent-most second acoustic structure 100. The lateral offset distance Di may range from about 5 cm to about 244 cm -including all distances and sub-ranges there-between.

[0058] The predetermined characteristic, such as a color aesthetic or texture, may be visually perceptible to a person standing in proximity to the acoustic structure 100 in the installed state, while the first characteristic and the second characteristic may not be visually perceptible to a person in the same position.

[0059] Also disclosed is a method for manufacturing an acoustic structure 100 having a predetermined characteristic as disclosed herein. The method advantageous provides a solution for creating acoustic structures 100 having custom colors without having to change manufacturing equipment, purchase and create expensive batches of dyes, and clean equipment between batches. The method allows for custom color selection by selecting specific amounts of different colored fibrous materials and binding materials to yield any desired color. The method may be further utilized to create custom textures or other aesthetic appearances via the use of different fibrous materials. Further, the method allows for the continuous manufacture of acoustic structures 100 having custom colors on the same production line such that a first acoustic structure 100 may have a first color aesthetic and the subsequent acoustic structure 100 may have a different color aesthetic than the previous acoustic structure 100.

[0060] In one or more examples, method includes providing a binding material having a first characteristic, such as a color aesthetic or texture aesthetic. In one example, the binding material includes a blend of a first binding fiber having a first color and a second binding fiber having a second color. The first color may be black and the second color may be white. The amount of first binding fiber and second binding fiber provided is adjustable based upon the predetermined characteristic. For example, if the predetermined characteristic is a lighter color aesthetic, the binding material may include more of the second binding fiber having a white color than the first binding fiber having a black color.

[0061] The binding material is selected for binding properties and sustainability properties. In one or more examples, the binding material includes a thermoplastic polymer. In another example, the binding material includes PET. In yet another example, the binding material includes a polymer having a melting temperature lower than the melting temperature of the fibrous material.

[0062] In one or more examples, the binding material includes a plurality of fibers having an average diameter ranging from about 0.1 pm to about 60 pm- including all ranges and sub-ranges there-between. In another example, the binding material is a biocomponent fibrous binder including a fiber coated in a sheath. For example, the sheath may have a melting temperature that is lower than the melting temperature of the fibrous binder. In one example, the binding material includes from about 0 wt.% to about 40 wt. % biocomponent fibrous binder- including all ranges and sub-ranges there-between, based on the total dry weight of the binding material.

[0063] In one or more examples, the method includes intermixing a fibrous material having a second characteristic, such as a color aesthetic or texture aesthetic, with the binding material to yield a nonwoven blend. The intermixing may include blending. In one example, the fibrous material includes a plurality of fibers having an average diameter ranging from about 0.1 pm to about 60 pm- including all ranges and sub-ranges there-between. In another example, the fibrous material includes one or more of natural fibers, organic fibers, and wool. In yet another example, the fibrous material includes one or more of hemp, jute, kenaf, flax, sisal, fique, coir, cotton, and wool.

[0064] In one or more examples, the fibrous material includes a first fibrous material having a first fiber characteristic, a second fibrous material having a second fiber characteristic, a third fibrous material having a third fiber characteristic, and a fourth fibrous material having a fourth characteristic. In one example, the first fiber characteristic is a first color, the second fiber characteristic is a second color, the third fiber characteristic is a third color, and the fourth fiber characteristic is a fourth color. In one example, the first color is different from the second color, the third color, and the fourth color. In another example, the first fiber characteristic is cyan, the second fiber characteristic is magenta, the third fiber characteristic is yellow, and the fourth color is black or white. In another example, the colors of each fibrous material may be selected from red, green, blue, black, and white. In yet another example, the colors of each fibrous material may be selected from cyan, yellow, magenta, black, orange, green, and violet.

[0065] The amount of first fibrous material, second fibrous material, and third fibrous material provided is adjustable based upon the predetermined characteristic. For example, if the predetermined characteristic is a blue color aesthetic, the fibrous material may include more of one of the first fibrous material, second fibrous material, third fibrous material, and fourth fibrous material to achieve that blue color aesthetic.

[0066] In one or more examples, the method includes forming the nonwoven blend to yield an acoustic structure having the predetermined characteristic resulting from the intermixed binding material and fibrous material. For example, the amount of each fibrous material and binding material may be determined by weight and added appropriately to the line. The fibrous material may then be opened and homogenized, and then carded into a thin web. The fibrous material is then crosslapped to build up thickness. The fibrous material then may go through a heated roller to bind them and squish to the appropriate thickness. The material may then be cut the boards to length and width. An airlaying technique may be used instead of carding and crosslapping.

[0067] In one example, the forming includes applying the nonwoven blend to a mold and heating the nonwoven blend. In another example, the forming includes an airlay process where the fibrous material and binding material are applied to a surface to the desired shape and cured. In yet another example, the forming includes carding the nonwoven blend. In another example, the forming includes carding and crosslapping the nonwoven blend, allowing the carded mat to increase in thickness.

[0068] The binding material is perceptible up to a first distance from the structure and the fibrous material is perceptible up to a first distance from the structure. For example, each of the first binding fiber and the second biding fiber may be visually perceptible under a microscope and up to a distance from the acoustic structure 100. Further, the predetermined characteristic is perceptible beyond a second distance from the structure. In one or more examples, the second distance is greater than the first distance.

[0069] In one example, the predetermined characteristic is different than the first characteristic and the second characteristic. For example, the predetermined characteristic may be a color aesthetic that is different from the color aesthetic of the first characteristic and the color aesthetic of the second characteristic. In one example, the first characteristic is a first color aesthetic and the second characteristic is a second color aesthetic, and the predetermined characteristic is a third color aesthetic created by the intermixture of the first color aesthetic and the second color aesthetic. All color aesthetics are visually perceptible within different distances from the acoustic structure 100. For example, the first color aesthetic and the second color aesthetic may be visually perceptible under a microscope while the third color aesthetic may be visually perceptible by a bystander standing on the ground looking up at the acoustic structure 100 on a ceiling or wall.

[0070] In one or more examples, the binding material is provided in an amount based upon the predetermined characteristic. The amount of binding material provided is adjustable based upon the predetermined characteristic. Similarly, the fibrous material is provided in an amount based upon the predetermined characteristic. The amount of fibrous material provided is adjustable based upon the predetermined characteristic.

[0071] In one or more examples, the method further includes applying a resin to the acoustic structure 100 after the forming. The resin may beneficially add mechanical strength, rigidity, fire retardancy, antifungal, and antimicrobial properties to the acoustic structure 100. For example, the resin may include, among other things, fire retardant, insecticide, and fungicide. In one example, the applying includes foaming a resin and applying the foamed resin to the acoustic structure. The resin may be a clear resin or a pigmented resin.

[0072] Also disclosed is a method for manufacturing an acoustic structure having a predetermined characteristic, such as a color aesthetic or texture. The predetermined characteristics may be different between each acoustic structure 100 manufactured on the same production line such that subsequent acoustic structures may have different predetermined characteristics or color aesthetics.

[0073] In one or more examples, the method includes determining an amount of binding material required to fulfill the predetermined characteristic, providing the determined amount of binding material, determining an amount of fibrous material required to fulfill the predetermined characteristic, intermixing the determined amount of fibrous material with the binding material to yield a nonwoven blend, and forming the nonwoven blend to yield the acoustic structure having the predetermined characteristic.

[0074] In one or more examples, the binding material has a first characteristic that is perceptible up to a first distance from the substrate. For example, the first characteristic may be a color aesthetic that is visually perceptible under a microscope and up to 1 inch from the acoustic structure 100. In another example, the first characteristic may be a color aesthetic that is visually perceptible up to 12 inches from the acoustic structure 100. The distance from the acoustic structure in which the first characteristic is visually perceptible is directly proportional to the diameter of the fibers of the binding material and the fibers of the fibrous material.

[0075] In one or more examples, the fibrous material has a second characteristic that is perceptible up to a first distance from the substrate. For example, the second characteristic may be a color aesthetic that is visually perceptible under a microscope and up to 1 inch from the acoustic structure 100.

[0076] In one or more examples, the predetermined characteristic is perceptible beyond a second distance from the substrate 110 of the acoustic structure 100. For example, the predetermined characteristic may be a color aesthetic that is not visually perceptible under a microscope like the first characteristic and the second characteristic, but is visually perceptible when standing within an inch of the acoustic structure 100 and beyond that distance.

[0077] In one or more examples, the second distance is greater than the first distance. The predetermined characteristic may be different than the first characteristic and the second characteristic. In one example, the predetermined characteristic results from the intermixing of the fibrous material with the binding material. In another example, the first characteristic is a first color aesthetic and the second characteristic is a second color aesthetic.

[0078] In one or more examples, the binding material includes a blend of a first binding fiber having a first color and a second binding fiber having a second color. In one example, the first color is black and the second color is white. In another example, the binding material includes a thermoplastic polymer. In another example, the binding material includes PET. In yet another example, the binding material includes a polymer having a melting temperature lower than the melting temperature of the fibrous material.

[0079] In one or more examples, the binding material includes a plurality of fibers having an average diameter ranging from about 0.1 pm to about 60 pm- including all ranges and sub-ranges there-between. In one example, the binding material is a biocomponent fibrous binder including a fiber coated in a sheath. The sheath may have a melting temperature that is lower than the melting temperature of the fibrous binder. In one example, the binding material includes from about 0 wt.% to about 40 wt. % biocomponent fibrous binder- including all ranges and sub-ranges therebetween, based on the total dry weight of the binding material.

[0080] In one or more examples, the determining an amount of binding material required to fulfill the predetermined characteristic includes calculating an amount of the first binding fiber required to fulfill the predetermined characteristic and calculating an amount of the second binding fiber required to fulfill the predetermined characteristic. The amount of binding material required is adjustable based upon the predetermined characteristic. For example, the amount of first binding fiber required for achieving one predetermined characteristic may be different than the amount of first binding fiber required for achieving a different predetermined characteristic. That amount may be adjustable between the manufacture of each individual acoustic structure 100 on a production line such that a first acoustic structure 100 may have one predetermined characteristic and a subsequent acoustic structure 100 may have a different predetermined characteristic, meaning that the first acoustic structure 100 has a different amount of first binding fiber than the subsequent acoustic structure 100.

[0081] In one or more examples, the fibrous material includes a plurality of fibers having an average diameter ranging from about 0.1 pm to about 60 pm- including all ranges and sub-ranges there-between. In one example, the fibrous material includes one or more of natural fibers, organic fibers, and wool. In another example, the fibrous material includes one or more of hemp, jute, kenaf, flax, sisal, fique, coir, cotton, and wool.

[0082] In one or more examples, the fibrous material includes a first fibrous material having a first fiber characteristic, a second fibrous material having a second fiber characteristic, and a third fibrous material having a third fiber characteristic. In one example, the first fiber characteristic is a first color, the second fiber characteristic is a second color, and the third fiber characteristic is a third color. In another example, the first color is different from the second color and the third color.

[0083] In one example, the determining an amount of fibrous material required to fulfill the predetermined characteristic includes calculating an amount of the first fibrous material required to fulfill the predetermined characteristic, calculating an amount of the second fibrous material required to fulfill the predetermined characteristic, and calculating an amount of the third fibrous material required to fulfill the predetermined characteristic. In one example, the amount of fibrous material required is adjustable based upon the predetermined characteristic. In one example, the predetermined characteristic is a color aesthetic.

[0084] In one example, the forming includes applying the nonwoven blend to a mold and heating the nonwoven blend. In another example, the forming includes carding the nonwoven blend. In another example, the forming includes carding and crosslapping the nonwoven blend, allowing the carded mat to increase in thickness. In yet another example, the forming includes using an airlay technique.

[0085] In one example, the method includes applying a resin to the acoustic structure 100 after the forming. The resin may beneficially add mechanical strength, rigidity, fire retardancy, antifungal, and antimicrobial properties to the acoustic structure 100. For example, the resin may include, among other things, fire retardant, insecticide, and fungicide. In one example, the method includes foaming a resin and applying the foamed resin to the acoustic structure. In one example, the resin is a clear resin. In one example, the resin is a pigmented resin.

[0086] Also disclosed is a method for manufacturing a structure having a predetermined characteristic. The method includes providing a fibrous material having a second characteristic and forming the fibrous material to yield the structure. The fibrous material is perceptible up to a first distance from the structure, the predetermined characteristic is perceptible beyond a second distance from the structure, the second distance is greater than the first distance. The structure may be a flexible structure having the predetermined characteristic, such as a color aesthetic, present throughout the entire thickness of the structure.

[0087] The method may further include applying a binding material having a first characteristic to the structure. In one example, the binding material is a resin, such as a foamed resin. The binding material may include one or more of fire retardant, insecticide, and fungicide. Adding the binding material may further add rigidity to the structure such that it is less flexible. The structure may be an acoustic structure, a building structure, or an architectural structure.

[0088] The disclosure may be characterized by the following clauses:

[0089] Clause 1: A method for manufacturing an acoustic structure having a predetermined characteristic, the method comprising: providing a binding material having a first characteristic; intermixing a fibrous material having a second characteristic with the binding material to yield a nonwoven blend; and forming the nonwoven blend to yield an acoustic structure having the predetermined characteristic resulting from the intermixed binding material and fibrous material; wherein the binding material is perceptible up to a first distance from the structure; wherein the fibrous material is perceptible up to a first distance from the structure; wherein the predetermined characteristic is perceptible beyond a second distance from the structure; and wherein the second distance is greater than the first distance.

[0090] Clause 2: The method according to clause 1, wherein the predetermined characteristic is different than the first characteristic and the second characteristic.

[0091] Clause 3: The method according to any one of clauses 1 or 2, wherein the binding material comprises a blend of a first binding fiber having a first color and a second binding fiber having a second color.

[0092] Clause 4: The method according to clause 3, wherein the first color is black and the second color is white.

[0093] Clause 5: The method according to any one of clauses 1 to 4, wherein the binding material comprises a thermoplastic polymer.

[0094] Clause 6: The method according to any one of clauses 1 to 5, wherein the binding material comprises PET.

[0095] Clause 7: The method according to any one of clauses 1 to 6, wherein the binding material comprises a polymer having a melting temperature lower than the melting temperature of the fibrous material.

[0096] Clause 8: The method according to any one of clauses 1 to 7, wherein the binding material comprises a plurality of fibers having an average diameter ranging from about 0.1 pm to about 60 pm.

[0097] Clause 9: The method according to any one of clauses 1 to 8, wherein the binding material is a biocomponent fibrous binder comprising a fiber coated in a sheath.

[0098] Clause 10: The method according to clause 9, wherein the sheath has a melting temperature that is lower than the melting temperature of the fibrous binder.

[0099] Clause 11: The method according to any one of clauses 9 or 10, wherein the binding material comprises from about 0 wt.% to about 40 wt. % biocomponent fibrous binder, based on the total dry weight of the binding material.

[0100] Clause 12: The method according to any one of clauses 1 to 11, wherein the fibrous material comprises a plurality of fibers having an average diameter ranging from about 0.1 pm to about 60 pm.

[0101] Clause 13: The method according to any one of clauses 1 to 12, wherein the fibrous material comprises one or more natural fibers, organic fibers, thermoplastic fibers, and wool.

[0102] Clause 14: The method according to any one of clauses 1 to 13, wherein the fibrous material comprises a first fibrous material having a first fiber characteristic, a second fibrous material having a second fiber characteristic, and a third fibrous material having a third fiber characteristic.

[0103] Clause 15: The method according to any one of clauses 1 to 14, wherein the first fiber characteristic is a first color, the second fiber characteristic is a second color, and the third fiber characteristic is a third color.

[0104] Clause 16: The method according to clause 15, wherein the first color is different from the second color and the third color.

[0105] Clause 17: The method according to any one of clauses 1 to 16, wherein the predetermined characteristic is a color aesthetic.

[0106] Clause 18: The method according to any one of clauses 1 to 17, wherein the first characteristic is a first color aesthetic and the second characteristic is a second color aesthetic.

[0107] Clause 19: The method according to any one of clauses 1 to 18, wherein the forming comprises an airlay technique.

[0108] Clause 20: The method according to any one of clauses 1 to 19, wherein the forming comprises carding the nonwoven blend.

[0109] Clause 21: The method according to any one of clauses 1 to 20, wherein the binding material is provided in an amount based upon the predetermined characteristic.

[0110] Clause 22: The method according to any one of clauses 1 to 21, wherein the amount of binding material provided is adjustable based upon the predetermined characteristic.

[0111] Clause 23: The method according to any one of clauses 1 to 22, wherein the fibrous material is provided in an amount based upon the predetermined characteristic.

[0112] Clause 24: The method according to any one of clauses 1 to 23, wherein the amount of fibrous material provided is adjustable based upon the predetermined characteristic.

[0113] Clause 25: The method according to any one of clauses 1 to 24, further comprising applying a resin to the acoustic structure after the forming.

[0114] Clause 26: The method according to clause 25, wherein the applying comprises foaming a resin and applying the foamed resin to the acoustic structure.

[0115] Clause 27: The method according to any one of clauses 25 or 26, wherein the resin is a clear resin.

[0116] Clause 28: The method according to any one of clauses 25 to 27, wherein the resin is a pigmented resin.

[0117] Clause 29: A method for manufacturing a structure having a predetermined characteristic, the method comprising: determining an amount of binding material required to fulfill the predetermined characteristic; providing the determined amount of binding material; determining an amount of fibrous material required to fulfill the predetermined characteristic; intermixing the determined amount of fibrous material with the binding material to yield a nonwoven blend; and forming the nonwoven blend to yield the structure having the predetermined characteristic.

[0118] Clause 30: The method according to clause 29, wherein the binding material has a first characteristic that is perceptible up to a first distance from the substrate; wherein the fibrous material has a second characteristic that is perceptible up to a first distance from the substrate; wherein the predetermined characteristic is perceptible beyond a second distance from the substrate; and wherein the second distance is greater than the first distance.

[0119] Clause 31: The method according to any one of clauses 29 or 30, wherein the predetermined characteristic is different than the first characteristic and the second characteristic.

[0120] Clause 32: The method according to any one of clauses 29 to 31, wherein the predetermined characteristic results from the intermixing of the fibrous material with the binding material.

[0121] Clause 33: The method according to any one of clauses 29 to 32, wherein the first characteristic is a first color aesthetic and the second characteristic is a second color aesthetic.

[0122] Clause 34: The method according to any one of clauses 29 to 33, wherein the binding material comprises a blend of a first binding fiber having a first color and a second binding fiber having a second color.

[0123] Clause 35: The method according to clause 34, wherein the first color is black and the second color is white.

[0124] Clause 36: The method according to any one of clauses 29 to 35, wherein the binding material comprises a thermoplastic polymer.

[0125]

[0126] Clause 37: The method according to any one of clauses 29 to 36, wherein the binding material comprises PET.

[0127] Clause 38: The method according to any one of clauses 29 to 37, wherein the binding material comprises a polymer having a melting temperature lower than the melting temperature of the fibrous material.

[0128] Clause 39: The method according to any one of clauses 29 to 38, wherein the binding material comprises a plurality of fibers having an average diameter ranging from about 0.1 pm to about 60 pm.

[0129] Clause 40: The method according to any one of clauses 29 to 39, wherein the binding material is a biocomponent fibrous binder comprising a fiber coated in a sheath.

[0130] Clause 41: The method according to clause 40, wherein the sheath has a melting temperature that is lower than the melting temperature of the fibrous binder.

[0131] Clause 42: The method according to any one of clauses 40 or 41, wherein the binding material comprises from about 0 wt.% to about 40 wt. % biocomponent fibrous binder, based on the total dry weight of the binding material.

[0132] Clause 43: The method according to any one of clauses 29 to 42, wherein determining an amount of binding material required to fulfill the predetermined characteristic comprises: calculating an amount of the first binding fiber required to fulfill the predetermined characteristic; and calculating an amount of the second binding fiber required to fulfill the predetermined characteristic.

[0133] Clause 44: The method according to any one of clauses 29 to 43, wherein the amount of binding material required is adjustable based upon the predetermined characteristic.

[0134] Clause 45: The method according to any one of clauses 29 to 44, wherein the fibrous material comprises a plurality of fibers having an average diameter ranging from about 0.1 pm to about 60 pm.

[0135] Clause 46: The method according to any one of clauses 29 to 45, wherein the fibrous material comprises one or more of natural fibers, organic fibers, thermoplastic fibers, and wool

[0136] Clause 47: The method according to any one of clauses 29 to 46, wherein the fibrous material comprises: a first fibrous material having a first fiber characteristic; a second fibrous material having a second fiber characteristic; and a third fibrous material having a third fiber characteristic.

[0137] Clause 48: The method according to clause 47, wherein the first fiber characteristic is a first color, the second fiber characteristic is a second color, and the third fiber characteristic is a third color.

[0138] Clause 49: The method according to clause 48, wherein the first color is different from the second color and the third color.

[0139] Clause 50: The method according to any one of clauses 29 to 49, wherein the determining an amount of fibrous material required to fulfill the predetermined characteristic comprises: calculating an amount of the first fibrous material required to fulfill the predetermined characteristic; calculating an amount of the second fibrous material required to fulfill the predetermined characteristic; and calculating an amount of the third fibrous material required to fulfill the predetermined characteristic.

[0140] Clause 51: The method according to any one of clauses 29 to 50, wherein the amount of fibrous material required is adjustable based upon the predetermined characteristic.

[0141] Clause 52: The method according to any one of clauses 29 to 51, wherein the predetermined characteristic is a color aesthetic.

[0142] Clause 53: The method according to any one of clauses 29 to 52, wherein the forming comprises airlaying the nonwoven blend.

[0143]

[0144] Clause 54: The method according to any one of clauses 29 to 53, wherein the forming comprises carding the nonwoven blend.

[0145] Clause 55: The method according to any one of clauses 29 to 54, further comprising applying a resin to the structure after the forming.

[0146] Clause 56: The method according to clause 55, wherein the applying comprises foaming a resin and applying the foamed resin to the structure.

[0147] Clause 57: The method according to any one of clauses 55 or 56, wherein the resin is a clear resin.

[0148] Clause 58: The method according to any one of clauses 55 to 57, wherein the resin is a pigmented resin.

[0149] Clause 59: A structure comprising: a substrate having a first surface opposite a second surface, the substrate comprising: a binding material having a first characteristic that is perceptible up to a first distance from the substrate; and fibrous material having a second characteristic intermixed with the binding material, the second characteristic perceptible up to the first distance from the substrate; wherein the structure has a predetermined characteristic resulting from the intermixed binding material and fibrous material; wherein the predetermined characteristic is perceptible beyond a second distance from the substrate; and wherein the second distance is greater than the first distance.

[0150] Clause 60: The structure according to clause 59, wherein the predetermined characteristic is different from the first characteristic and the second characteristic.

[0151] Clause 61: The structure according to any one of clauses 59 or 60, wherein the first characteristic is a first color aesthetic, the second characteristic is a second color aesthetic, and the predetermined characteristic is a third color aesthetic.

[0152] Clause 62: The structure according to any one of clauses 59 to 61, wherein the binding material comprises a blend of black fibers and white fibers.

[0153] Clause 63: The structure according to any one of clauses 59 to 62, wherein the binding material comprises a thermoplastic polymer.

[0154] Clause 64: The structure according to any one of clauses 59 to 63, wherein the binding material comprises PET.

[0155] Clause 65: The structure according to any one of clauses 59 to 64, wherein the binding material comprises a polymer having a melting temperature lower than the melting temperature of the fibrous material.

[0156] Clause 66: The structure according to any one of clauses 59 to 65, wherein the binding material comprises a plurality of fibers having an average diameter ranging from about 0.1 pm to about 60 pm.

[0157] Clause 67: The structure according to any one of clauses 59 to 66, wherein the binding material is a biocomponent fibrous binder comprising a fiber coated in a sheath.

[0158] Clause 68: The structure according to clause 67, wherein the sheath has a melting temperature that is lower than the melting temperature of the fibrous binder.

[0159] Clause 69: The structure according to any one of clauses 67 or 68, wherein the binding material comprises from about 0 wt.% to about 40 wt. % biocomponent fibrous binder, based on the total dry weight of the binding material.

[0160] Clause 70: The structure according to any one of clauses 59 to 69, wherein the fibrous material comprises a plurality of fibers having an average diameter ranging from about 0.1 pm to about 60 pm.

[0161]

[0162] Clause 71: The structure according to any one of clauses 59 to 70, wherein the fibrous material comprises one or more of natural fibers, organic fibers, thermoplastic fibers, and wool.

[0163] Clause 72: The structure according to any one of clauses 59 to 71, wherein the fibrous material comprises a first fibrous material having a first fiber characteristic, a second fibrous material having a second fiber characteristic, and a third fibrous material having a third fiber characteristic.

[0164] Clause 73: The structure according to clause 72, wherein the first fiber characteristic is a first color, the second fiber characteristic is a second color, and the third fiber characteristic is a third color.

[0165] Clause 74: The structure according to clause 73, wherein the first color is different from the second color and the third color.

[0166] Clause 75: The structure according to any one of clauses 73 or 74, wherein the first color is cyan, the second color is magenta, and the third color is yellow.

[0167] Clause 76: The structure according to any one of clauses 59 to 75, wherein the predetermined characteristic is a color aesthetic.

[0168] Clause 77: The structure according to any one of clauses 59 to 76, wherein the first characteristic is a first color aesthetic and the second characteristic is a second color aesthetic.

[0169] Clause 78: The structure according to any one of clauses 59 to 77, further comprising a resin intermixed with the fibrous material and the binding material.

[0170] Clause 79: The structure according to any one of clauses 59 to 78, wherein the structure is an acoustic structure.

[0171] Clause 80: The structure according to any one of clauses 59 to 79, wherein the structure is an architectural structure.

[0172] Clause 81: A method for manufacturing a structure having a predetermined characteristic, the method comprising: providing a fibrous material having a second characteristic; and forming the nonwoven blend to yield the structure; wherein the fibrous material is perceptible up to a first distance from the structure; wherein the predetermined characteristic is perceptible beyond a second distance from the structure; and wherein the second distance is greater than the first distance.

[0173] Clause 82: The method according to clause 81, wherein the predetermined characteristic is different than the second characteristic.

[0174] Clause 83: The method according to any one of clauses 81 or 82, wherein the predetermined characteristic is continuous throughout the structure.

[0175] Clause 84: The method according to any one of clauses 81 to 83, wherein the fibrous material comprises a plurality of fibers having an average diameter ranging from about 0.1 pm to about 60 pm.

[0176] Clause 85: The method according to any one of clauses 81 to 84, wherein the fibrous material comprises one or more natural fibers, organic fibers, thermoplastic fibers, and wool.

[0177] Clause 86: The method according to any one of clauses 81 to 85, wherein the fibrous material comprises a first fibrous material having a first fiber characteristic, a second fibrous material having a second fiber characteristic, a third fibrous material having a third fiber characteristic, and a fourth fibrous material having a fourth fiber characteristic.

[0178] Clause 87: The method according to any one of clauses 81 to 86, wherein the first fiber characteristic is a first color, the second fiber characteristic is a second color, the third fiber characteristic is a third color, and the fourth fiber characteristic is a fourth color.

[0179] Clause 88: The method according to any one of clauses 81 to 87, wherein the predetermined characteristic is a color aesthetic.

[0180] Clause 89: The method according to any one of clauses 81 to 88, wherein the forming comprises an airlay technique.

[0181] Clause 90: The method according to any one of clauses 81 to 89, wherein the forming comprises carding the nonwoven blend.

[0182] Clause 91: The method according to any one of clauses 81 to 90, wherein the amount of binding material provided is adjustable based upon the predetermined characteristic.

[0183]

[0184] Clause 92: The method according to any one of clauses 81 to 91, wherein the amount of fibrous material provided is adjustable based upon the predetermined characteristic.

[0185] Clause 93: The method according to any one of clauses 81 to 92, wherein the fibrous material is provided in an amount based upon the predetermined characteristic.

[0186] Clause 94: The method according to any one of clauses 81 to 93, further comprising applying a binding material having a first characteristic to the structure.

[0187] Clause 95: The method according to any one of clauses 81 to 94, wherein the binding material comprises a resin.

[0188] Clause 96: The method according to any one of clauses 81 to 95, wherein the binding material comprises one or more of a fire retardant, insecticide, and fungicide.

[0189] Clause 97: The method according to any one of clauses 81 to 96, wherein the binding material is applied as a foam.

[0190] Clause 98: The method according to any one of clauses 81 to 97, wherein the binding material is pigmented.

[0191] Clause 99: The method according to any one of clauses 81 to 98, wherein the binding material is clear.

[0192] Clause 100: The method according to any one of clauses 81 to 99, wherein the structure is an acoustic structure.

[0193] Clause 101: The method according to any one of clauses 81 to 100, wherein the structure is an architectural structure.

[0194] While the present disclosure has been described with reference to several examples, which examples have been set forth in considerable detail for the purposes of making a complete disclosure of the disclosure, such examples are merely representative and are not intended to be limiting or represent an exhaustive enumeration of all aspects of the disclosure. The scope of the disclosure is to be determined from the claims appended hereto. Further, it will be apparent to those of skill in the art that numerous changes may be made in such details without departing from the spirit and the principles of the disclosure.

Claims

1. A method for manufacturing an acoustic structure having a predetermined characteristic, the method comprising:providing a binding material having a first characteristic;intermixing a fibrous material having a second characteristic with the binding material to yield a nonwoven blend; andforming the nonwoven blend to yield an acoustic structure having the predetermined characteristic resulting from the intermixed binding material and fibrous material;wherein the binding material is perceptible up to a first distance from the structure;wherein the fibrous material is perceptible up to a first distance from the structure;wherein the predetermined characteristic is perceptible beyond a second distance from the structure; andwherein the second distance is greater than the first distance.

2. The method according to claim 1, wherein the binding material comprises a blend of a first binding fiber having a first color and a second binding fiber having a second color.

3. The method according to any one of claims 1 or 2, wherein the binding material comprises a thermoplastic polymer having a melting temperature lower than the melting temperature of the fibrous material.

4. The method according to any one of claims 1 to 3, wherein the binding material is a biocomponent fibrous binder comprising a fiber coated in a sheath, and wherein the sheath has a melting temperature that is lower than the melting temperature of the fibrous binder.

5. The method according to any one of claims 1 to 4, wherein the fibrous material comprises a first fibrous material having a first fiber characteristic, a second fibrous material having a second fiber characteristic, and a third fibrous material having a third fiber characteristic.

6. The method according to any one of claims 1 to 5, further comprising applying a resin to the acoustic structure after the forming, wherein the applying comprises foaming a resin and applying the foamed resin to the acoustic structure.

7. A method for manufacturing a structure having a predetermined characteristic, the method comprising:determining an amount of binding material required to fulfill the predetermined characteristic;providing the determined amount of binding material;determining an amount of fibrous material required to fulfill the predetermined characteristic;intermixing the determined amount of fibrous material with the binding material to yield a nonwoven blend; andforming the nonwoven blend to yield the structure having the predetermined characteristic.

8. The method according to claim 7, wherein the binding material has a first characteristic that is perceptible up to a first distance from the substrate;wherein the fibrous material has a second characteristic that is perceptible up to a first distance from the substrate;wherein the predetermined characteristic is perceptible beyond a second distance from the substrate; andwherein the second distance is greater than the first distance.

9. The method according to any one of claims 7 or 8, wherein the predetermined characteristic results from the intermixing of the fibrous material with the binding material.

10. The method according to any one of claims 7 to 9, wherein the first characteristic is a first color aesthetic and the second characteristic is a second color aesthetic.

11. The method according to any one of claims 7 to 10, wherein the binding material comprises a blend of a first binding fiber having a first color and a second binding fiber having a second color.

12. The method according to any one of claims 7 to 11, wherein the binding material comprises a thermoplastic polymer having a melting temperature lower than the melting temperature of the fibrous material.

13. The method according to any one of claims 7 to 12, wherein the binding material is a biocomponcnt fibrous binder comprising a fiber coated in a sheath, and wherein the sheath has a melting temperature that is lower than the melting temperature of the fibrous binder.

14. The method according to any one of claims 7 to 13, wherein determining an amount of binding material required to fulfill the predetermined characteristic comprises:calculating an amount of the first binding fiber required to fulfill the predetermined characteristic; andcalculating an amount of the second binding fiber required to fulfill the predetermined characteristic.

15. The method according to any one of claims 7 to 14, wherein the fibrous material comprises:a first fibrous material having a first fiber characteristic;a second fibrous material having a second fiber characteristic; anda third fibrous material having a third fiber characteristic.

16. The method according to claim 15, wherein the first fiber characteristic is a first color, the second fiber characteristic is a second color, and the third fiber characteristic is a third color.

17. The method according to any one of claims 7 to 16, wherein the determining an amount of fibrous material required to fulfill the predetermined characteristic comprises:calculating an amount of the first fibrous material required to fulfill the predetermined characteristic;calculating an amount of the second fibrous material required to fulfill the predetermined characteristic; andcalculating an amount of the third fibrous material required to fulfill the predetermined characteristic.

18. The method according to any one of claims 7 to 17, further comprising applying a resin to the structure after the forming, wherein the applying comprises foaming a resin and applying the foamed resin to the structure.

19. A structure comprising:a substrate having a first surface opposite a second surface, the substrate comprising:a binding material having a first characteristic that is perceptible up to a first distance from the substrate; andfibrous material having a second characteristic intermixed with the binding material, the second characteristic perceptible up to the first distance from the substrate;wherein the structure has a predetermined characteristic resulting from the intermixed binding material and fibrous material;wherein the predetermined characteristic is perceptible beyond a second distance from the substrate; andwherein the second distance is greater than the first distance.

20. A method for manufacturing a structure having a predetermined characteristic, the method comprising:providing a fibrous material having a second characteristic; andforming the nonwoven blend to yield the structure;wherein the fibrous material is perceptible up to a first distance from the structure;wherein the predetermined characteristic is perceptible beyond a second distance from the structure; andwherein the second distance is greater than the first distance.

21. The method according to claim 20, wherein the fibrous material comprises a first fibrous material having a first fiber characteristic, a second fibrous material having a second fiber characteristic, a third fibrous material having a third fiber characteristic, and a fourth fibrous material having a fourth fiber characteristic.

22. The method according to any one of claims 20 or 21, wherein the first fiber characteristic is a first color, the second fiber characteristic is a second color, the third fiber characteristic is a third color, and the fourth fiber characteristic is a fourth color.

23. The method according to any one of claims 20 to 22, further comprising applying a binding material having a first characteristic to the structure, wherein the binding material comprises a resin, and wherein the binding material is applied as a foam.

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