Method of manufacturing acoustic panel

Abstract

The present invention relates to a manufacturing process for an acoustic panel (12) comprising the steps of: providing (S10) a substrate (14) made of a sound-absorbing material; applying (S12) a mineral filler (16) to the substrate; and incorporating (S14) a structure (18) into the mineral filler. The present invention further relates to an acoustic panel.

Description

[0001] The present invention relates to a manufacturing method for an acoustic panel. The present invention further relates to an acoustic panel and a method for dampening sound emissions.

[0002] Depending on the size and layout, indoor spaces can have acoustics that people find disturbing or that are unsuitable for the intended use of the room. This is especially true if several people are present in the room and / or there are other or additional noise emissions within the room, for example, from machinery, etc. Sound absorbers or acoustic panels are used to improve room acoustics or to equip an interior for recording purposes. During the room planning phase, it can be considered that such elements are installed or planned in suitable locations to dampen or insulate noise and reverberation.

[0003] These sound absorbers or acoustic panels are usually panels or flat objects arranged within a room to absorb sound. The sound energy is converted into other forms of energy, such as heat or vibration energy. Porous structures are often used for this purpose, such as foams (acoustic foam), wool (rock wool), or PET tiles (polyethylene terephthalate). The use of such components is often combined with a design effect, particularly in office environments, but also in residential or industrial settings. The acoustic panels or sound absorbers are therefore also used in interior design. Relevant factors in this regard include cost, appearance, and manufacturing and variation options.

[0004] Previous approaches often suffer from the disadvantage that the sound absorbers are relatively conspicuous and difficult to integrate into existing environments. Based on this, the present invention aims to provide an approach for efficiently improving room acoustics that, on the one hand, enables cost-effective production and, on the other, allows for a wide range of different designs in terms of shape and appearance.

[0005] To achieve this object, the present invention relates in a first aspect to a manufacturing method for an acoustic panel comprising the steps: Providing a substrate made of a sound-absorbing material; applying a mineral filler to the substrate; and introducing a structure into the mineral filler.

[0006] In a further aspect, the present invention relates to an acoustic panel for dampening sound emissions comprising a carrier with a mineral filler applied thereto and a structure incorporated into the mineral filler, in particular produced by a method as described above.

[0007] In a further aspect, the present invention relates to a method for dampening sound emissions comprising a step of attaching an acoustic panel as described above to a wall in an interior space.

[0008] Preferred embodiments of the invention are described in the dependent claims. It is understood that the features mentioned above and those to be explained below can be used not only in the respective combinations specified, but also in other combinations or individually, without departing from the scope of the present invention. In particular, the acoustic panel and the method for dampening sound emissions can be designed according to the embodiments described for the manufacturing method in the dependent claims.

[0009] According to the invention, a support made of a sound-absorbing material is first provided. A mineral filler is applied to this support, into which a structure is then incorporated. Sound is absorbed by the sound-absorbing material itself. In particular, sound energy or sound waves are converted into heat. The mineral filler and the structure incorporated therein improve the sound-absorbing effect. In particular, reflections or scattering can occur on the filler, allowing a higher proportion of the incident sound to be absorbed by the sound-absorbing material.

[0010] The acoustic panel produced according to the invention can then be installed in a room, for example on a wall or on the ceiling, in order to improve the room acoustics and contribute to a better spatial feeling.

[0011] Compared to previous approaches of using a sound-absorbing material as a sound absorber or the direct use of an acoustic panel made of sound-absorbing material without an applied structure, this results in an expanded range of design possibilities. Furthermore, improved sound absorption can be achieved. In particular, the manufacturing method according to the invention makes it possible to produce acoustic panels that resemble a wide variety of surfaces and, for example, have a concrete or stone appearance. This opens up a wide range of design possibilities. High sound absorption coefficients are achieved, so that even comparatively small acoustic panels can achieve high effectiveness. Furthermore, this offers design freedom, enabling application in a variety of areas.The open structure of the mineral filler allows sound waves to preferentially penetrate the upper layer, thus improving the sound insulation of the trigger material. The resulting acoustic panels or boards can be manufactured to a precise fit and can therefore be joined or mounted together without the need for joints. Furthermore, it is possible to digitally print the acoustic panels produced according to the invention.

[0012] In a preferred embodiment, the step of applying the mineral filler is carried out by directly spreading it onto the substrate and / or by attaching a prefabricated veneer to the substrate, in particular by gluing. The prefabricated veneer preferably comprises filler applied to a fiberglass substrate. On the one hand, it is therefore possible for a mineral filler to be spread onto the substrate. On the other hand, a prefabricated veneer can also be used in addition or in addition. By directly spreading it, a wider range of different shapes and structures can be realized. Using a prefabricated veneer results in potential savings, thus enabling greater production efficiency. Using a fiberglass substrate enables a further improvement in acoustics.A previously produced veneer is glued on. This can be done using a suitable adhesive that doesn't impair the acoustics.

[0013] In a preferred embodiment, a filler compound comprising stone powder and acrylate is applied during the application step. A mineral filler compound comprising stone powder and acrylate enables a corresponding improvement in the acoustic effect. Furthermore, stone optics can be achieved, opening up a wide range of different design possibilities. The result is a filler compound that is efficient to process and yet comparatively inexpensive to produce. Furthermore, a wide range of design options is possible.

[0014] In a preferred embodiment, an oscillating knife, in particular an oscillating tangential knife, and / or a computer-assisted milling machine is used to create the structure. The use of an oscillating knife results in efficient and cost-effective production. The oscillating knife can be used in particular in a cutter machine or in a computer-controlled corresponding machine for cutting materials. The oscillating knife can be moved in different directions and allows for a high degree of freedom in the implementation of different patterns.

[0015] Alternatively, milling can also be used. However, it has been found that the use of an oscillating blade enables greater efficiency in terms of fast production with low wear and precise processing of cut edges.

[0016] In a preferred embodiment, a structure is also introduced into the carrier during the step of introducing the structure. Additionally or alternatively, a structure with a triangular profile is introduced during the step of introducing the structure. By also introducing a structure into the carrier, the acoustic properties can be further improved. The surface area of ​​the carrier can be enlarged if necessary. Furthermore, it can be ensured that the applied filler is completely removed in order to enable direct contact of the incoming sound waves with the carrier. The filler is, so to speak, completely removed at the relevant locations in order to enable an improvement in the sound penetration properties. The introduction of a structure with a triangular profile has proven to be particularly advantageous with regard to the sound properties generated.In particular, a large surface area is created. Furthermore, efficient insertion is achieved by enabling simple tool selection. A triangular profile is defined as a triangular cross-section or a tapered groove or structure.

[0017] In one embodiment of the manufacturing method according to the invention, several elongated and parallel recesses are introduced during the step of introducing the structure. The recesses preferably have at least a partial triangular profile. The use of several elongated and parallel recesses ensures favorable acoustics. This results in high sound absorption. Furthermore, design options resembling a stone appearance arise, allowing for the adaptation of existing structures.

[0018] In a preferred embodiment, the method comprises a step of printing the acoustic panel before or after the structure has been inserted, preferably after the structure has been inserted. The printing step preferably comprises printing using a digital printing process. An additional printing step enables further design options. This results in a multitude of design possibilities. Furthermore, integration into existing environments can be facilitated or enabled. The use of a digital printing process is particularly advantageous, as it enables efficient and cost-effective processing. Furthermore, precise design options arise.

[0019] In a preferred embodiment, a plastic carrier is provided as the carrier, in particular a plastic carrier with a thermoplastic material, preferably polyethylene terephthalate or polyethylene terephthalate felt. Such carriers are also used without an applied structure as acoustic panels or as sound absorbers and have advantageous sound absorption properties. Furthermore, an efficient and permanent application of the mineral filler can be achieved. The use of a felt material is particularly advantageous in this case.

[0020] In a preferred embodiment, a soundproofing panel is provided as the support. The use of a soundproofing panel enables comparatively cost-effective production of an acoustic panel according to the invention.

[0021] In a preferred embodiment, a substrate with a thickness between 5 mm and 24 mm is provided, preferably between 9 mm and 15 mm. Additionally or alternatively, in the step of applying the mineral filler, this is applied in a thickness between 1 mm and 10 mm, preferably between 2 mm and 4 mm. The use of correspondingly thick substrates or layers of mineral filler results in advantageous acoustic properties with regard to sound absorption. Furthermore, acoustic panels are produced that can be installed comparatively easily and efficiently within an interior space using a method according to the invention for dampening sound emissions.

[0022] Here, a carrier is understood to mean, in particular, a plate, particularly preferably a rectangular or square plate. A mineral filler can, in particular, comprise a mineral powder and a binder. Application can, in particular, be carried out by troweling. This step can be performed manually or automatically. An oscillating blade is used, in particular, in a corresponding machine tool. The introduced structure is, in particular, two-dimensional (at a constant depth into the filler or into the carrier).

[0023] The invention is described and explained in more detail below using selected embodiments in conjunction with the accompanying drawings. They show: Figure 1 shows a schematic representation of an interior space with an acoustic panel attached to a wall of the interior space; Figure 2 shows a schematic representation of an embodiment of an acoustic panel according to the invention; Figure 3 shows a schematic representation of a manufacturing method according to the invention; and Figure 4 shows a schematic representation of various structures in acoustic panels manufactured according to the invention.

[0024] In Figure 1An interior space 10 is schematically indicated, in which an acoustic panel 12 is attached to a wall. For example, within an office space or in a living space, an acoustic panel 12 can be attached to a wall or even to the ceiling in order to dampen sound emissions and thus improve the room acoustics. The acoustic panel 12 can be mounted, for example, by screwing or gluing. It is possible for a plurality of acoustic panels 12 to be attached next to one another in order to completely or largely cover a wall. It is also possible for the room to be completely equipped with acoustic panels 12 according to the invention.

[0025] In Figure 2An acoustic panel 12 according to the invention is shown schematically. In the illustrated embodiment, the acoustic panel 12 comprises a carrier 14 onto which a mineral filler 16 is applied. A structure 18 is incorporated into the acoustic panel 12.

[0026] The carrier 14 can, for example, be a plastic carrier with a thermoplastic material. For example, a PET or PET felt carrier can be used. A mineral filler 16 is applied, in particular troweled, to the carrier 14. This mineral filler 16 can, in particular, be directly applied by troweling and comprise rock powder and acrylate. As an alternative to directly applying the mineral filler 16 by troweling, it can also be provided that a prefabricated veneer with the filler is provided, to which the filler is applied. This veneer can then be connected to the carrier, for example by gluing. A fiberglass carrier, for example, can be used as the veneer. In the illustrated embodiment, the introduced structure 18 comprises several recesses arranged in parallel.In the illustrated embodiment, the recesses have a triangular profile and are arranged parallel and straight. It is understood that other shapes, profiles, and arrangements may also be provided.

[0027] The acoustic panel 12 according to the invention absorbs incoming sound. In particular, the sound is absorbed by the carrier 14 made of sound-absorbing material. However, absorption, reflection, and scattering also occur at the mineral filler 16 or at the structure 18. Thus, the structure 18 may increase the surface area to improve the sound-absorbing properties.

[0028] In Figure 2An embodiment of an acoustic panel 12 according to the invention is shown, in which the structure 18 extends through the layer of mineral filler 16 into the carrier 14. However, it is also possible for the structure 16 to extend only within the layer of mineral filler 16.

[0029] In Figure 3A manufacturing method according to the invention for an acoustic panel is shown schematically. The method comprises steps of providing S10 a carrier, applying S12 a mineral filler, and introducing S14 a structure. Optionally, the method also comprises a step of printing S16 the acoustic panel. The method according to the invention can, in particular, be used to produce an acoustic panel as described above. The method can, for example, be carried out fully or partially automated. It can be designed as an operating method for a corresponding manufacturing device. It is also possible for parts of the steps to be carried out manually.

[0030] In the step S14 of introducing the structure, an oscillating knife can be used. For example, an oscillating tangential knife used in a corresponding machine tool can be used. The use of an oscillating knife results in efficient manufacturing. Furthermore, it provides degrees of freedom in the choice of structure. Thus, a wide variety of possible structures can be realized. Both straight and curved structures with the same or different depths can be used. Different or identical profiles can also be used.

[0031] Optionally, it is possible to print the acoustic panel. In the illustrated example in Figure 3The printing step S16 is intended to take place after the structure has been applied. However, it is also possible for the printing step S16 to be performed before the mineral filler is applied S14. A digital printing process can be used in this case, as this enables efficient processing.

[0032] In Figure 4 Four different embodiments of acoustic panels 12 according to the invention are shown. In particular, the various representations in Figure 4It can be seen that different shapes of supports with mineral filler applied thereto can be used. Furthermore, different structures 18 can be provided in the supports. The structures 18 can be incorporated into the mineral filler and / or the support more or less arbitrarily or in any desired shape and depth. The use of an oscillating blade for introducing the structures 18 is particularly advantageous, since this type of tool enables a wide range of different structures 18 to be realized.

[0033] The invention has been comprehensively described and explained with reference to the drawings and the description. The description and explanation are to be understood as exemplary and not restrictive. The invention is not limited to the disclosed embodiments. Other embodiments or variations will become apparent to those skilled in the art upon use of the present invention and upon careful analysis of the drawings, the disclosure, and the following claims.

[0034] In the claims, the words "comprising" and "having" do not exclude the presence of further elements or steps. The undefined article "a" or "an" does not exclude the presence of a plurality. A single element or unit can perform the functions of several of the units recited in the claims. The mere reciting of some measures in several different dependent claims should not be understood to mean that a combination of these measures cannot also be used advantageously. Reference signs in the claims are not to be understood as limiting.

Claims

1. Manufacturing method for an acoustic panel (12) comprising the steps of: providing (S10) a carrier (14) made of a sound-absorbing material; applying (S12) a mineral filler (16) to the carrier; and introducing (S14) a structure (18) into the mineral filler.

2. Manufacturing method according to claim 1, wherein in the step of applying (S12) the mineral filler (16), the application is carried out by direct filling onto the carrier (14) and / or by attaching a prefabricated veneer to the carrier, in particular by gluing; and the prefabricated veneer preferably comprises filler applied to a fiberglass carrier.

3. Manufacturing method according to one of the preceding claims, wherein in the step of applying (S12) a filler (16) comprising stone powder and acrylate is applied.

4. Manufacturing method according to one of the preceding claims, wherein an oscillating knife, in particular an oscillating tangential knife, and / or a computer-assisted milling machine is used for the introduction of the structure (18) 5. Manufacturing method according to one of the preceding claims, wherein in the step of introducing (S14) the structure (18), a structure is also introduced into the carrier (14); and / or a structure with a triangular profile is introduced.

6. Manufacturing method according to one of the preceding claims, wherein in the step of introducing (S14) the structure (18) a plurality of elongated and parallel recesses are introduced; and the recesses preferably have at least partially a triangular profile.

7. Manufacturing method according to one of the preceding claims, comprising a step of printing (S16) the acoustic panel (12) before or after the introduction of the structure (18), preferably after the introduction of the structure, wherein the step of printing preferably comprises printing using a digital printing process.

8. Manufacturing method according to one of the preceding claims, wherein a plastic carrier is provided as the carrier (14), in particular a plastic carrier with a thermoplastic plastic, preferably polyethylene terephthalate or polyethylene terephthalate felt.

9. Manufacturing method according to one of the preceding claims, wherein a soundproofing plate is provided as the carrier (14).

10. Manufacturing method according to one of the preceding claims, wherein a carrier (14) is provided with a thickness between 5 mm and 24 mm, preferably between 9 mm and 15 mm; and / or in the step of applying (S12) the mineral filler (16) is applied in a thickness between 1 mm and 10 mm, preferably between 2 mm and 4 mm.

11. Acoustic panel (12) for dampening sound emissions with a carrier (14) with a mineral filler (16) applied thereto and a structure (18) introduced into the mineral filler, in particular produced by a method according to one of the preceding claims.

12. A method for dampening sound emissions comprising a step of attaching an acoustic panel (12) according to claim 11 to a wall in an interior space.

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