Plate-shaped building element and method for its manufacture

Abstract

The invention relates to a plate-shaped component, in particular an acoustic panel (1), which has a plate body (2) with a front surface (3). The plate body (2) is formed in one piece from an open-pored, sound-absorbing felt, wherein the front surface (3) has a milled surface structure (4). The front surface (3) of the plate body (2) is milled, whereby a relief is formed in the surface of the front surface (3) by material removal. The felt is preferably made from polyethylene terephthalate, polypropylene, and / or natural fibers.

Description

[0001] The invention relates to a plate-shaped component, in particular an acoustic panel, which has a plate body with a front side, and to a method for its manufacture.

[0002] Surface coverings made of panel-shaped components are available in various configurations and designs. These include panel-shaped components in the form of acoustic panels. These have diverse applications, the primary purpose being noise reduction. Acoustic panels can be used as wall and ceiling coverings. As sound absorbers and to improve room acoustics, acoustic panels can also be incorporated into home accessories, furniture, or interior design elements. Acoustic panels are an elegant and modern furnishing element that contributes to good room acoustics and a pleasant atmosphere.

[0003] Known are panel-shaped building elements in the form of acoustic panels with an open-pored sound-absorbing substrate layer and a visible decorative layer made of wooden strips.

[0004] According to DE 10 2013 010 091 B4, an acoustic element with a large number of sound-absorbing channels is considered state of the art.

[0005] EP 2 295 240 B1 discloses a method for manufacturing a sound-insulating panel comprising an overlay containing a fiber-reinforced thermosetting plastic, a wood-based substrate, an insulating layer, and a backing layer containing a thermosetting plastic, which is arranged between the substrate and the insulating layer. The overlay, the substrate, the backing layer, and the insulating layer are arranged between two press plates, with the insulating layer resting on one of the press plates. The layers are then heated between the two heated press plates to a temperature and for a time sufficient to ensure the curing of the overlay and backing layer, whereby the backing layer bonds the insulating layer to the substrate.

[0006] WO 2018 / 130636 A1 describes a process for manufacturing an acoustic insulation panel, in which a mixture of wool fibers and binding fibers is heated and pressed in a mold. In this way, an acoustic insulation panel is produced comprising a mixture of wool fibers and binder with at least two areas of different density.

[0007] The known acoustic panels or insulation boards fulfill their purpose more or less satisfactorily, depending on the design. From a manufacturing perspective, the known acoustic panels are relatively complex. They also do not offer the best properties in terms of resource conservation, recyclability, reuse, or disposal.

[0008] Starting from the prior art, the invention is based on the objective of creating an ecologically, technically, optically and application-wise advantageous plate-shaped building element and of demonstrating a method for manufacturing such plate-shaped building elements.

[0009] The solution to the present part of the problem consists of a plate-shaped component according to claim 1.

[0010] The method according to the invention is defined in claim 11.

[0011] A panel-shaped building element is, in particular, an acoustic panel. The element consists of a single, flat body with a front surface. The panel body is made of open-pored, sound-absorbing felt. Sound is captured and absorbed within the panel body. This occurs primarily through the conversion of sound energy into another form of energy, such as heat or vibrational energy.

[0012] According to the invention, the plate body is a single piece and consists of an open-pored, sound-absorbing felt, the front side having a surface structure produced by milling.

[0013] Felt is a non-woven textile material. Felt consists of pressed fibers, which in turn can be made of natural materials or plastics. Within the scope of the invention, the felt or felt fabric consists in particular of polyethylene terephthalate (PET) and / or polypropylene (PP) and / or natural fibers, or is at least based on the aforementioned materials. The felt fabric can also consist of a fiber mixture of the aforementioned materials. It is essential that the sheet body consists of the felt fabric in one piece with the surface structure milled into the front surface. Here, the felt fabric is partially removed from the sheet body by milling, creating a surface structure in the form of a relief on the front surface. A recessed relief is milled into the front surface of the sheet body.

[0014] The more open-pored and lighter the felt of the panel body is, the better the sound-absorbing function or the sound-absorbing properties of the panel-shaped building element.

[0015] The starting materials for felt fabrics include virgin wool, other animal hair, cotton, coconut, hemp, polyethylene terephthalate or polypropylene.

[0016] Felt belongs to the group of nonwoven fabrics. These are characterized by the fact that the fibers are bonded together.

[0017] In principle, it is possible to felt almost all natural or synthetic fibers.

[0018] The surface structure on the front side of the panel is produced by milling. Milling is a machining process. During machining, felt material in the form of chips is removed from the panel using a milling tool. Any desired contours or reliefs can be created on the front side of the panel. Milling is a broaching process which, according to the invention, is used to shape the front side of the panel.

[0019] In terms of milling technology, linear milling indentations, grooves, slots and / or irregularly stepped geometries can be formed in the front of the plate body, which form the surface structure.

[0020] During milling, felt material is removed by rotating the milling tool at high speed around its own axis, either while the tool follows the contour to be produced or while the panel is moved accordingly. This milling process creates a structured surface on the front of the panel using milled recesses. This is done using CNC-controlled cutters such as router bits, template cutters, or with saws and profile cutters on profiling machines.

[0021] The surface texture on the front of the panel is produced using a subtractive manufacturing process, in which felt material is removed by milling. The machining is precise. The finished product, or surface texture, has a smooth finish with tight dimensional tolerances. Distortion or material stresses in the panel, especially in areas near the surface, are avoided.

[0022] A particular advantage of the invention arises from the fact that the side walls of the surface structure are open-pored and sound-permeable. The side surfaces of the surface structure are, in particular, the side walls or side wall areas of milled recesses, such as grooves, in the front of the panel body, which thus increase the acoustically active product surface area.

[0023] The milled surface structure can be formed by groove- or strip-shaped depressions, especially slots. Milling creates depressions in the surface of the front face. These depressions are bordered by raised surface sections. Such surface sections are either not milled or milled to a lesser extent than adjacent recessed areas.

[0024] Milling can create recesses in the form of grooves on the front surface. The grooves run parallel to each other, spaced apart, preferably along the length of a plate-shaped component. Grooves of varying widths and depths can be provided on the front surface of a plate-shaped component.

[0025] The front surface of the plate body has at least one milled recess. In particular, the front surface of the plate body has a pattern of one or more recesses. Each recess has a depth between 20% and 50% of the plate body's thickness. The plate body's thickness is the material thickness of the plate body in its initial state. In practice, the depth is preferably one-third of the plate body's thickness. A depth greater than 2 mm is advantageous.

[0026] The density of a felt material used in the invention is 200 kg / m³ ± 60 kg / m³. This results in basis weights between 1 kg / m² and 11 kg / m² for material thicknesses of the sheet bodies or felt mats used as the starting material for the sheet bodies between 5 mm and 45 mm.

[0027] In one embodiment, a sheet can be made entirely of polyethylene terephthalate (PET) and have a total thickness of 8 mm. The basis weight is between 1300 g / m² and 1500 g / m², particularly 1400 g / m². A surface structure is milled into the front face of such a sheet. This is done in a defined manner, creating a pattern on the surface of the front face. The depth is approximately one-third of the total material thickness.

[0028] In another embodiment, a felt fabric made from recycled polyethylene terephthalate (PET) is used. The material can be 100% recycled, preferably the proportion of recycled polyethylene terephthalate is more than 50%. The material density is 0.18 g / cm³ ± 25%. The material weight is 900 g / m² to 2900 g / m². The material thickness is between 5 mm and 45 mm, depending on the application, preferably between 8 mm and 12 mm.

[0029] The higher the proportion of milled areas, the better the acoustic properties and the lower the surface weight. In a preferred embodiment, at least 25% of the front surface is milled or provided with milled recesses. The milled surface structure is configured to create the desired external appearance of the plate-shaped component while optimizing sound absorption.

[0030] Sheet materials with thicknesses between 7 mm and 12 mm and weights between 1200 g / m² and 1500 g / m² are preferred. This applies in particular to sheets made of polyethylene terephthalate (PET) and especially to PET sheets with up to 100% recycled content.

[0031] For practical applications, the use of a felt material made from polyester fibers or polyethylene terephthalate (PET) is particularly suitable. Polyester fibers are lightweight and are bonded together to form the felt material in a thermal process. Adhesives or other binding agents are unnecessary. Due to the purity of the polyester felt material, complete or near-complete recycling is possible after its service life. The material is fully recyclable. The milled fibers or shavings can be extracted, collected, and reused. The material can be formulated to meet the "flame-retardant" classification. The inventive panels possess very high sound absorption and excellent acoustic insulation properties.

[0032] The plate bodies are particularly advantageous in terms of weight, as they are relatively light, which simplifies transport costs and also the fastening options at an installation site.

[0033] The milled surface structure of the front of the panel can create a relief, potentially incorporating ornaments or decorative elements. These can include floral patterns, circles, irregular shapes, or similar decorative elements or motifs in three dimensions.

[0034] The milled surface structure gives the front a three-dimensional shape.

[0035] In particular, according to the invention, a striped appearance is created on the front surface of the panel body by means of parallel milled grooves or recesses. This gives the panel body a particularly decorative, but above all also sound-absorbing, three-dimensional depth effect.

[0036] The front surface of the panel may be coated, at least in some areas. A coating is a thin, decorative layer, preferably made of a natural material.

[0037] A coating is, in particular, an application of varnish or paint. The coating is preferably applied using printing techniques, especially gravure printing or digital printing, or similar processes. Applying the coating using printing techniques is efficient and cost-effective.

[0038] A coating has a thickness that is a maximum of 10% of the thickness of the plate body.

[0039] Preferably, the coating is sound-permeable and / or made of a material that contributes to sound absorption.

[0040] Thin, decorative layers, such as wood veneer, cork, leather, and similar materials, can also be advantageous coatings. Wood veneer strips with a thickness of less than 2 mm are particularly practical. A thickness of less than 1 mm for a decorative layer, especially a wood veneer or wood veneer strip, is especially beneficial.

[0041] Another advantageous embodiment provides that the coating is perforated. In particular, the coating is provided with micro-perforations or micro-perforations. This measure improves the acoustic properties of the coating. Perforations can be punched, drilled, or created using a laser.

[0042] In principle, a primer can be applied beneath the coating. It is advisable to apply a primer to the front surface areas that are to be coated beforehand. This improves the application of the coating and its adhesion to the open-pored felt material.

[0043] In particular, sections of the front surface are coated with a material that is raised above the milled, recessed areas. These raised areas, or those projecting from the recesses, are painted or coated with a paint or decorative print to contrast with the underlying background. A coating of wood or wood veneer, cork, or leather is then adhered to the outer surfaces of the raised areas.

[0044] A method for manufacturing a plate-shaped building element, in particular an acoustic panel, which has a plate body with a front side, is characterized by the following steps: Providing a panel body made of open-pored, sound-absorbing felt; transferring the panel body to a milling device; milling the front of the panel body in the milling device and creating a milled surface structure on the front.

[0045] During the milling process of the panel body, material is removed from the panel body in the form of chips using a milling tool. Felt is removed from the panel body in a geometrically defined shape and contour, creating a surface texture on the front of the panel body.

[0046] After milling the plate body and creating the surface structure on the front side, the front side can be coated, at least in certain areas. In particular, areas that are raised compared to recessed areas of the front side are coated.

[0047] In an advantageous embodiment of both the plate-shaped component according to the invention and the method for manufacturing a plate-shaped component, the starting material of the plate body is first coated on one side. This coated plate body consists of an open-pored, sound-absorbing felt and is coated on one side. The coating can be a decorative print. Prior to this, the starting plate body can be provided with an adhesive primer or print-receiving layer. The plate body is then printed and sealed. Subsequently, milling takes place, in which the milled surface structure is formed on the front side.

[0048] The coating can also be a decorative layer. Such decorative layers can consist of wood veneer, cork, or similar materials. Here, too, the base panel is first coated on one side. This is followed by milling, in which material is removed from the front surface to create the three-dimensional surface structure.

[0049] The coating can be perforated with holes extending through its thickness. Such perforation of the coating improves its acoustic properties. In principle, any coating applied within the scope of the invention can be provided with micro-perforations, regardless of whether it is a lacquer or paint application, or a coating in the form of a decorative layer made of wood and / or veneer strips, leather-cork strips, or similar decorative strips.

[0050] The invention provides a panel-shaped building element, in particular an acoustic panel, with advantageous sound-absorbing and room acoustic-improving properties. The panel body is formed in one piece from felt. This contributes to improving the recyclability, reuse, or subsequent disposal of the panel-shaped building elements. On the visible side, the panel body has a front surface formed in one piece within the panel itself, featuring a surface structure created by milling. This surface structure forms a relief on the front and can have a wide variety of visual designs.

[0051] In addition to their advantageous sound-absorbing and room acoustics-enhancing properties, the panel-shaped building elements according to the invention prove to be resource-efficient, environmentally friendly, and advantageous from a manufacturing perspective. Essential to this is the one-piece construction of the panel body from only one material, or almost entirely from only one material. Additional separate decorative elements, such as wooden strips applied to the front, can be dispensed with. The production of the panel-shaped building elements according to the invention is more efficient and also more cost-effective.

[0052] According to the invention, a plate-shaped component in the form of an acoustic panel is created which, unlike prior art, has strip-shaped raised areas or depressions that are made from the felt itself, i.e., the acoustic felt material, and not from glued-on strips of other materials such as solid wood, decorative-covered strips, laminate strips, or the like. This makes the acoustic panel materially uniform and gives it optimal sound-reducing acoustic properties. It is advantageous that the side walls of the grooves, i.e., the side walls of the surface structure, are open-pored and sound-permeable. The side walls are formed in the felt material, which increases the effective sound-absorbing surface. As a result of the depressions, the plate-shaped component becomes more flexible and, in particular, lighter.

[0053] The invention is described in more detail below with reference to exemplary embodiments illustrated in the drawings. The drawings show: Figure 1: A plate-shaped building element in the form of an acoustic panel in a perspective view; Figure 2: A section of a plate-shaped building element in perspective; Figure 3: A detail from the plate-shaped building element according to the representation of the Figure 2 Figure 4 shows a section of a plate-shaped component showing various milled groove configurations, Figure 5 shows a section of another embodiment of a plate-shaped component in perspective, and Figure 6 shows a section of another embodiment of a plate-shaped component.

[0054] Corresponding components and component parts are in the Figures 1 to 6 with the same reference symbols.

[0055] The depictions in the Figures 1 to 6They are technically schematic and not to be understood as being to scale.

[0056] The Figure 1 Figure 1 shows a plate-shaped component in the form of an acoustic panel 1. The acoustic panel 1 has a plate body 2 with a front surface 3. The plate body 2 is made entirely of, or consists of, an open-pored sound-absorbing felt.

[0057] The Figures 2 and 3 show excerpts from an acoustic panel 1 according to the representation of Figure 1 .

[0058] The Figures 4, 5 and 6 Each represents a section of an acoustic panel 1.

[0059] The front surface 3 of the panel body 2 has a milled surface structure 4. This surface structure 4 forms a relief on the surface of the front surface 3. The relief is formed by ribs 5, spaced apart and running longitudinally along the acoustic panel 1, with recesses 6 between them. The ribs 5 stand out plastically from the substrate. The recesses 6 run between the ribs 5. The recesses 6 are milled into the front surface 3 of the panel body 2. In this process, the surface of the front surface 3 is mechanically processed by milling, removing felt material from the panel body 2. The milling removes felt from the original panel body in certain areas, creating the surface structure 4.

[0060] In the illustrated embodiments, the surface structure 4 is formed in a strip-like manner from ribs 5 arranged parallel and spaced apart from each other in the longitudinal direction of the acoustic panel 1 and recesses 6 located between them. The recesses 6 are configured like grooves and have a groove base 8 extending between two side walls 7 of a rib 5.

[0061] Although the illustrated embodiments depict a milled surface structure 4 consisting of ribs 5 and recesses 6, the invention is by no means limited to this configuration. The milled surface structure 4 can be executed three-dimensionally in a wide variety of geometric, figurative, or abstract ornamental designs.

[0062] The panel body 2 is formed from a single piece of felt. The felt is open-pored and sound-absorbing. The felt consists of fibers made of polyethylene terephthalate (PET), polypropylene (PP), or natural fibers, or is based on the aforementioned materials.

[0063] To produce a panel body 2 with a milled surface structure 4, a starting panel body, or an undeformed panel body made of open-pored sound-absorbing felt, is provided and appropriately prepared before being transferred to a milling device. The milling device includes a milling tool. In the milling device, the front surface 3 of the panel body 2 is mechanically machined, and felt material is partially removed. The surface structure 4 is milled into the front surface 3 of the panel body 2.

[0064] After milling, the front side 3 of the plate body 2 has the milled three-dimensional surface structure 4.

[0065] The front surface sections 9 of the ribs 5 are not machined during the milling process. These surface sections 9 are raised relative to the milled areas of the front surface 3. In the illustrated embodiments, the surface sections 9 of the ribs 5 are strip-shaped.

[0066] A recess 6 milled into the front surface 3 of the plate body 2 has a depth t. The depth t is between 20% and 50% of the thickness d of the plate body 2. In practice, a depth t that corresponds to approximately one-third of the thickness d of the plate body 2 appears advantageous.

[0067] The Figure 4Figure 1 shows a section of an acoustic panel 1 illustrating various embodiments of milled recesses 6 in the front surface 3 of a panel body 2. The panel body 2 is made entirely of felt. The figures shown are recesses 6 with a rectangular cross-section, a partially concave groove base 8, and a semicircular cross-sectional profile of one recess 6.

[0068] Furthermore, the Figure 4 that the front surface 3 is partially coated with a coating 10. Specifically, the surface sections 9 of the front surface 3 are coated with a coating 10, which are raised compared to the milled areas of the front surface 3.

[0069] The raised surface sections 9 extend along the upper surfaces of the ribs 5. The coating 10 can be applied using a coating material, for example, a varnish or paint. This is preferably done using printing technology, in particular by gravure or digital printing.

[0070] A coating 10 of the surface sections 9 can also be made of thin strips of wood, cork or leather or similar materials.

[0071] The coating 10 can be combined with a Figure 4 The coating 10 is provided with the perforation 11 shown in an indicative manner. The perforation 11 consists of holes penetrating transversely through the coating 10. It is a microperforation that extends over the surface of a coating 10 or a strip of the coating 10.

[0072] The Figure 5Figure 1 shows a section of another embodiment of an acoustic panel 1. Here, the groove-like recesses 6 are wider than the front or visible raised ribs 5.

[0073] In all embodiments of the acoustic panel 1, the side walls 7 of the surface structure 4, which run laterally along the ribs 5, are open-pored and sound-permeable. The side walls 7 are unsealed and uncoated. The groove base 8 of the recesses 6, extending between the side walls 7, is also open-pored and sound-permeable.

[0074] The surface structure 4 on the front side 3 of the plate body 2 is produced by subtractive manufacturing using milling. In this process, felt material is removed in certain areas using a milling cutter, thereby forming the recesses 6.

[0075] The recesses 6 extend between the strip-shaped ribs 5, which are manufactured in one piece from the felt of the panel body 2, using a single material. The ribs 5 are not formed by glued-on strips of other materials. However, the front surface sections 7 of the ribs 5 may be coated 10. The panel body 2 of the acoustic panel 1 is made of a single material and has optimal sound-reducing properties. Since the open-pored, sound-permeable felt material is also present in the side walls 7 and the groove bases 8, the effective surface area is increased, thus improving sound absorption.

[0076] In the Figure 6 Figure 1 shows a section of another embodiment of a plate-shaped component in the form of an acoustic panel 1.

[0077] As previously described, the acoustic panel 1 has a panel body 2 made in one piece of open-pored, sound-absorbing felt. The front surface 3 has a milled surface structure 4. The surface structure 4 is formed by groove-shaped recesses 6 milled into the front surface 3. A recess 6 is bordered by ribs 5 that are raised above the recesses 6. The recess 6 according to the embodiment of Figure 6 The recess 6 has a stepped groove base 8. The recess 6 has a stepped rebate 12 and two groove base sections 13, 14 of different depths. The stepped rebate 12 is located between the groove base sections 13, 14. The recess 6 is bounded by side walls 7 of the ribs 5.

[0078] The side walls 7 have a chamfer 15 on the decorative side, at least in some areas. A chamfer 15 is provided at the transition of a side wall 7 to an upper surface section 9 or a coating 10. Reference symbol:

[0079] 1 - Acoustic panel 2 - Panel body 3 - Front side 4 - Surface structure 5 - Rib 6 - Recess 7 - Side walls 8 - Tongue and groove base 9 - Surface section 10 - Coating 11 - Perforation 12 - Step rebate 13 - Tongue and groove base section 14 - Tongue and groove base section 15 - Chamfer t - depth v. 6 d - thickness v. 2

Claims

1. Plate-shaped building element, in particular acoustic panel (1), which has a plate body (2) with a front side (3), characterized by the fact that the plate body (2) consists in one piece of an open-pored, sound-absorbing felt, the front side (3) having a milled surface structure (4).

2. Component according to claim 1, characterized by the fact that The felt is made from polyethylene terephthalate (PET) and / or polypropylene (PP) and / or natural fibers.

3. Component according to claim 1 or 2, characterized by the fact that the surface structure (4) forms a relief in the surface of the front (3).

4. Component according to one of claims 1 to 3, characterized by the fact that the front side (3) of the plate body (2) has at least one recess (6) formed by milling, wherein the recess (6) has a depth (t) which is dimensioned between 20% and 50% of the thickness (d) of the plate body (2).

5. Component according to one of claims 1 to 4, characterized by the fact that The side walls (7) of the surface structure (4) are open-pored and sound-permeable.

6. Component according to one of claims 1 to 5, characterized by the fact that the front (3) is at least partially provided with a coating (10).

7. Component according to claim 6, characterized by the fact that Surface sections (9) of the front (3), which are raised compared to milled areas of the front (3), are provided with a coating (10).

8. Component according to claim 6 or 7, characterized by the fact that the coating (10) has a thickness which is at most 10% of the thickness (d) of the plate body (2).

9. Component according to one of claims 5 to 8, characterized by the fact that the side walls (7) have a chamfer (15) at least in some areas on the decorative side.

10. Component according to one of claims 4 to 9, characterized by the fact thata recess (6) has a groove base (8) with a stepped rebate (12) and groove base sections (13, 14) of different depths.

11. Method for manufacturing a plate-shaped component comprising a plate body (2) with a front side (3), characterized by the following steps: - Providing a panel body (2) made of an open-pore, sound-absorbing felt; - Transferring the panel body (2) into a milling device; - Milling the front side (3) of the panel body (2) in the milling device and forming a milled surface structure (4) on the front side (3).

12. Method according to claim 11, characterized by the fact that the front (3) is provided with a coating (10) at least in certain areas, in particular surface sections (7) which are raised above recessed areas of the front (3) are provided with a coating (10).

13. Method according to claim 11 or 12, characterized by the fact thatthe front (3) of the plate body (2) is coated with a coating (10) over its entire surface before the milling of the front (3) and then the front (3) of the plate body (2) is machined in the milling device and the surface structure (4) is milled.

14. Method according to one of claims 11 or 13, characterized by the fact that the coating (10) is formed by a decorative print.

15. Method according to any one of claims 1 to 13, characterized by the fact that the coating (10) is formed by a decorative layer, in particular a wood veneer, a cork layer or a leather layer.

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