Acoustic panel fabrication jigs and acoustic panels

Abstract

A fabrication jig 101 for manufacturing an insulation panel having a body and an acoustic covering including a main wall and a number of peripheral walls comprises a support structure 102 for receivin

Description

30 01 25 Field [1] The present invention relates to an acoustic product. In particular, an acoustic panel fabrication jig and to a method of fabricating an acoustic panel(s) and more specifically an acoustic panel(s) including recycled or repurposed materials. Background [2] Sound absorbing materials, and acoustic products, including acoustic panels in particular, are used in a variety of environments to mange noise levels. Generally, sound absorbing materials dampen and / or reduce sound wave intensity across the frequencies of the human hearing range to reduce the reverberation times within any given enclosed internal space. [3] Acoustic panels are frequently located on walls and ceilings, in both domestic and commercial settings, e.g. offices, and are also often used as freestanding or integrated room dividers. As such, and due to their typical size (e.g. they may be installed across a whole wall), the look and feel of an acoustic panel is also an important design or architectural consideration as well as their sound dampening characteristics. [4] Bespoke acoustic panels are often required or preferred in order to perform adequately in a given space, and to meet interior design requirements. The need for bespoke acoustic panels increases manufacturing burden and limits the extent to which mass production techniques and systems can be utilised. Also, material and structural differences between acoustic panels and other products means that fabrication techniques for non-acoustic panels are not straightforwardly transferable. [5] Bespoke or not, acoustic panels include several components which must be brought together during fabrication in a neat and tidy fashion and while maintaining suitable sound dampening performance. 30 01 25 [6] An acoustic panel typically comprises a panel body covered by an acoustic covering, including sound dampening material. The panel body may also include sound absorbing material as well as a frame. The acoustic covering may also include one or more fabric layers. In other words, an acoustic panel may be a fabric-wrapped acoustic panel. Often, an acoustic covering will include a fabric layer to cover the acoustic material and render the acoustic panel, and thus the sound dampening material, more aesthetically pleasing. The inclusion of a fabric layer allows the acoustic panel to have different textures, colours, and / or patterns, for example. [7] The presence of these several layers and components in an acoustic panel makes the bringing together of those elements in a suitably tidy and efficient manner difficult, which the prior art has failed to successfully address. [8] There is also a need to improve the ease with which recycled or repurposed materials can be utilised in the fabrication of acoustic panels, particularly given their size and widespread use. Currently, when acoustic panels are fabricated, off-cuts of excess acoustic material are created and cannot be straightforwardly incorporated in acoustic panels, thereby increasing the amount of waste material which may end up in landfill. [9] The present invention aims to solve these and other problems with the prior art. Summary

[10] The invention is defined by the claims. Accordingly, in a first aspect, the present invention provides an acoustic panel fabrication jig for fabricating an acoustic panel, the acoustic panel having a body and an acoustic covering including a main wall and a number of peripheral walls.

[11] Typically, the acoustic covering may comprise a main wall and a number of adjacent peripheral walls of the acoustic covering may be joined to the main wall thereof by one or more hinges, e.g. living hinges. An acoustic covering may include at least one layer of acoustic material and a fabric layer. 30 01 25

[12] The jig comprises a support structure configured to receive the acoustic covering. The jig further comprises one or more dies.

[13] The jig comprises one or more engagement positions for the or each die. Generally, the or each die is positioned relative to the support structure to substantially match or conform to the size and shape of the main wall of the acoustic covering so that the peripheral walls are deflected as the or each die engages the acoustic covering.

[14] The or each die is configured to deflect and hold one or more said peripheral walls of the acoustic covering relative to the main wall thereof. At least one die is configured to deflect and hold neighbouring peripheral walls of the acoustic covering towards a corner thereof

[15] As used herein, the term “die” refers to a member configured to manipulate, e.g. bend or fold, the acoustic covering to a desired configuration. Typically, a die functions in conjunction with a pressing force which acts on the acoustic covering to engage the die. The pressing force may be applied manually, e.g. the acoustic covering may be pushed towards the die by a user, or applied automatically, e.g. by an automated or semi-automated clamping bar.

[16] Generally, the jig may comprise a plurality of dies, e.g. four dies. Typically, the plurality of dies collectively may define a space which is substantially similar in geometry to the main wall and which is smaller than the total footprint of the acoustic covering when the main wall and peripheral walls are in a substantially planar configuration. Thus, the or each die is configured to deflect at least one peripheral wall of the acoustic covering when it engages the acoustic covering such that the main wall and peripheral wall are no longer in a substantially planar configuration. The or each deflected peripheral wall may instead extend in a different plane to the main wall. In embodiments, the or each die is configured to deflect a said peripheral wall through around 90 degrees.

[17] Until conception of the invention, acoustic panel fabrication was often a time consuming and manually demanding process requiring several people (fabricators). 30 01 25 Typically, several people were required to manually deflect the peripheral walls of the acoustic covering relative to the main wall and to hold the peripheral walls, either manually or with one or more clamps, in a deflected position while the acoustic covering was fixed, e.g. with screws and / or adhesive, to the panel body.

[18] Other existing acoustic panels are fabricated using additional framing members to improve the tidiness and efficiency with which an acoustic panel can be manufactured. For example, such a permanent framing member may be provided on the rear of an acoustic panel to pull and retain an acoustic covering taut over the panel body. However, these require additional, often bespoke components which is more costly, materially wasteful and only results in a need for even more bespoke parts. Moreover, acoustic panels fabricated this way rely more heavily on specialist installation.

[19] By contrast, the present invention provides a system which may be used to more conveniently and efficiently fabricate an acoustic panel. The requirement for manual intervention during fabrication may be reduced, saving man hours and allowing a greater number of acoustic panels to be produced within a given timeframe. Therefore, a greater number of acoustic panels of the same size, and acoustic panels of different sizes, may be fabricated using the acoustic panel fabrication jig of the present invention.

[20] More specifically, the or each die is configured to, in use, deflect and hold one or more peripherals walls of the acoustic covering relative to the main wall of the acoustic covering. In embodiments, a portion of a given peripheral wall may be deflected by a corresponding die. In embodiments, substantially an entire given peripheral wall may be deflected by a corresponding die. The or each die may therefore exert a reactional, e.g. frictional, force on the acoustic covering to prevent the acoustic covering returning to a substantially planar configuration. The jig may also prevent or at least reduce the formation of folds or creases in the acoustic covering, particularly towards the comers thereof, for example while the covering is fixed to the panel body. 30 01 25

[21] Also, pertinently, the acoustic panel fabrication jig may improve the ease with which off-cuts of acoustic material, i.e. recycled or repurposed material, can be incorporated in an acoustic panel. In particular, by deflecting the peripheral walls of the acoustic covering relative to the main wall, a structure is formed within which the panel body of the acoustic panel may be formed. Advantageously, the structure formed via the deflection of the peripheral walls may allow smaller segments of sound absorbing material than usual to be included and held together more straightforwardly. In particular, the structure formed by the deflected peripheral walls may bound segments of sound absorbing material of the panel body. The environmental impact of acoustic panel fabrication may thereby be improved. In particular, the length of the small segments of sound absorbing material may be the same width as the structure formed and therefore there is no gap created between the deflected peripheral wall and the small segments of acoustic material.

[22] As described, an acoustic covering may have a main wall and a plurality of peripheral walls extending therefrom which are separated by a living hinge or the like. A living hinge may be in the form of a substantially V-shaped cut out. Thus, when deflected by the or each die during fabrication, the acoustic covering has a configuration wherein the living hinge between adjacent walls of the acoustic covering is substantially closed.

[23] When used herein a living hinge refers to a relatively flexible hinge (or flexure bearing) made from the same material as the two relatively rigid pieces it connects (e.g. the main wall and one or more peripheral walls). Typically the living hinge is relatively thin compared to the rigid pieces to allow the rigid pieces to bend along the line of the hinge. The living hinge may be made subtractively, by cutting or thinning, or additively, e.g. by moulding. The skilled person will appreciate that, while preferred, in some embodiments and aspects of the invention the living hinge may be replaced by an alternative hinge or flexure and / or may comprise a different material to one or more of the thus connected relatively rigid pieces.

[24] Generally, the support structure may be in the form of a substantially planar board having a substantially flat support surface, e.g. a baseboard, comprising one or more engagement positions for the or each die. In embodiments, the support structure 30 01 25 may be formed of wood, metal or plastic. In embodiments, the support structure may comprise a plurality of engagement positions for the or each die. Thus, the jig may be used to fabricate differently sized acoustic panels without the need for separate or bespoke support structures or dies.

[25] Generally, the or each die may be of any shape suitable for the deflecting and holding the one or more peripheral walls of the acoustic covering relative to the main wall thereof. For example, a said die may be substantially linear. Alternatively, a die may include more than one limb, for example.

[26] In embodiments, a said die may be formed of metal, for example a said die may be formed of mild steel.

[27] Generally, the jig may comprise a plurality of dies which are together arranged to hold the acoustic covering in place and to substantially prevent sideways, e.g. lateral, movement of the acoustic covering.

[28] Generally, a panel body may include a frame, e.g. a polyethylene terephthalate (PET) or wooden frame, and one or more acoustic elements, e.g. layers of acoustic material. The frame may also be formed at least partially of acoustic material. The acoustic elements may include ‘seconds’, or offcuts or repurposed segments of acoustic material. Typically, offcuts are segments of material left over from panels which have already been cut. Typically, seconds may be segments or whole acoustic elements which may not have passed a previous quality control assessment with regard to colour or finish quality, for example. The acoustic material may be a sound absorbing material. The acoustic material may be formed substantially of recycled material, for example recycled polyethylene terephthalate (PET). Additionally or alternatively, in embodiments, the acoustic covering may include ‘seconds’ of acoustic material.

[29] Generally, an acoustic covering may include an acoustic element, e.g. a substantially continuous sheet or ‘tray’ of acoustic material. The acoustic covering generally includes a fabric layer which is fixed to and which substantially envelopes the acoustic element of the acoustic covering. For example, the fabric layer may cover 30 01 25 a front face, side faces and part of a rear face of the tray of acoustic material. Peripheral walls of the acoustic covering adjacent the main wall thereof are generally joined to the main wall by a living hinge. In other words, the adjacent peripheral walls are typically resiliently bendable relative to the main wall. Similarly, a living hinge or similar typically exists between peripheral walls adjacent the main wall and any further adjoined peripheral walls, e.g. those peripheral walls which are configured to be adjacent a rear surface of the panel body in an assembled configuration.

[30] A tray of acoustic material is typically more rigid than a fabric layer and / or may exhibit a degree of elastic deformation when folded. In particular, as acoustic material is typically formed of a foam, PET, or similar, deflection of the peripheral walls of the acoustic covering may compress gas within the foam pores. When deflected or folded, the acoustic covering may be biased towards a planar configuration. In the present invention, the or each die acts to deflect and retain the at least a portion of one or more said peripheral walls of the acoustic covering relative to the main wall thereof and, if the panel body is present, adjacent at least part of the profile of the panel body.

[31] The present invention may allow repurposed or recycled materials, seconds or offcuts of acoustic material for example, to be more easily included in an acoustic panel. In particular, the jig may be configured so that, when the peripheral walls of the acoustic covering are deflected, a recess or cavity structure is formed into which the panel body may be inserted or assembled. Thus, where off-cuts or the like are to be utilised, these may be more easily assembled within the recess formed by the deflected acoustic covering.

[32] At least one said die is configured to deflect and hold neighbouring peripheral walls of the acoustic covering at or towards a corner thereof. In embodiments, a said die may be configured to deflect and hold neighbouring peripheral walls to substantially form a deflected corner of the acoustic covering.

[33] Neighbouring peripheral walls may be more conveniently held together at or towards a corner of the acoustic covering. This is particularly advantageous because acoustic covering material typically gathers towards comers thereof. By deflecting and holding neighbouring peripherals walls of the acoustic covering at or towards a corner 30 01 25 of the acoustic covering, a neater corner of the acoustic panel may be formed because a user is not required to manually deflect and hold the peripheral walls, including while the acoustic covering is fixed to the panel body.

[34] In embodiments, the or each die is configured to have a height which is substantially equal to or greater than the depth of the panel body. In some embodiments, a height of the or each die is configured to be substantially equal to or greater than the depth of the acoustic panel to be fabricated.

[35] In embodiments, the or each die may be configured to apply a compressive force to the acoustic covering. In other words, as well as deflecting and holding a peripheral wall of the acoustic covering, a said die may be configured to temporarily brace the peripheral wall in the deflected configuration.

[36] In embodiments, at least one said die may be substantially linear.

[37] In embodiments, at least one said die may be a corner die including two limbs; wherein each limb is configured to deflect and hold one of two neighbouring peripheral walls of the acoustic covering relative to the main wall towards a comer thereof. A die may have more than two limbs. For example, a said die may have a form a substantially closed structure.

[38] Typically, acoustic panels have a rectangular (or square) configuration. In embodiments, the two limbs may extend substantially perpendicularly to one another.

[39] In embodiments, the or each corner die may include a recess at the junction of the two limbs, wherein the recess is configured to receive and hold together end portions of each of the neighbouring peripheral walls of the acoustic covering.

[40] It is desirable to fabricate an acoustic panel wherein the meeting of adjacent peripheral walls of the acoustic covering, e.g. the seams between them, are flush and substantially free of wrinkles or bulges, and that acoustic panels may be reliably reproduced with the same or substantially similar characteristics. The recess at the junction of the two limbs of the corner die receives and retains end portions of adjacent 30 01 25 peripheral walls during fabrication. Thus, a neater and substantially wrinkle-free joint between the adjacent peripheral walls is provided. The recess being at the intersection of where the two limbs meet means that a pinch-point is formed where the recess pinches the covering and this helps hold the covering in place. The risk of damage to the acoustic covering may also be reduced because the recess provides greater flexibility for adjustment of the acoustic covering in a deflected configuration thereof. In other words, once deflected, a corner of the acoustic covering can be more easily readjusted if necessary. Additionally, or alternatively, the recess may allow the corner to be more easily viewed during fabrication so that a user can determine whether a deflected corner is suitably formed.

[41] In embodiments, the or each corner die may include a stopper at the junction of the two limbs, wherein the stopper is configured to abut a said end portion of the neighbouring peripheral walls of the acoustic covering.

[42] Advantageously, the stopper abuts the end portion of the neighbouring peripheral walls. This may enable a wrinkle-free and neat and tidy joint between the peripheral walls to be obtained.

[43] In embodiments, the or each corner die may include the stopper at said recess, wherein the stopper is configured to abut a said end portion of at least one of the neighbouring peripheral walls of the acoustic covering. In embodiments, the stopper may be located substantially within said recess.

[44] In embodiments, the stopper may be configured to abut an end portion of each of the neighbouring peripherals walls of the acoustic covering.

[45] The stopper of the or each die may further improve the joint between adjacent peripheral walls of the acoustic covering. The repeatable fabrication of successive acoustic panels may thereby be improved. Acoustic panels may be more consistently and reliably produced with reduced manual intervention. For example, several substantially identical acoustic panels of the same size can be more straightforwardly fabricated in shorter time. 30 01 25

[46] In embodiments, the stopper may be substantially in the form of a blade or fin. The blade or fine may be configured to extend substantially in parallel to an adjacent join between neighbouring peripheral walls of the acoustic panel. The blade or fin may therefore abut the acoustic covering at a corner thereof to provide a more tidy and repeatable acoustic panel corner.

[47] In embodiments, the one or more engagement positions for the or each die may be located on the support structure. In embodiments, the or each die may be configured to operably engage the support structure at a given engagement position dependent on the size of the main wall of the acoustic covering.

[48] In other words, the jig may be arranged such that the support structure and the or each die are configured collectively to deflect and hold the peripheral walls of the acoustic covering, as the support structure retains and substantially prevents sideways movement of the or each die when the two are operably engaged.

[49] In embodiments, the support structure may comprise a framework including a plurality of said engagement positions for the or each die. Thus, the or each die may operably engage the support structure at one of several engagement positions of the support structure. Advantageously, therefore, the jig may be utilised to fabricate acoustic panels of different sizes.

[50] In embodiments, the support structure may include a set of indicia, preferably sizing indicia. Typically, the indicia are configured to indicate an appropriate engagement position for the or each die for a given size of acoustic panel to be fabricated. For example, the support structure may include a set of width and height measurements, and the support structure may include an engagement position for a said die which corresponds to a height and / or width of an acoustic panel to be fabricated. Additionally, or alternatively, the indicia may be in the form of a code or classification system for a given size or sizes of boards. Each of the indicia may therefore be associated with a corresponding engagement position.

[51] Generally, the or each die may be moveable about the support structure between engagement positions. In embodiments, the or each die may be detachable 30 01 25 from the support structure in order to move between engagement positions and / or for different arrangements of dies.

[52] In embodiments, the plurality of engagement positions may be substantially uniformly separated. For example, the plurality of engagement positions may be separated at 50 mm intervals, or at 100 mm intervals. For example, indicia may be provided at every 100 mm interval with engagement positions located at every 50 mm on the support structure. A greater or lesser number of intervals, or different interval sizes are also envisaged.

[53] In embodiments, the support structure may include one or more openings at each engagement position, and the or each die may include a number of pegs configured to reversibly engage at least one said opening at an engagement position. In embodiments, the or each die may be configured to transition between distinct engagement positions and / or to be semi-permanently fixed to the support structure at an engagement position between transitions. For example, a said die may be configured to slide across a support surface of the support structure during a said transition.

[54] In embodiments, the support structure may include a plurality of holes at each engagement position, and the or each die may include a corresponding plurality of pegs configured to reversibly engage corresponding depressions, e.g. holes, at the engagement position. For example, each engagement position may include four holes and a die may include four corresponding pegs configured to engage the four holes of the support structure at the engagement position. As such, sideways movement of the die relative to the support structure is substantially prevented while operably engaged thereto. In embodiments, the pegs of a said die may be substantially distinctly formed or they may be substantially integrally formed with one another. In embodiments, an opening of the support structure may form part of more than one engagement position. In other words, an opening or hole may be shared between multiple engagement positions. In embodiments, the openings of the support structure may be substantially uniformly separated on the support structure. 30 01 25

[55] In embodiments, the jig may comprise a plurality of dies. A plurality of dies allows for the covering, and in particular the peripheral walls of the acoustic covering, to be held at multiple positions, e.g. before being attached to the panel body. This may be advantageous because fewer people are required to fabricate the acoustic panel, for example to assemble the panel body within the bounds of the deflected acoustic covering and / or to attach the acoustic covering to the panel body and vice versa, because the plurality of dies, as opposed to a plurality of users, can deflect and hold the acoustic covering in multiple positions.

[56] In embodiments, at least two said dies may be provided and configured to deflect and hold one or more said peripheral walls of the acoustic covering substantially towards opposing ends of the acoustic covering. For example, where the acoustic panel has a substantially rectangular or square configuration, at least two dies of the jig may be configured to engage the acoustic covering at diagonally opposing corners thereof. Advantageously, therefore, the acoustic covering may be more securely held between the opposing dies allowing fewer people to more straightforwardly manufacture the acoustic panel. In particular, movement of the acoustic covering, and panel body when present, may be substantially prevented when held between the opposing dies.

[57] In embodiments, the jig may further comprise one or more clamps. In embodiments, a said clamp may be configured to clamp the acoustic covering in a deflected configuration. In embodiments, a said clamp may be configured to clamp the acoustic covering, and in particular the peripheral walls thereof, against the panel body. The requirement for manual intervention may thereby further reduced.

[58] In embodiments, the jig may comprise a plurality of clamps. For example, in embodiments, the jig may comprise a plurality of clamps, with at least one clamp configured to clamp the acoustic covering against the panel body at each edge of the acoustic body.

[59] In embodiments, the panel body may include a rear surface and the acoustic covering may include one or more peripheral walls configured to be located adjacent a side surface of the panel body, and one or more further peripheral walls configured 30 01 25 to locate adjacent the rear surface, wherein one or more said clamps of the jig may be configured to clamp the one or more further peripheral walls against the rear surface of the panel body for fixing.

[60] The acoustic covering may include one or more retaining strips configured to be fixed to the rear surface of the panel body. Typically, the retaining strips are relatively more rigid than substantially the remainder of the acoustic covering. For example, a retaining strip may be formed substantially of metal, e.g. aluminium. The acoustic covering may include a said retaining strip at each side thereof. The acoustic covering may include one or more retaining strips at each side thereof. In embodiments, the or each clamp is configured to locate a said retaining strip adjacent the rear surface of the panel body. For example, a said clamp may contact a peripheral wall which, in turn, locates a corresponding retaining strip such that it may be fixed to the panel body.

[61] In embodiments, the support structure may comprise engagement positions which are configured to be engaged by either a die and / or a clamp. In other words, a die and / or a clamp may be configured to engage the support structure at a common engagement position. For example, where each engagement position comprises one or more openings the openings may be configured to receive a corresponding member of a die and / or a clamp.

[62] Alternatively, or in addition, the framework may include distinct engagement positions for the or each die and the or each clamp.

[63] In embodiments, the framework may comprise a grid defining a plurality of recesses for the or each clamp; and the or each clamp is configured to operably engage a said recess dependent on the size of the acoustic covering (in a deflected configuration). In embodiments, a recess may be in the form of a cut-out groove.

[64] Typically, the acoustic panel includes one or more hanging rails to be fixed to the panel body and / or acoustic covering. The one or more hanging rails are usually provided in order that the fabricated acoustic panel may be hung from a ceiling or wall. For example, the hanging rail may be attached to the panel body in such a fashion 30 01 25 that the acoustic panel is not crooked when hung up. This may be achieved by the hanging rail being attached to the panel body such that the hanging rail is parallel to an edge of the acoustic covering and / or panel body. In embodiments, a said hanging rail may comprise means for fixing to a wall or ceiling by screws or the like. In embodiments, a said hanging rail may comprise magnetic means for substantially magnetically attaching a fabricated acoustic panel to a wall or ceiling.

[65] In embodiments, the jig may further comprise one or more stays configured to align a hanging rail relative to the acoustic covering and / or panel body. Therefore, a hanging rail can be more conveniently and more quickly fixed to the panel body and / or acoustic covering, without the requirement for additional manual alignment or retaining of the hanging rail before and while it is fixed to the panel body and / or acoustic covering. The or each stay may substantially resist sideways, e.g. lateral, movement of the engaged hanging rail.

[66] In embodiments, a said hanging rail stay may be formed of metal, e.g. mild steel.

[67] A hanging rail may be located towards an end of the acoustic panel, e.g. extending along a short end thereof between opposing long sides, or may be located at a mid-region of the acoustic panel. In embodiments, a hanging rail may extend along a long end of the acoustic panel between opposing short sides.

[68] Typically, a fixing for a hanging rail, e.g. a screw, will be fixed such that it extends at least partially through the acoustic covering and panel body such that it joins the acoustic covering to the panel body and substantially conceals excess acoustic covering material.

[69] In embodiments, the or each hanging rail stay may comprise a seat configured to be engaged by a clamp. Therefore the hanging rail stay, and thereby the hanging rail, may be held in position while the hanging rail is fixed to the panel body and / or acoustic covering. In embodiments, the jig may comprise a clamp configured to engage the hanging rail stay, wherein clamp is configured to clamp the hanging rail stay against the panel body and / or acoustic covering. 30 01 25

[70] In embodiments, a said hanging rail stay may comprise first, second and third sides, wherein the first and third sides are substantially parallel to one another and the second side extends between the firstand third sides. In embodiments, a said hanging rail stay may have a substantially C-shaped cross-section. Thus, the hanging rail stay forms an alcove into which a hanging rail having a corresponding shape may locate. [71 ] In embodiments, a said hanging rail stay may be configured to operably engage a corresponding die, and the die may be configured to substantially resist sideways movement of the hanging rail stay when operably engaged thereto. Advantageously, therefore, a die may serve the dual purpose of deflecting and holding one or more peripheral walls of the acoustic covering, and substantially resisting sideways movement of the hanging rail stay.

[72] For example, where the corresponding die is a corner die the hanging rail stay may be configured to be bounded by the corresponding corner die, e.g. the hanging rail may be configured to abut against the corner of the corner die, so that sideways movement of the hanging rail stay is substantially prevented.

[73] In embodiments, the hanging rail stay may be configured to operably engage a corresponding die after the peripheral walls of the acoustic covering have been clamped against the panel body.

[74] In a further aspect, the present invention provides use of the acoustic panel fabrication jig according to any preceding aspect.

[75] In a further aspect, the present invention provides a method of manufacturing an acoustic panel having a panel body and an acoustic covering including a main wall and a number of peripheral walls, the method including the steps of: a. providing the acoustic panel fabrication jig of any preceding aspect; b. positioning one or more dies at an engagement position of the jig such that the or each die deflects and holds one or more said peripheral walls 30 01 25 of the acoustic covering relative to the main wall thereof when the acoustic covering is placed thereon; and c. placing an acoustic covering on the support structure of the jig.

[76] The present invention thus provides a method which may more conveniently and efficiently fabricate an acoustic panel, or part thereof. The requirement for manual intervention during fabrication may be reduced, saving man hours and allowing a greater number of acoustic panels to be produced within a given timeframe. Therefore, a greater number of acoustic panels of the same size, and acoustic panels of different sizes, may be fabricated using the acoustic panel fabrication jig of the present invention.

[77] More specifically, during step c., i.e. when the acoustic covering is placed on the support structure and is substantially located between the dies, one or more peripheral walls of the acoustic covering are deflected and held relative to the main wall of the acoustic covering. The or each die may thereby exert a reaction force on the acoustic covering to prevent the acoustic covering from returning to a substantially planar configuration. The method may also prevent or at least reduce the formation of folds or creases in the acoustic covering while the covering. Generally, step b. occurs prior to step c. but, in embodiments, step c. may occur prior to step b.

[78] In embodiments, the method may comprise the further step of, prior to or after step c., placing a panel body on top of the acoustic covering such that the acoustic covering is located between the support structure and the panel body. The panel body may be pre-fabricated or assembled on top of the acoustic covering. Thus, the panel body may be placed on top of the main wall of the acoustic covering and substantially between bounding peripheral walls of the acoustic covering.

[79] In embodiments, the method may comprise the further step of, after step c., fixing the acoustic covering to the panel body. More specifically, the peripheral walls of the acoustic covering may be fixed to the covering after step c.

[80] In embodiments, step c. may include positioning at least one said die such that neighbouring peripheral walls of the acoustic covering are deflected and held relative 30 01 25 to the main wall towards a corner of the acoustic covering. In embodiments, step c. may include positioning at least one said die such that neighbouring peripheral walls of the acoustic covering are deflected and held relative to the main wall towards a corner of the main wall.

[81] Thus, neighbouring peripheral walls may be more conveniently held together at or towards a corner of the acoustic covering. This is particularly advantageous because acoustic covering material typically gathers towards comers thereof. By deflecting and holding neighbouring peripherals walls of the acoustic covering at or towards a corner of the acoustic covering, a neater corner of the acoustic panel may be formed because a user is not required to manually deflect and hold the peripheral walls, e.g. while the acoustic covering is fixed to the panel body.

[82] Typically, an acoustic panel body has a plurality of comers. For example, an acoustic panel may have a substantially rectangular configuration. In embodiments, the jig may comprise a plurality of dies, preferably a die for each corner of the panel body. Step c. may include positioning a said die towards a said corner of the acoustic covering such that neighbouring peripheral walls of the acoustic covering are deflected and held relative to the main wall at or towards each corner thereof.

[83] Generally, the acoustic covering may include a fabric layer and an acoustic layer. Typically, an excess of fabric material exists towards a corner of the acoustic covering once the fabric layer has been joined to the acoustic layer. Generally, the acoustic covering includes a transitional edge between adjacent peripheral walls thereof. The transitional edge may extend at approximately 45 degrees to each adjacent peripheral wall. The transitional edge allows the adjacent peripheral walls to be folded relative to the main wall of the acoustic covering and to conform to a corresponding corner of the panel body.

[84] In embodiments, the or each die may be a corner die including two limbs; wherein each limb is configured to deflect and hold one of two neighbouring peripheral walls of the acoustic covering relative to the main wall. A said corner die therefore improves the ease with which excess material located towards a corner of the acoustic 30 01 25 covering is gathered such that the corner of the resulting acoustic panel is neat and free of wrinkles.

[85] In embodiments, the main wall of the acoustic covering may have a substantially rectangular configuration, and the jig may comprise four dies. The method may comprise the step of positioning a die at an engagement position corresponding to each corner of the main wall such that neighbouring peripheral walls, preferably all neighbouring peripheral walls, of the acoustic covering are deflected and held relative to the main wall at or towards each corner of the main wall. Where a panel body is present, the peripheral walls maybe deflected and held adjacent at least part of the profile of the panel body.

[86] Generally, the jig comprises a plurality of dies which collectively define a space which is substantially similar in geometry to the main wall and which is smaller than the total footprint of the acoustic covering when the main wall and peripheral walls thereof are in a substantially planar configuration. Thus, in embodiments, the or each die is configured to deflect at least one peripheral wall, typically two adjacent peripheral walls, of the acoustic covering when it engages the acoustic covering, such that the main wall and peripheral wall are no longer in a substantially planar configuration and the or each deflected peripheral wall instead extends in a different plane to the main wall.

[87] In embodiments, the jig may comprise one or more clamps. The method may further comprise the step of clamping the acoustic covering against the panel body. Typically, the acoustic covering may be clamped to the panel body prior to being fixed thereto.

[88] In embodiments, the panel body may include a rear surface and the acoustic covering may include one or more peripheral walls to be secured against the rear surface, and wherein the method may further comprise the step of clamping the one or more peripheral walls against the rear surface of the panel body. For example, the panel body may include side surfaces and a rear surface, and the method may comprise the step of clamping the acoustic covering against the panel body such that a peripheral wall is adjacent each side surface and at least part of the rear surface. 30 01 25 The acoustic covering can therefore be more straightforwardly fixed to the panel body and the risk of relative movement between the acoustic covering and the panel body is reduced.

[89] In embodiments, the acoustic panel may have one or more hanging rails to be fixed to the panel body and / or acoustic covering; and the method may further comprise the steps of: • providing one or more hanging rail stays; • aligning a hanging rail relative to the panel body with the one or more hanging rail stays; and • fixing the or each hanging rail to the panel body.

[90] In embodiments, the method may further comprise the step of clamping the one or more hanging rail stays against the acoustic covering and / or panel body prior to fixing the hanging rail to the acoustic covering and / or the panel body.

[91] In embodiments, the acoustic covering may include a fabric layer and an acoustic layer, and wherein the method may further comprise the step of joining (e.g. permanently or semi-permanently affixing) the fabric layer to the acoustic layer. For example, the fabric layer may be stapled or otherwise adhered to the acoustic layer. In embodiments, joining the fabric layer to the acoustic layer may occur prior to step c.

[92] In embodiments, the method may comprise the step of forming one or more living hinges in the acoustic layer between adjacent walls thereof. In embodiments, the step of forming one or more living hinges in the acoustic layer between adjacent walls thereof may occur prior to step c. In embodiments, the living hinge may be made subtractively, by cutting or thinning, or additively, e.g. by moulding. In embodiments, forming one or more living hinges in the acoustic layer between adjacent walls thereof may occur prior to step b.

[93] In embodiments, the method may comprise the step of forming two or more parallel living hinges at or towards each edge of the acoustic covering to define a main wall and two substantially parallel and adjacent peripheral walls at each side thereof. 30 01 25 Thus, during fabrication, at each edge of the acoustic covering a peripheral wall adjacent the main wall can be deflected (such that it locates adjacent a side surface of the panel body, where / when present), and a further peripheral wall adjacent the first peripheral wall can be deflected (such that it located adjacent a rear surface of the panel body, where / when present), e.g. prior to fixing the acoustic covering the panel body.

[94] An acoustic panel fabricated in accordance with the method of any preceding aspect is described.

[95] A method of fabricating an acoustic panel is described. The method comprising the steps of: • providing an acoustic covering comprising a main wall and a number of peripheral walls wherein the main wall and each peripheral wall are in a substantially planar configuration; • deflecting and holding the or each peripheral wall relative to the main wall.

[96] In other words, when deflected, the main wall and each deflected peripheral wall may be in a substantially non-planar configuration.

[97] The method may further comprise the step of placing a panel body on the acoustic covering. The method may further comprise the step of fixing the acoustic covering to the panel body. Generally, the steps of the method may be carried out in the order in which they are set out above. Alternatively, the steps of the method may be carried out in a different order.

[98] In embodiments, the acoustic covering may include a fabric layer and an acoustic layer, and wherein the method may further comprise the step of joining the fabric layer to the acoustic layer. For example, the fabric layer may be stapled to the acoustic layer. In embodiments, joining the fabric layer to the acoustic layer may occur prior to deflecting and holding the or each peripheral wall relative to the main wall. 30 01 25

[99] In embodiments, the method may comprise the steps of forming one or more joints between adjacent walls of the acoustic covering. In embodiments, the or each joint may be in the form of a substantially resiliently flexible hinge. In embodiments, the or each hinge may be a living hinge. The method may comprise the step of clamping the or each peripheral wall relative to the main wall in a deflected configuration.

[100] As described, an acoustic covering may have a main wall and a plurality of peripheral walls extending therefrom which are joined thereto by a living hinge or the like. A living hinge may be formed subtractively, e.g. the living hinge may be in the form of a substantially V-shaped cut out. Thus, when deflected during fabrication, the acoustic covering may have a configuration wherein the living hinge between adjacent walls of the acoustic covering is substantially closed.

[101] The acoustic covering may include a first subset of peripheral walls which are substantially contiguous with the main wall and a second subset of peripheral walls which are substantially contiguous with and substantially separated from the main wall by the first subset of peripheral walls. In embodiments, each peripheral wall of the second subset may be deflected relative to a corresponding peripheral wall of the first subset as the peripheral walls are deflected and held relative to the main wall of the acoustic covering. In other words, the method may comprise the step of forming two or more substantially parallel living hinges at or towards each edge of the acoustic covering to define a main wall and two substantially parallel and adjacent peripheral walls at each side thereof. Thus, during fabrication, at each edge of the acoustic covering a peripheral wall adjacent the main wall can be deflected (such that it may locate adjacent a side surface of the panel body, where / when present), and a further peripheral wall adjacent the first peripheral wall can be deflected (such that it may locate adjacent a rear surface of the panel body, where / when present), e.g. prior to fixing the acoustic covering the panel body.

[102] In embodiments, the step of placing a panel body on the acoustic covering may include locating at least part of the panel body substantially between opposing peripheral walls of the acoustic covering. In embodiments, the panel body may comprise a plurality of segments, e.g. offcuts, of acoustic material. 30 01 25

[103] The method of fabricating an acoustic panel may be performed substantially using the acoustic panel fabrication jig as described herein.

[104] In a further aspect, the present invention provides an acoustic panel fabricated in accordance with the method of the preceding aspect.

[105] An acoustic covering for an acoustic panel, particularly as described above, the acoustic covering having a main wall and one or more peripheral walls joined to the main wall at an extremity thereof; wherein the or each peripheral wall is joined to the main wall by a substantially resiliently flexible joint arranged between the peripheral wall and the main wall is described.

[106] A said resiliently flexible joint may be a living hinge. In a deflected, e.g. assembled, configuration of the acoustic covering the or each substantially resiliently flexible joint may be in a substantially closed state. For example, where a said joint is a living hinge, e.g. formed as a substantially V-shaped cut-out, the living hinge may be substantially closed in a deflected configuration of the acoustic covering. Thus adjacent walls of the acoustic covering may abut and rest against one another in a deflected configuration.

[107] The acoustic covering may comprise at least one peripheral wall at each side of the main wall. The acoustic covering may comprise two or more peripheral walls at or near each side of the main wall. For example, the acoustic covering may comprise two substantially parallel adjacent peripheral walls. Generally, the adjacent walls may be defined by a further living hinge located between them. Thus a first peripheral wall located immediately adjacent the main wall at a side thereof may fold relative to the main wall, and a second peripheral wall separated from the main wall by the first peripheral wall may fold relative to the main wall and relative to the first peripheral wall. Each wall may be joined to an adjacent wall by a said joint, e.g. living hinge.

[108] The acoustic covering may include an acoustic element, e.g. a substantially continuous sheet or ‘tray’ of acoustic material. The acoustic covering generally may include a fabric layer which is fixed to and which substantially envelopes the acoustic 30 01 25 element of the acoustic covering. For example, the fabric layer may cover a front face, side faces and part of a rear face of the tray of acoustic material. Generally, the tray of acoustic material may include the said joints between adjacent walls of the acoustic covering, and the fabric layer may substantially conform (due to its relative flexibility) to the configuration, e.g. deflected configuration, of the tray.

[109] As described above, the acoustic material may be formed substantially of recycled material, for example recycled polyethylene terephthalate (PET). Additionally or alternatively the acoustic covering may include ‘seconds’ of acoustic material.

[110] An acoustic panel comprising an acoustic covering as described above and a panel body is described.

[111] The panel body may include a frame, e.g. a polyethylene terephthalate (PET) or wooden frame, and one or more acoustic elements, e.g. layers of acoustic material. The acoustic elements may include offcuts or seconds, e.g. repurposed segments of acoustic material. The acoustic material may be a sound absorbing material. The acoustic material may be formed substantially of recycled material, for example recycled polyethylene terephthalate (PET). Additionally or alternatively the acoustic covering may include seconds of acoustic material. The panel body may include two or more acoustic elements which are substantially perpendicularly arranged. For example, the panel body may include an array of segments of acoustic material which are arranged in a substantially parallel adjacent manner, and a set of additional segments of acoustic material which are arranged substantially perpendicularly to the array.

[112] The panel body may include a front surface, one or more side surfaces and a rear surface. The acoustic covering may include one or more peripheral walls which are secured against the rear surface. For example, the acoustic covering may include one or more retaining strips which secure the acoustic covering to the panel body.

[113] The acoustic panel may include one or more hanging rails configured for hanging the acoustic panel on a wall and / or ceiling or the like. Said hanging rail may comprise means for fixing to a wall or ceiling by screws or the like. Said hanging rail 30 01 25 may comprise magnetic means for substantially magnetically attaching the acoustic panel to a hanging surface. Said hanging rail may be located substantially towards an end of the acoustic panel, e.g. extending along a short end thereof between opposing long side where the acoustic panel is substantially rectangular in shape. Additionally or alternatively, a said hanging rail may be located at a mid-region of the acoustic panel.

[114] Typically, a fixing for a hanging rail, e.g. a screw, may be fixed such that it may extend at least partially through the acoustic covering and panel body such that it joins the acoustic covering to the panel body and, additionally or alternatively, substantially conceals any excess acoustic covering material. Advantageously, the use of screws or the like may allow the acoustic panel to be fully disassembled and reassembled, and / or for parts to be reused or recycled. The acoustic covering may be at least partly glued to the panel body.

[115] For example, the acoustic covering may include a tray of seconds PET acoustic material joined to a fabric layer. The panel body may include a plurality of PET offcuts positioned adjacent the tray of seconds PET of the acoustic covering. A number of retaining strips, e.g. aluminium retaining strips, may fix the acoustic covering to the panel body, and / or the acoustic panel may further comprise a number of hanging rails or hooks for hanging the acoustic panel to a wall or ceiling.

[116] The acoustic panel may be an acoustic ceiling panel. The acoustic panel may be an acoustic wall panel. The acoustic panel may be an acoustic tile, or divider, screen, or other acoustic product.

[117] The acoustic panel may have an absorption rating in accordance with ISO 11654 and / or ISO 354 of Class C or better. The acoustic panel may have a Class A absorption rating in accordance with ISO 11654 and / or ISO 354.

[118] When tested in accordance with ISO 354 and / or ISO 11654, the acoustic panel may have a practical sound absorption coefficient of: between around 0.01 and around 0.20 at a frequency of 125 Hz; and / or between around 0.10 and around 0.70 at a frequency of 250 Hz; and / or between around 0.50 and around 1.00 at a frequency of 30 01 25 500 Hz; and / or between around 0.80 and around 0.90 at a frequency of 1000 Hz; and / or between around 0.80 and around 1.00, optionally around 0.80 and around 0.99 at a frequency of 2000 Hz; and / or between around 0.90 and around 1.0, optionally around 0.90 and around 0.99 at a frequency of 4000 Hz, for example 0.99.

[119] When tested in accordance with ISO 354 and / or ISO 11654 the acoustic panel may have a weighted sound absorption coefficient of between around 0.65 and around 1.0. For example, when tested in accordance with ISO 354 and / or ISO 11654 the acoustic panel may have a weighted sound absorption coefficient of around 0.90.In a further aspect, the present invention provides a support structure for an acoustic panel fabrication jig, the support structure including one or more engagement positions for a number of corresponding dies of the jig; wherein the or each engagement position is configured to operably engage a said die such that one or more peripheral walls of an acoustic covering of an acoustic panel are deflected and held by the die relative to the main wall of the acoustic covering.

[120] In embodiments, the support structure may comprise a framework including a plurality of said engagement positions for the or each die.

[121] In embodiments, the framework may comprise a grid defining a plurality of recesses for a clamp of the jig.

[122] In embodiments, the support structure may include a set of indicia configured to indicate a suitable engagement position for the or each die for a given size of acoustic panel.

[123] In a further aspect, the present invention provides a die for an acoustic panel fabrication jig; the die being configured to assume an engagement position on a jig and to deflect and hold one or more peripheral walls of an acoustic covering of an acoustic panel relative to the main wall of the acoustic covering.

[124] In embodiments, the die may be a corner die including two limbs; wherein each limb is configured to deflect and hold one of two neighbouring peripheral walls of the acoustic covering relative to the main wall thereof towards a corner of the acoustic 30 01 25 covering. In embodiments, the two limbs may extend substantially perpendicularly to one another.

[125] In embodiments, the die may include a recess at the junction of the two limbs. In embodiments, the recess may be configured to receive and hold together end portions of each of the neighbouring peripheral walls of the acoustic covering.

[126] In embodiments, the die may include a stopper at the junction of the two limbs; wherein the stopper is configured to abut said end portion of at least one of the neighbouring peripheral walls of the acoustic covering.

[127] In embodiments, the corner die may include the stopper at said recess. The stopper may be configured to abut a said end portion of at least one of the neighbouring peripheral walls of the acoustic covering. In embodiments, the stopper may be configured to abut an end portion of each of the neighbouring peripheral walls of the acoustic covering.

[128] In embodiments, the die may further comprise a detachable hanging rail stay. In embodiments, wherein the hanging rail stay may be configured to align a hanging rail of the acoustic panel relative to the acoustic covering and / or panel body thereof.

[129] In embodiments, the hanging rail stay may comprise clamping means. The clamping means may be configured to clamp the stay against the acoustic covering and / or panel body. In embodiments, the clamping means may be detachable from the remainder of the stay.

[130] In a further aspect, the present invention provides a kit for an acoustic panel fabrication jig comprising at least one of a support structure or die or stay according to any preceding aspect.

[131] In embodiments, the kit may comprise a support structure and four dies according to any preceding aspect. 30 01 25

[132] For the avoidance of doubt, features of aspects and embodiments described herein may be combined, and still fall within the scope of the present invention. Brief Description of Figures

[133] Preferred features of the present invention will now be described, by way of example, with reference to the accompanying drawings, in which:

[134] Figure 1 illustrates a perspective view of the acoustic panel fabrication jig according to the present invention.

[135] Figure 2 illustrates a perspective view of the support structure of the acoustic panel fabrication jig.

[136] Figure 3 illustrates a perspective view of a die of the acoustic panel fabrication jig- fi 37] Figure 4 illustrates a perspective view of a die of the acoustic panel fabrication jig- fi 38] Figure 5 illustrates an exploded view of a die of the acoustic panel fabrication jig- fi 39] Figure 6 illustrates a side view of a die of the acoustic panel fabrication jig.

[140] Figure 7 illustrates a side view of a die of the acoustic panel fabrication jig.

[141] Figure 8 illustrates a plan view of a die of the acoustic panel fabrication jig.

[142] Figure 9 illustrates a side view of part of a die of the acoustic panel fabrication jig along section A-A of Figure 8.

[143] Figure 10 illustrates an exploded view of an acoustic panel according to the present invention. 30 01 25

[144] Figure 11 illustrates a plan view and magnified portions of the rear of an acoustic panel according to the present invention.

[145] Figure 12 illustrates a plan view of the front of an acoustic panel in accordance with the present invention.

[146] Figure 13 illustrates a side view of an acoustic panel in accordance with the present invention.

[147] Figure 14 illustrates a section of part of an acoustic panel in accordance with the present invention.

[148] Figure 15 illustrates a perspective view of a hanging rail stay of the acoustic panel fabrication jig.

[149] Figure 16 illustrates a plan view of a hanging rail stay of the acoustic panel fabrication jig.

[150] Figure 17 illustrates a side view of a hanging rail stay of the acoustic panel fabrication jig.

[151] Figure 18 illustrates a plan view of part of a hanging rail stay of the acoustic panel fabrication jig along section A-A of figure 17.

[152] Figure 19 illustrates a plan view of the acoustic panel fabrication jig according to the present invention.

[153] Figure 20 illustrates a cross sectional view of an acoustic panel fabrication jig along section A-A of Figure 19. Detailed Description 30 01 25

[154] Figure 1 shows part of an acoustic panel fabrication jig 101 according to an embodiment of the present invention.

[155] The acoustic panel fabrication jig 101 is suitable for fabricating an acoustic panel. Typically, an acoustic panel has a panel body and an acoustic covering. The acoustic covering has at least one acoustic element, e.g. a layer or segment of acoustic material. The panel body also typically includes one or more acoustic elements. As described in greater detail below, an acoustic covering includes a main wall and a number of peripheral walls. Such an acoustic covering typically includes a peripheral wall along each edge of the main wall, and adjacent walls of the acoustic covering are joined to one another via a living hinge or similar.

[156] The acoustic panel fabrication jig comprises a support structure 102 configured to receive the acoustic covering and panel body such that the acoustic covering is located substantially between the jig and the panel body. In other words, what will be a forward facing surface of the acoustic panel once fabricated is positioned face-down on the support structure 102.

[157] The jig 101 further comprises a plurality of dies, such as 106. The support structure 102 includes a plurality of engagement positions for a die 106.

[158] In use, the plurality of dies 106 are configured to each assume an engagement position on the support structure 102 and to deflect and hold a peripheral wall of the acoustic covering relative to the main wall of the acoustic covering. Figure 1 shows the acoustic covering in a deflected configuration and with the panel body joined to the acoustic covering by several screws which are screwed through a hanging rail 112.

[159] Referring to Figure 2, the support structure 102 comprises a framework 103 and a plurality of indica 104. The framework 103 comprises a plurality of holes 105 for engaging a corresponding plurality of pegs of the dies 106. The indicia 104 are associated with one or more holes 105 at a given engagement position and are configured to indicate an appropriate engagement position for the or each die 106 for a given size of acoustic panel to be fabricated. In the embodiment of Figure 2, the support structure 102, which here is formed of MDF, has a length of around 3000 mm 30 01 25 and a width of around 1400 mm. In other embodiments, the support structure 102 may have a width of around 600 mm. The support structure 102 has a depth of around 24 mm. It will be appreciated that support structure 102 may have different dimensions depending on the size of acoustic panel to be fabricated.

[160] The holes 105 are substantially uniformly distributed across the support structure 102. In Figure 2, the holes 105 are distributed between around 0 mm and around 1000 mm along a ‘width axis’ and between around 0 mm and around 2600 mm along a ‘length axis’.

[161] The framework 103 also includes a plurality of grooves 107 for engaging one or more clamps. The jig may comprise a number of clamps configured to clamp the acoustic covering in a deflected configuration and to clamp the acoustic covering against the panel body. In Figure 2, the grooves do not extend to the extremity of the support structure 102. It is envisaged that the grooves could extend substantially to one or more edges of the support structure 102.

[162] As shown in Figures 3 and 4, a die 106 may be a corner die including limbs 301, 302. In this embodiment, the limbs 301,302 extend substantially perpendicularly to one another. Corner die 106 comprises pegs 303 for engaging corresponding holes 105 of the support structure 102 at an engagement position.

[163] The corner die 106 also comprises a recess 108 at the junction of the two limbs 301, 302. The recess 108 is configured to receive and hold together end portions of each of neighbouring peripheral walls of the acoustic covering. As described above, it is desirable to fabricate an acoustic panel wherein the meeting of adjacent peripheral walls of the acoustic covering, e.g. the seams between them, are flush and substantially free of wrinkles or bulges, and that acoustic panels may be reliably reproduced with the same or substantially similar characteristics. The recess at the junction of the two limbs of the corner die receives and retains end portions of adjacent peripheral walls during fabrication. Thus, a neater and substantially wrinkle-free joint between the adjacent peripheral walls is provided. 30 01 25

[164] The corner die 106 further includes a stopper 109 at the recess 108 in the form of a fin. The stopper 109 is configured to abut an end portion of at least one of the neighbouring peripheral walls, possibly an end portion of both of the neighbouring peripheral walls. The stopper 109 may, for example, locate between end portions of the neighbouring peripheral walls when the die 106 deflects the peripheral walls relative to the main wall of the acoustic covering.

[165] In use, each die 106 functions in conjunction with a pressing force which acts against the die 106 and on the acoustic covering such that the acoustic covering engages the die 106. The pressing force may typically be a manual force. In other words, a user may push the acoustic covering into the die 106 such that each corresponding peripheral wall is deflected relative to the main wall and neighbouring peripheral walls are brought together to form a corner of the acoustic panel.

[166] Typically, the jig comprises four corner dies 106 arranged to engage four corresponding corners of the acoustic covering and to collectively hold the acoustic covering in place during fabrication.

[167] Figure 5 shows an exploded view of a die 106 according to an embodiment of the present invention, including two limbs 301 302, each with a notch 501 and 502 which together form the recess 108. Corner die 106 comprises pegs 303, 304, 305, 306. Stopper 109 is located between two limbs 301 and 302.

[168] Figures 6 and 7 show further views of a corner die 106 according to the present invention, including pegs 303-306 and stopper 109 which protrudes from a top surface of the die 106.

[169] Figure 8 shows a top view of corner die 106 according to an embodiment of the present invention. The top of pegs 303, 304, 305, 306 are shown as 303a, 304a, 305a, and 306a.

[170] As shown in Figure 9, pegs 303-306 include a chamfered end in order to facilitate their engagement with a corresponding hole 105 of the support structure 102 30 01 25 at an engagement position. Figure 9 shows the view along section A-A labelled in Figure 8.

[171] Referring now to Figure 10, an exploded view of an acoustic panel 1000 according to the present invention is shown. The acoustic panel 1000 comprises an acoustic covering comprising a fabric 1001a and an acoustic layer or ‘tray’ 1001b. A plurality of retainers 1003a, 1003b, 1003c, 1003d are provided for fixing the acoustic covering to the panel body.

[172] The panel body includes a frame comprised of frame parts 1002a-d and a plurality of acoustic material segments 1005, 1005a-d. The acoustic tray 1001 b of the acoustic covering may be formed substantially of polyethylene terephthalate (PET).

[173] In Figure 10, the tray 1001b is a substantially continuous sheet. As stated, the acoustic covering has a main wall and a plurality of peripheral walls extending therefrom. The main wall and each peripheral wall are joined by a living hinge (or flexure bearing) which is formed of substantially the same material as the main and peripheral walls of the acoustic covering and is relatively thin compared to the main and peripheral walls, i.e. the more rigid pieces of the acoustic covering. Each living hinge is in the form of a substantially V-shaped cut out. Thus, when deflected during fabrication, the acoustic covering has a configuration wherein the living hinge between adjacent walls of the acoustic covering is substantially closed.

[174] The acoustic material segments of the panel body are a series of substantially rectangular strips. A subset of strips 1005, 1005a are arranged substantially perpendicularly to the frame parts 1002a-d, and a further three strips of acoustic material 1005b-d are arranged substantially perpendicularly to the subset of strips 1005, 1005a. These perpendicularly arranged strips 1005b-d help to retain each of strips 1005 once the acoustic covering is attached to the panel body.

[175] A set of hanging rails 1006a-c are provided and are attached to the acoustic covering and panel body via a plurality of screws 1007. Stays for aligning the hanging rails 1006a-c are described in greater detail below. Screws 1004 attach the acoustic covering to the panel body via retainers 1004. 30 01 25

[176] Figure 11 shows an assembled rear view of acoustic panel 1000 that may be fabricated according to the present invention. Three hanging rails 1006a-c are fixed to the acoustic cover and panel body to hold the acoustic panel together in an assembled configuration. Each of the magnified views of Figure 11 shows how peripheral walls of the acoustic covering are wrapped around the panel body and are fixed thereto via the hanging rails 1006a-c. For example, as shown in magnified view B screw 1007 attaches the peripheral wall of the acoustic covering 1001 to the acoustic panel 1000.

[177] Figures 12 and 13 show front and side views of the acoustic panel 1000, respectively. More specifically, the main wall of the acoustic panel 1000 is shown in Figure 12 and a peripheral wall of the acoustic panel 1000 is shown in Figure 13, including hanging rails 1006a-c.

[178] Figure 14 shows a cross sectional view through a fabricated acoustic panel, fabricated according to a method of the present invention, along Section D-D of Figure 11. In particular, it is shown how screw 1007 extends through each of a hanging rail 1006a, acoustic material layer 1402, frame member 1002d and the main wall 1404 of the acoustic covering. A first peripheral wall 1401 adjacent the main wall 1404 is located adjacent an edge of the panel body and more specifically the frame member 1002d, and a second peripheral wall 1403 adjacent the first peripheral wall 1401 is located adjacent the frame member 1002d at a rear surface of the panel body and is also adjacent acoustic material layer 1402.

[179] As discussed, the acoustic panel includes hanging rails to hang the acoustic panel from a ceiling or wall. In order to be hung suitably, the hanging rails must be aligned with the panel body and / or acoustic covering, in particular so that the panel is not crooked. Figures 15 through 18 show a hanging rail stay 110 configured to align a hanging rail relative to the acoustic covering and / or panel body.

[180] The hanging rail stay 110 comprises a seat 111 configured to be engaged by a corresponding clamp. Therefore, the jig may comprise a clamp configured to clamp the hanging rail stay against the panel body and / or acoustic covering. The seat 111 is comprised of five layered plates 111a-e. 30 01 25 [181 ] The hanging rail stay comprises a first member 110a, a second member 110b and a third member 110c where the first 110a and third member 110c are arranged parallel to one another and second member 110b connects the first 110a and third member 110c and the first member 110a and third member 110c are substantially at a right angle to the second member 110b.

[182] Figure 19 shows part of an acoustic panel fabrication jig 101 according to an embodiment of the present invention.

[183] As described, the acoustic panel fabrication jig comprises a support structure 102 configured to receive the acoustic covering and panel body such that the acoustic covering is located substantially between the jig and the panel body. In other words, what will be a forward facing surface of the acoustic panel once fabricated is positioned face-down on the support structure 102.

[184] The jig 101 further comprises a plurality of dies, such as 106. The support structure 102 includes a plurality of engagement positions for a die 106.

[185] In use, the plurality of dies 106 are configured to each assume an engagement position on the support structure 102 and to deflect and hold a peripheral wall of the acoustic covering relative to the main wall of the acoustic covering. Figure 19 shows the acoustic covering in a deflected configuration and with the panel body joined to the acoustic covering by several screws which are screwed through a hanging rail 112.

[186] Figure 20 shows a cross sectional view along line A-A shown in figure 19. A first peripheral wall 1401 adjacent the main wall 1404 is located adjacent an edge of the panel body and more specifically the frame member 1002, and a second peripheral wall 1403 adjacent the first peripheral wall 1401 is located adjacent the frame member 1002 at a rear surface of the panel body and is also adjacent acoustic material layer 1005. The die 106 engages and deflects the peripheral walls and holds them in place. The hanging rail stay 110 is placed within the die 106 so that lateral movement of the hanging rail stay is substantially resisted. The hanging rail stay 110 comprises a seat 111 which is engaged by the clamp 114 and the base of the clamp 114 engages one 30 01 25 of the plurality of grooves on the support structure 102.The clamp thus helps to secure the peripheral walls, the die 106, the hanging rail stay 110, and the hanging rail in place so that these all can be attached to the acoustic panel.

[187] In use of the acoustic panel fabrication jig, for example, a fabric layer is placed on the support structure 102 and a tray of acoustic material comprising a main wall and a plurality of peripheral walls separated by living hinges is placed on top of the fabric layer. The fabric layer is fixed, e.g. stapled, to the tray, typically along an outermost peripheral wall at each edge of the acoustic covering.

[188] Four corner dies 106 are then engaged with the support structure 102. More specifically, pegs of each die engage corresponding holes of the support board at an engagement position in such a way that two adjacent edges of the peripheral wall are held off the support board. In other words, each die deflects and holds the peripheral wall(s) that it engages relative to the main wall of the acoustic covering. More specifically, the acoustic covering is pushed towards the dies 106 by a user such that corresponding peripheral wall(s) are deflected. This is repeated at each corner of the acoustic covering so that all of the peripheral walls are no longer in contact with the support board. The peripheral walls are instead deflected such that a cavity is formed by the raised peripheral walls.

[189] A frame is then installed inside the cavity and a sound dampening material is then placed on top of and within the boundary of the frame. These elements form the panel body.

[190] A further living hinge facilitates further folding of the acoustic covering so that a peripheral wall is brought into contact with a rear surface of the panel body.

[191] A plurality of clamps engage with the grooves on the support structure and are tightened to hold the one or more peripheral walls against the panel body. A hanging rail stay is engaged with the die and clamped in place via a seat on the hanging rail stay. A hanging rail is then placed across rear of the acoustic panel and is retained by the hanging rail stay. Screws fix the hanging rail(s), panel body and acoustic covering together.

[192] In a further example, a prefabricated panel body comprising a sound absorbing material is placed inside the cavity. The acoustic covering is then further folded so that a peripheral wall is in contact with a rear surface of the panel body placed inside the cavity. Clamps are engaged with the grooves on the support structure and are tightened to hold the peripheral wall against the panel body.

[193] A hanging rail stay is engaged with the die and clamped in place via a seat on the hanging rail stay. A hanging rail is then placed across rear of the acoustic panel and is retained by the hanging rail stay. Screws fix the hanging rail(s), panel body and acoustic covering together.

[194] The use of screws throughout allows the acoustic panel to be disassembled and components reused or repurposed. 30 01 25

Claims

23 05 251. An acoustic panel fabrication jig for fabricating an acoustic panel, the jig comprising:a support structure for receiving an acoustic covering for an acoustic panel; andone or more dies;wherein the support structure comprises one or more engagement positions for the or each die;wherein, in use, in a said engagement position the or each die operably engages the support structure to deflect and hold one or more peripheral walls of the acoustic covering relative to a main wall thereof; and wherein, in use, in a said engagement position at least one said die operably engages the support structure to deflect and hold neighbouring peripheral walls of the acoustic covering towards a corner thereof.

2. The acoustic panel fabrication jig according to claim 1, wherein at least one said die is a corner die including two limbs; wherein each limb is for deflecting and holding one of two neighbouring peripheral walls of the acoustic covering towards a corner thereof.

3. The acoustic panel fabrication jig according to claim 2 wherein the two limbs extend substantially perpendicularly to one another.

4. The acoustic panel fabrication jig according to claim 2 or 3, wherein the or each corner die includes a stopper at the junction of the two limbs, wherein the stopper is configured to abut an end portion of at least one of the neighbouring peripheral walls of the acoustic covering.

5. The acoustic panel fabrication jig according to any of claims 2 to 4, wherein the or each corner die includes a recess at the junction of the two limbs; wherein the recess is for receiving and holding together end portions of each of the neighbouring peripheral walls of the acoustic covering.23 05 256. The acoustic panel fabrication jig according to claim 5 wherein the stopper is located substantially within said recess.

7. The acoustic panel fabrication jig according to any preceding claim, wherein the support structure comprises a framework including a plurality of said engagement positions for the or each die; and wherein the or each die is moveable about the support structure between engagement positions.

8. The acoustic panel fabrication jig according to claim 7 wherein the plurality of engagement positions are substantially uniformly separated.

9. The acoustic panel fabrication jig according to any preceding claim, comprising a plurality of dies; wherein at least two said dies are for deflecting and holding one or more said peripheral walls of the acoustic covering substantially towards opposing ends of the acoustic covering.

10. The acoustic panel fabrication jig according to any preceding claim, further comprising one or more clamps configured to clamp the acoustic covering in a deflected configuration.

11. The acoustic panel fabrication jig according to claim 10 wherein the jig comprises a plurality of clamps.

12. The acoustic panel fabrication jig according to claim 10 or claim 11, wherein one or more said clamps are configured to clamp the one or more peripheral walls against a rear surface of a panel body for the acoustic panel.13.The acoustic panel fabrication jig according to any of claims 10 to 12, wherein the framework comprises a grid defining a plurality of recesses for the or each clamp; and the or each clamp is configured to operably engage a said recess.23 05 2514. The acoustic panel fabrication jig according to any preceding claim, the jig further comprising one or more stays for aligning a hanging rail for the acoustic panel relative to the acoustic covering and / or panel body.

15. The acoustic panel fabrication jig according to claim 14 when dependent on any of claims 10 to 13, wherein the or each hanging rail stay comprises a seat configured to be engaged by a clamp; and the clamp is configured to clamp the hanging rail stay against the panel body and / or acoustic covering.

16. The acoustic panel fabrication jig according to claim 14 or claim 15, wherein a said hanging rail stay is configured to operably engage a corresponding die; and the die is configured to substantially resist lateral movement of the hanging rail stay when operably engaged thereto.

17. A method of manufacturing an acoustic panel, the method including the steps of:a. providing the acoustic panel fabrication jig of any of claims 1 to 16;b. positioning one or more dies of the jig at an engagement position of the support structure such that the or each die operably engages the support structure to deflect and hold one or more peripheral walls of an acoustic covering for an acoustic panel relative to a main wall thereof; andc. prior to or after step b., placing an acoustic covering for an acoustic panel on the support structure of the jig.

18. The method of claim 17, comprising the further steps of, prior to or after step c. placing a panel body on top of the acoustic covering such that the acoustic covering is located between the support structure and the panel body; and after step c. fixing the acoustic covering to the panel body.23 05 2519. The method of claim 17 or claim 18, wherein step c. includes positioning at least one said die such that neighbouring peripheral walls of the acoustic covering are deflected and held substantially contiguously relative to the main wall thereof.

20. The method of claim any of claims 17 to 19, wherein step c. includes positioning a said die towards each corner of the acoustic covering such that neighbouring peripheral walls of the acoustic covering are deflected and held relative to the main wall at or towards each corner thereof.

21. The method of any of claims 17 to 20, the jig comprising one or more clamps; wherein the method further comprises the step of, clamping the acoustic covering in a deflected configuration.

22. The method of claim 21, wherein the method further comprises the step of clamping the one or more peripheral walls against a rear surface of the panel body.

23. The method of any of claims 17 to 22, further comprising the steps of providing one or more hanging rail stays; aligning a hanging rail of the acoustic panel relative to the acoustic covering and / or panel body with the one or more hanging rail stays; and fixing the or each hanging rail to the acoustic covering and / or panel body.

24. The method of claim 23 wherein the method further comprises the step of clamping the one or more hanging rail stays against the acoustic covering and / or panel body prior to fixing the hanging rail.

Images