Perforated acoustic panel, method for manufacturing the same, and use thereof

Abstract

A perforated acoustic panel (100) for mounting to a wall and / or ceiling is provided, including a visible front side (110) and a rear side (120) that is hidden by the panel when mounted. It is an object of the present disclosure to provide an illuminated wall or ceiling. This object is solved by a flexible printed circuit layer, FPC (130), mounted to the rear side of the panel, the FPC including a plurality of LEDs (140), each arranged so as to be positioned to emit light through a perforation (150) in the panel.

Description

Technical Field

[0001] The present invention relates to a perforated acoustic panel according to claim 1, a method for manufacturing a perforated acoustic panel according to claim 12, and the use of a perforated acoustic panel according to claim 13.

Background Art

[0002] The acoustics of a room are an important factor that must be considered during construction or renovation. Many public institutions such as classrooms and lecture halls have strict regulations regarding the indoor acoustics that must be complied with, while areas such as offices and apartments require noise management for comfort or even health, especially when the minimal furniture style of an open plan is used. Furthermore, indoor acoustics are a variable factor that needs to be carefully controlled in environments such as theaters and music rooms in order to provide optimal conditions for their intended use.

[0003] An important factor used to indicate indoor acoustics is the reverberation time. The reverberation time refers to the amount of time required for sound to decay in an enclosed space. Sound in a room can reverberate when it is not absorbed by the surfaces that the sound waves contact and is instead reflected by the surfaces.

[0004] This reverberation time can be shortened by modifying the surfaces so that more sound within the relevant frequency range is absorbed and thus reflections are minimized. Open-cell acoustic absorption materials such as mineral fiber / wool, polyester fiber, PUR foam or felt can be utilized for this effect.

[0005] For the improvement of room acoustics in the required environment, such sound-absorbing materials can be used on walls, ceilings, and even floor surfaces. These sound-absorbing materials can be sold together with a finished surface such as a mineral fiber ceiling, or the surface can be manufactured on a perforated plasterboard ceiling that is attached to a suspension system of metal profiles or wooden slats with a mineral wool backing during the installation of these materials, for example. The sound-absorbing materials are typically placed behind the perforated plasterboard.

[0006] The perforated surface of the sound-absorbing material allows sound and / or air to flow through the material, increasing the absorption effect of the sound-absorbing material behind. The perforations (holes) provide sound attenuation characteristics that can be utilized for the acoustic management of the room. The above-mentioned holes can bring an acoustic attenuation effect to the environment in which they are installed. These holes can have any one of various cross-sectional shapes such as rectangular, square, or circular. Since the holes in the material, panel, or board play a major role in providing the noise attenuation effect of the material, the distribution and size of the holes can thus be selected to provide the required acoustic attenuation effect for the selected environment.

[0007] An example of a perforated surface is the Knauf Cleaneo Akustikplatte (acoustic panel). The acoustic attenuation effect is achieved by a complete structure that includes a laminated film or fiber fleece on the side facing the wall and mineral wool in the cavity between the plasterboard and the wall. The structure also includes fastening means for attaching the board to the wall.

[0008] Perforated acoustic panels such as the Knauf Cleaneo Akustikplatte or the Knauf Cleaneo Acoustic linear panel can be suspended from the ceiling, while mineral fiber panels are often held in place through a grid-like rail structure that surrounds the ends of the individual panels. The sound-absorbing materials can be laid out in a way that substantially hides the ends and makes the surface look like a plain wall. Summary of the Invention

Means for Solving the Problem

[0009] The present invention is based on the discovery that a flexible printed circuit (FPC) can be combined with a perforated acoustic panel to provide lighting in a highly efficient and cost-effective manner.

[0010] An advantageous embodiment of the present invention provides that the first and second web sections are arranged in a first plane and the central region of the web bead is arranged in a second plane. Preferably, the central region can be formed linearly.

[0011] The complex and expensive integration of lighting into acoustic panels according to the prior art is overcome by the perforated acoustic panel according to claim 1, the method of manufacturing the perforated acoustic panel according to claim 12, and the use of the perforated acoustic panel according to claim 13.

[0012] According to the present invention, there is provided a perforated acoustic panel for attachment to a wall and / or ceiling, the panel including a visible front side and a rear side opposite the front side that is hidden when the panel is attached. The perforated panel includes at least one, preferably a plurality of perforations. The perforated panel is characterized by a flexible printed circuit layer (FPC) attached to its rear side, the FPC including a plurality of LEDs, each LED being arranged to be positioned to emit light through the perforations of the panel. The FPC is preferably a paper FPC or a film FPC. In the context of the present application, an LED (light emitting diode) shall also include an OLED (organic light emitting diode) or any other light source adapted to be incorporated within the FPC.

[0013] In one embodiment, the panel includes a gypsum body, and the perforated gypsum wall reflects (i.e., directs) the light emitted from the LEDs through the perforations.

[0014] Advantages include that the perforations of the acoustic panel naturally provide a light-directing effect, especially when the panel body is made of a light-reflective material such as gypsum.

[0015] The optical properties are also known to change with the perforated gypsum wall, presumably due to the reflection and absorption effects brought about by the perforated plaster wall.

[0016] By arranging the LEDs on the back side of the panel, disturbing glare is avoided. The comprehensive arrangement of the LEDs eliminates the influence of shadows.

[0017] In one embodiment, the LEDs mounted on the FPC are positioned to emit light through each perforation of the panel.

[0018] In one embodiment, the LEDs mounted on the FPC are positioned to emit light through some of the perforations of the panel.

[0019] The LEDs can be arranged at each perforation, or not provided at each perforation and provided only at some of the perforations, for example, in a clustered arrangement or a regular arrangement that regularly omits individual perforations. The number of LEDs per perforation depends on factors such as the desired lighting effect and the intensity of each LED.

[0020] In one embodiment, the FPC is attached with an attachment that includes an attachment-free margin around each perforation to facilitate the propagation of sound waves through the FPC. Preferably, the attachment-free margin is 3 mm to 5 mm.

[0021] An important factor for the good sound absorption characteristics of the acoustic panel is to enable sound waves to pass through the panel and penetrate into the sound-absorbing material behind the panel by perforation. If the FPC is attached too tightly to the panel, the sound transmission will be restricted. Therefore, the FPC should preferably be loosely attached to the back side of the panel, preferably attached only at specific points, and / or have a margin with respect to the holes in the panel, enabling the FPC to vibrate with sound waves and allowing sound to propagate into the cavity with the sound-absorbing material behind the panel. To further increase the sound transmission, the FPC is preferably perforated over at least the panel perforations that do not include LEDs.

[0022] In one embodiment, the thickness of the FPC is less than 1.5 mm, preferably less than 1.2 mm. For example, the substrate (paper or film) of the FPC can be about 0.1 mm thick, while the LED can have a height of about 0.8 mm. The combined thickness of the substrate and the LED would be about 0.9 mm. By reducing the thickness of the FPC, the sound transmission is facilitated and the mounting height can be lowered. Paper is a particularly suitable material for being laminated on the plasterboard, but other materials as the basic material for the FPC are also considered for forming the perforated acoustic panel according to the present invention. In a preferred embodiment, the FPC is a roll product, that is, the length of the FPC material is preferably provided from a roll in the range of 50 m to 150 m. The FPC material is cut to provide a specific FPC intended to be attached or laminated to the back side of the panel.

[0023] According to another embodiment, the FPC is a film FPC.

[0024] According to one embodiment, the plurality of LEDs emit light that is perceived as white.

[0025] According to one embodiment, the LEDs are wide-spectrum LEDs.

[0026] According to one embodiment, the emitted light is perceived as white. This light is emitted by a combination of narrow-band LEDs of primary colors. The light intensity and color can be adjusted by adjusting the intensity of each primary color LED independently of the other primary color LEDs.

[0027] Typically, the illumination is preferably white. However, the panel can be configured with LEDs of a specific color, or a combination of LEDs of different colors in each perforation or separate perforations. The LED intensity can be adjustable to adjust the intensity and / or perceived color of the lighting panel.

[0028] The disadvantages of the prior art are further overcome by the method of manufacturing the perforated acoustic panel according to the present disclosure.

[0029] In one embodiment, the method includes placing an FPC on the rear side of the panel such that each of a plurality of LEDs disposed on the FPC is disposed over a perforation of the perforated acoustic panel, and attaching the FPC to the panel using lamination, adhesion, or connection elements such as nails or staples. Other suitable means for attaching the FCP are also possible.

[0030] Alternatively, the flange beads of one flange can preferably be arranged along two, three, or more lines parallel to each other. These two, three, or more lines can be oriented parallel to the longitudinal direction of the stud.

[0031] Advantageously, the paper FCP can be very easily contacted via a horizontally elongated contact zone that enables connection to all (lateral) parts of the ceiling, usually taking into account the electrical connections provided within the building.

[0032] The disadvantages of the prior art are further overcome by using a perforated acoustic panel as described in the present disclosure for illuminating a room.

[0033] The benefits and advantages of the methods and uses described herein are equal to or similar to the benefits of the panel described herein.

[0034] Exemplary embodiments of the present invention will be described below with reference to the drawings.

Brief Description of the Drawings

[0035]

Figure 1

Figure 2

Figure 3

Mode for Carrying Out the Invention

[0036] FIG. 1 shows a cross-section of a lighting acoustic panel 100. The panel includes a front side 110 of the panel, a rear side 120 of the panel, and a flexible printed circuit layer (FPC; 130) including one or more light-emitting diodes (LEDs; 140). The panel also includes perforations 150 and a panel core 160, preferably a gypsum core. The acoustic panel according to this example is an acoustic plasterboard. The walls of the perforations 150 function as light reflectors that direct light through the perforations. Thereby, the light beam is narrowed compared to a panel in which the LEDs are arranged on the front surface of the panel. When the panel core 160 is a gypsum core, the walls of the perforations have an essentially whitish color and function as light reflectors without further treatment. When the panel core 160 is made of another material, such as wood, it may be desirable to coat the perforation walls with a light-reflective material.

[0037] The FPC is preferably a paper FPC or a film FPC when used on an acoustic plasterboard. When the FPC is a paper FPC, the paper preferably has a thickness of less than 1.5 mm, more preferably less than 1.2 mm. According to this example, the paper substrate of the FPC has a thickness of about 0.1 mm, and the mounted LED has a height of about 0.8 mm. The paper substrate and the LED together have a thickness of about 0.9 mm. Since the acoustic panel is a plasterboard, the plasterboard usually has a paper liner, and thus the use of the paper FPC is particularly beneficial for easy attachment. However, if the panel or its casing is made of other materials, the film FPC may be more preferably used.

[0038] The panel 100 may be configured to be attached to a wall and / or ceiling (not shown). An acoustic material such as mineral wool (not shown) may be disposed behind the panel (the rear side 120 of the panel) when attached. As shown, the FPC 130 is attached to the rear side of the panel, and the LEDs 140 of the FPC 130 are arranged such that their emitted light is directed through the perforations 150 of the panel 100.

[0039] Figure 2 shows an overview of the illuminated acoustic panel from the front side 110. The FPC is attached to the rear side 120 and provided and arranged such that the LEDs 140 are disposed within the perforations 150. Depending on the desired effect of the illuminated acoustic panel, the LEDs may be disposed on only some of the panels, clustered, disposed one by one, or disposed within each perforation 150.

[0040] Figure 3 shows an overview of the illuminated acoustic panel 100 from the rear side 120. The FPC is provided and positioned such that the LEDs 140 are disposed within the perforations 150. The FPC is attached to the panel at a specific location 310. Preferably, the panel comprises an attachment-free zone or margin 320 that maintains the distance to the perforations to allow the FPC to vibrate and thereby prevent the reflection of sound waves. The attachment-free margin 320 preferably includes a region of 3 mm to 5 mm from the end of each perforation 150 to facilitate the propagation of sound waves through the FPC.

[0041] The LED preferably emits light that is perceived as white, such as by using a wide-spectrum white LED. The LEDs may also have different colors that can be individually adjusted in intensity, with respect to intensity and perceived color, or to have adaptable lighting along the panel, thereby resulting in color patterns, shapes, or images.

[0042] The illuminated acoustic panel can be used in wall or ceiling installations or as an illuminated acoustic sail / acoustic absorber.

Description of the Reference Numerals

[0043] 100 Perforated Acoustic Panel 110 Front side (of the panel) 120 Rear side (of the panel) 130 Flexible Printed Circuit Layer (FPC) 140 Light Emitting Diode (LED) 150 Panel Perforation 160 Panel Core 310 FPC Attachment 320 Attachment-Free Margin

Claims

1. A perforated acoustic panel (100) for attachment to a wall and / or ceiling, said panel (100) including a visible front side (110) and a rear side (120) opposite said front side (110), said rear side (120) being adapted to be hidden when the panel (100) is attached, in a perforated acoustic panel (100). Comprising a flexible printed circuit layer FPC (130) attached to the rear side (120) of said panel (100), said FPC (130) including a plurality of LEDs (140), each LED being arranged to be positioned to emit light through a perforation (150) of said panel (100). Said FPC (130) is attached to said perforated acoustic panel (100) using an attachment including an attachment-free margin which is an area having no attachment location around said perforation (150), characterized in that, a perforated acoustic panel (100).

2. Said FPC (130) is a paper FPC or a film FPC, the perforated acoustic panel (100) according to Claim 1.

3. Said panel (100) includes a panel core (160), and The wall of said perforation (150) reflects light emitted from said LED (140) through said perforation (150), the perforated acoustic panel (100) according to Claim 1 or 2.

4. Said LEDs (140) are arranged such that light is emitted through each perforation (150) of said panel (100), the perforated acoustic panel (100) according to any one of Claims 1 to 3.

5. Said LEDs (140) are arranged such that light is emitted through some of the perforations (150) of said panel (100), the perforated acoustic panel (100) according to any one of Claims 1 to 3.

6. Said attachment-free margin is 3 mm to 5 mm, the perforated acoustic panel (100) according to any one of Claims 1 to 5.

7. Said FPC (130) is a paper FPC having a thickness of less than 1.5 mm, the perforated acoustic panel (100) according to any one of Claims 1 to 6.

8. Said FPC (130) is a paper FPC having a thickness of less than 1.2 mm, the perforated acoustic panel (100) according to Claim 7.

9. The perforated acoustic panel (100) according to any one of claims 1 to 8, wherein the plurality of LEDs (140) emit light perceived as white.

10. The LED (140) is a wide-spectrum LED. The perforated acoustic panel (100) according to claim 9.

11. The light perceived as white is emitted by a combination of narrow-band LEDs of primary colors. The perforated acoustic panel (100) according to claim 9.

12. The perforated acoustic panel (100) according to claim 11, wherein the light intensity and light color are adjustable by independently adjusting the intensity of the LEDs of each primary color.

13. A method of manufacturing the perforated acoustic panel (100) according to any one of claims 1 to 12, placing an FPC (130) on the rear side (120) of the perforated acoustic panel (100) such that each of the plurality of LEDs (140) disposed on the FPC is disposed above a perforation (150) of the panel (100); attaching the FPC (130) to the panel (100).

14. A method of using the perforated acoustic panel (100) according to any one of claims 1 to 12 for illuminating a room.

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