Panel for soundproofing an environment and thermoforming process for the manufacture of such a panel
The panel with a sound-absorbing base, cladding, and textile reinforcement layer addresses the limitations of existing panels by ensuring durable and adaptable soundproofing with complex geometries and improved sound insulation.
Patent Information
- Application Number
- PCT/IB2025/051013
- Authority / Receiving Office
- WO · WO
- Patent Type
- Applications
- Current Assignee / Owner
- Priority Date
- 2024-01-31
- Filing Date
- 2025-01-30
- Publication Date
- 2025-08-07
AI Technical Summary
Existing soundproofing panels, both monomaterial and laminated, fail to optimally adapt geometric, structural, and functional properties to the environment's needs, with monomaterial panels lacking adequate absorbency and sound insulation, and laminated panels suffering from poor durability and reduced machining freedom.
A panel comprising a sound-absorbing base layer, a cladding layer made of different material, and an intermediate layer with a reinforcement layer of textile material to enhance compressive strength, allowing for complex geometries and improved soundproofing properties while maintaining durability.
The panel achieves effective soundproofing with high durability and adaptability to structural and aesthetic needs, enabling production of panels with varied surface geometries without layer breakage, and maintaining sound-insulating or sound-absorbing functions.
Smart Images

Figure IB2025051013_07082025_PF_FP_ABST
Abstract
Description
[0001] Title: "Panel for soundproofing an environment and thermoforming process for the manufacture of such a panel"
[0002] DESCRIPTION
[0003] Technical Field
[0004] The object of the present invention is a panel for soundproofing an environment. This panel finds particular application in the soundproofing of environments, or parts thereof, such as, for example, offices, homes, hospital rooms, school buildings, hotels or public places in general. The panels of the present invention may, by way of example, be integrated into ceilings, false ceilings, walls, floors, furnishing elements.
[0005] The present invention also relates to a thermoforming process for the manufacture of such a panel for soundproofing environments.
[0006] Description of the prior art
[0007] In the prior art it is known to make soundproofing panels for environments based on sound absorption or sound insulation principles, which are attached to a noise source to insulate an environment or absorb sound waves generated by the noise source. One example is shown by document US 2010 / 019416, which describes a vehicle acoustic panel having a porous core and at least one cladding layer.
[0008] In particular, panels and processes are known for the manufacture of monomaterial panels, i.e. made of materials belonging to the same class. For example, panels and processes are known for the manufacture of panels made of polymeric material, capable of absorbing the noise generated by a noise source. Panels and processes for the manufacture of wood panels are also known, which are capable of ensuring the soundproofing of an environment by performing a sound absorption or sound-insulating function.
[0009] In the prior art, laminated polymaterial panels are also known comprising a layer of polymeric material for sound absorption, and a layer of textile or wood material, adapted to absorb the sound waves generated by the noise source, thus supporting the sound absorption function of the polymeric material. An example of a laminated polymer panel is shown in the previous document EP 2990557 Al.
[0010] Further examples of laminated panels are shown by documents ES 2157725 Bl and US 2019 / 392809 Al, both showing a panel having a support layer, a cladding layer and fibres interposed between said layers.
[0011] Problem of the prior art
[0012] The known panels for the soundproofing of an environment, monomaterial or laminated, do not make it possible to optimally adapt the respective geometric, structural and functional properties to the type of environment to be soundproofed.
[0013] In detail, the known monomaterial panels do not guarantee adequate absorbency or adequate sound insulation.
[0014] On one hand, panels laminated with wood do not make it possible to effectively adapt the sound-absorbing or sound-insulating properties to the geometric and structural properties of the panel to the aesthetic or structural needs of the environment. On the other hand, panels laminated with fabric have poor durability over time. In fact, the presence of a textile layer superimposed on the sound-absorbing layer entails the need for a high maintenance frequency, as this textile layer undergoes wear or degradation.
[0015] In addition, the laminated panels cause a reduction in machining freedom. In more detail, the layers of the known panels, which form the semi-finished panel, have poor mechanical properties, thus affecting the forming step of the finished panel.
[0016] Summary of the invention
[0017] The object of the present invention is to provide a panel for soundproofing an environment and a thermoforming process for the manufacture of panels for soundproofing environments capable of overcoming the disadvantages of the prior art as described above.
[0018] In particular, the object of the present invention is to provide a panel and a thermoforming process for the manufacture of panels capable of effectively combining excellent soundproofing properties with a high durability over time and an optimal adaptation of the properties of the panel to the structural and aesthetic needs of the environment.
[0019] The technical task mentioned and the objects stated are substantially achieved by a panel and a process comprising the technical features set out in one or more of the appended claims.
[0020] Advantages of the invention
[0021] The panel for soundproofing an environment of the present invention comprises a base layer in a first material of the sound-absorbing type, a cladding layer made of a second material different from the first, facing a noise source to perform a soundabsorbing or sound-insulating function of an environment, and an intermediate layer adapted at least to fasten the base layer to the cladding layer. In particular, the intermediate layer further comprises a reinforcement layer adapted to increase the compressive strength of the cladding layer.
[0022] Advantageously, the reinforcement layer prevents breakage of the cladding layer when subjected to compression during the production process. In this way, it is possible to obtain panels for the soundproofing of environments with different patterns and different surface geometries, thus able to adapt to the structural and aesthetic needs of the environment to be soundproofed.
[0023] Another advantage of the reinforcement layer is that it is made of a layer of textile material, which can ensure a uniform reinforcement effect for the entire cladding layer.
[0024] Still advantageously, the use of a cladding layer free of holes or perforations makes it possible to obtain a panel having a sound-insulating or sound-absorbing function, respectively.
[0025] Still advantageously, the cladding layer being manufactured from veneered, unstructured or laminated wood makes it possible to facilitate the production process thanks to its flexibility and its elastic properties and resistance to flexion and torsion. This allows complex surface geometries to be obtained without ruining, weakening or breaking the cladding layer.
[0026] In one embodiment, the intermediate layer comprises a barrier layer interposed between the cladding layer and the reinforcement layer.
[0027] Advantageously, the panel of the present invention lends itself to numerous applications. In fact, it is possible to make a mono-facial panel, having a single cladding layer made of plant-based material, or a bi-facial panel, having a substantially sandwich structure comprising two opposite cladding layers and surrounding the base layer.
[0028] The thermoforming process for the manufacture of panels for soundproofing environments of the present invention advantageously makes it possible to couple two or more different materials, while maintaining a panel of reduced thickness. Still advantageously, the thermoforming process makes it possible to deform the main layer to obtain a layer of reduced volume and higher density, and to thermally deform the cladding layer according to one or more surface geometries to adapt the panel to the aesthetic or structural needs of the environment in which the panel is inserted.
[0029] BRIEF DESCRIPTION OF THE DRAWINGS
[0030] The characteristics and advantages of the present invention will become clear from the following detailed description of a possible practical embodiment, illustrated by way of non-limiting example in the set of drawings, wherein: figure 1 shows a sectional side view of a first embodiment of a panel for soundproofing environments according to the present invention; figure 2 shows a sectional side view of a second embodiment of a panel for soundproofing environments according to the present invention; figure 3 shows a sectional side view of a third embodiment of a panel for soundproofing environments according to the present invention; figure 4a shows a sectional perspective view of the panel of figure 3, figure 4b shows a sectional perspective view of a semi-finished panel in a first step of a thermoforming process according to the present invention; figure 4c shows a perspective view of the panel of figure 4b following a second step of a thermoforming process according to the present invention; figure 4d shows a perspective view of an alternative embodiment of the panel of figure 4c; figure 4e shows a perspective view of the panel of figure 2 following a thermoforming process according to the present invention; figure 4f shows a perspective view of an alternative embodiment of the panel of figure 4e; figure 5a shows a sectional view from above of a fourth embodiment of a panel for soundproofing environments according to the present invention; figure 5b shows a sectional view from above of a fifth embodiment of a panel for soundproofing environments according to the present invention; figure 5c shows a sectional view from above of a sixth embodiment of a panel for soundproofing environments according to the present invention; figure 5d shows a sectional view from above of a seventh embodiment of a panel for soundproofing environments according to the present invention; figure 5e shows a sectional view from above of an eighth embodiment of a panel for soundproofing environments according to the present invention; figure 5f shows a sectional view from above of a ninth embodiment of a panel for soundproofing environments according to the present invention; figure 5g shows a sectional view from above of a tenth embodiment of a panel for soundproofing environments according to the present invention; figure 5h shows a top sectional view of an eleventh embodiment of a panel for soundproofing environments according to the present invention according to a different surface geometry.
[0031] DETAILED DESCRIPTION
[0032] With reference to the appended figures, the number 1 indicates a panel for soundproofing an environment in accordance with the present invention.
[0033] For the purposes of the present description, soundproofing means a phenomenon adapted to limit the diffusion of sound or noise by means of acoustic insulation, thus reflecting the sound energy generated by a noise source, or by means of acoustic absorption, instead absorbing the sound energy generated and reducing reverberation.
[0034] According to one aspect, the panel 1 has a plurality of layers extending along a first direction X and a second direction Y on substantially parallel planes.
[0035] The panel 1 of the present description comprises a base layer 2 made of a first sound-absorbing type material. Preferably, the first material is a highly flexible material. Still preferably, the first material is defined by a polymer having soundabsorbing properties, more preferably a polyester. Alternatively the first material may be a natural fibre fabric.
[0036] According to one aspect, the base layer 2 has a first surface 2a and an opposite second surface 2b, as shown in figure 4a.
[0037] The panel 1 further comprises at least one cladding layer 3, placed on the base layer 2, and made of a second material different from the first material. The second material is defined by one or more plant-based materials selected from veneered wood, unstructured wood or laminated wood. Advantageously, the use of wood for the cladding layer makes it possible to obtain a high durability over time, since, in contrast to the fabric used in the panels known in the state of the art, wood is far less subject to degradation or wear.
[0038] Within the scope of the present description, unstructured wood means an elastically deformable and highly malleable fibre weave. Advantageously, unstructured wood has excellent elastic properties and high flexural and torsional strength.
[0039] Optionally, the cladding layer 3 is alternatively made of flax or plant-based elements, including fabrics obtained from floral elements.
[0040] In more detail, according to an alternative embodiment, not illustrated, the cladding layer comprises a first layer of linen fabric and a second layer comprising a composition of floral elements.
[0041] According to one aspect of the invention, one or more layers of the panel 1 may be made of flame-retardant material and / or a material treated with a flame-retardant treatment.
[0042] In the context of this description, flame-retardant treatment means any treatment that reduces the flammability of a material. By way of example, the flame-retardant treatment may comprise a treatment of coating with a flame-retardant agent.
[0043] Preferably, at least the second material of the cladding layer 3 is of the flameretardant type and / or treated with flame-retardant treatment. Additionally, or alternatively, the first material of the base layer 2 and / or the material of the reinforcement layer 5a are of the flame-retardant type and / or treated with flameretardant treatment. Optionally, all the layers of the panel 1 are made of flame-retardant material and / or of material treated with flame-retardant treatment.
[0044] It should be noted that a panel 1 made in this way is therefore advantageously able to limit the risk of combustion or delay its development, thus increasing the safety of the environment in which the panel 1 is inserted.
[0045] The cladding layer 3 has an inner surface 3a facing the base layer 2, and in particular the first surface 2a of the base layer 2, and an opposite outer surface 3b facing a noise source for absorbing and / or blocking sound waves generated by the noise source. Advantageously, the cladding layer 3 can be adapted to the needs of the environment, thus making it possible to obtain a sound-absorbing or sound-insulating function, as better described below.
[0046] The panel 1 also comprises an intermediate layer 4 interposed between the base layer 2 and the cladding layer 3. The intermediate layer 4 is at least in part configured to fasten the base layer 2 to the cladding layer 3. In more detail, the intermediate layer 4 comprises at least one layer of adhesive 6 adapted to adhere the cladding layer 3 to the base layer 2.
[0047] The intermediate layer 4 further comprises a reinforcement layer 5a constrained to the inner surface 3a of the cladding layer 3 and configured to increase the compressive strength of the cladding layer 3.
[0048] For the purposes of the present description, compression means an action applied along a third direction Z perpendicular to the first direction X and the second direction Y, along which the thickness of the panel 1 is defined.
[0049] According to the invention, the reinforcement layer 5a comprises a layer of textile material, which is preferably made entirely of textile material. It should be noted that the adhesive layer 6 is at least partly absorbed or penetrated into the base layer 2 and / or the reinforcement layer 5a. In more detail, it should be noted that the layer of adhesive 6 partially or totally absorbed by the adjacent layers is in any case identifiable in the line of separation between the base layer 2 and the reinforcement layer 5a or, alternatively, between the base layer 2 and a layer interposed between the base layer 2 and the reinforcement layer 5a, as further detailed in the following description.
[0050] Preferably, the layer of textile material is continuous. For the purposes of this description, "continuous" means a substantially homogeneous layer, and not composed of individual fibres unbonded to each other. Still preferably, the layer of textile material is a fabric, i.e. composed of textile fibres woven together by weaving.
[0051] It is noted that the layer of textile material uniformly coats the inner surface 3a of the cladding layer 4, ensuring uniform reinforcement within the cladding layer 4.
[0052] Advantageously, the reinforcement layer 5a prevents the cladding layer 3 from breakage during the manufacturing process, thus allowing the manufacture of different surface geometries capable of adapting to the structural and aesthetic needs of the environment to be soundproofed.
[0053] By way of example, the sectional geometry of the panel 1 may have a flat, corrugated, wavy, domed or zigzagged shape, as illustrated in the attached figures 5 a- 5h.
[0054] In accordance with a first embodiment of the invention, illustrated in figure 1 and in figure 4d, at least the outer surface 3b, and optionally also the inner surface 3a, of the cladding layer 3 is substantially continuous, i.e. free of holes. The cladding layer 3 is therefore configured to block the sound waves generated by the noise source and acoustically insulate the environment. In other words, in the first embodiment the panel 1 is formed by continuous, non-perforated layers.
[0055] In accordance with a second embodiment, alternative to the first and shown in figure 4c, the panel 1 has a plurality of holes 7 obtained at least on the cladding layer 3. The holes are configured to diffuse, i.e. let through, the sound waves generated by the noise source. Preferably, the plurality of holes 7 is further obtained on the reinforcement layer 5a. These holes are intended for the same purpose. Preferably, the holes have a millimeter or micrometer size.
[0056] The base layer 2 is thus configured to absorb the sound waves passing through the plurality of holes 7. The panel 1 being manufactured in this way thus allows it to perform a sound-absorbing function.
[0057] Optionally, as illustrated in the embodiment of figure 3 and figure 4a, the intermediate layer 4 comprises an acoustically transparent barrier layer 5b, interposed between the adhesive layer 6 and the cladding layer 3, in more detail between the adhesive layer 6 and the reinforcement layer 5a.
[0058] Within the scope of the present description, acoustically transparent means a layer with high acoustic transparency, i.e. with a high capacity to absorb vibrating air and allow penetration into the layer itself.
[0059] Said barrier layer 5b has at least one substantially continuous surface.
[0060] Note that in alternative embodiments wherein the cladding layer 3 is perforated, the panel 1 may not comprise the barrier layer 5b, as shown by way of example in Figures 4b and 4c. Optionally in such embodiments, the drilling step takes place at the end of the machining step, as better detailed in the following of the present description.
[0061] In accordance with what is shown in figures l-4c, the panel 1 comprises a further cladding layer 8, or second cladding layer, placed on the second surface 2b of the base layer 2.
[0062] According to one aspect, shown in figures 1, 3 and 4a-d, the second cladding layer 8 is made of textile material and / or natural fibres, and preferably in a continuous layer of textile material. In this way, it is possible to obtain a single-face panel, i.e. with a single face made of a material of plant-based origin that can be turned towards the noise source.
[0063] According to an alternative aspect, illustrated in figure 2 and in figures 4e-4f, the second cladding layer 8 is made of the second material, i.e. of a material of plantbased origin, including unstructured, veneered or laminated wood. In this way, it is possible to obtain a bi-facial panel, having a substantially sandwich structure, with sound insulation or sound absorption function on both sides of the panel 1.
[0064] In accordance with both aspects mentioned, the panel 1 comprises a further intermediate layer 9, or second intermediate layer, interposed between the base layer 2 and the second cladding layer 8 and at least in part configured to fasten the base layer 2 to the second cladding layer 8. Preferably, the second intermediate layer 9 comprises a second adhesive layer 10 made of adhesive material and adapted to adhere the base layer 2 to the second cladding layer 8. Still preferably, the second intermediate layer 9 comprises a second reinforcement layer 9a constrained to an inner surface, not visible in the attached figures, of the second cladding layer 8 to increase its compression strength.
[0065] It should be noted that the second cladding layer 8 and the second intermediate layer 9 can have one or more of the technical characteristics set out above relating to the cladding layer 3 and the intermediate layer 4, respectively. By way of example, in the event that the panel has a further plurality of holes obtained on the second cladding layer 8 and on the second reinforcement layer 9a, the second intermediate layer 9 may comprise a second barrier layer 9b interposed between the second cladding layer 8 and the second reinforcement layer 9a, and in more detail between the second adhesive layer 10 and the second reinforcement layer 9a. It should therefore be noted that these layers have the same advantages explained above.
[0066] Still by way of example, the second cladding layer 8 and / or the second reinforcement layer 9a can be made of flame-retardant type material and / or of material treated with flame-retardant treatment.
[0067] In alternative embodiments, this second barrier layer 9b may be absent.
[0068] Optionally, the panel 1 of the present invention has a surface cladding layer, not illustrated, placed on the cladding layer 3 and / or on the further cladding layer 8. The surface cladding layer comprises a surface finish and / or a geometric pattern, obtainable for example by surface processing techniques of the second material. Alternatively, the surface cladding layer comprises a film of paint that can be obtained, for example, by a painting process.
[0069] According to one aspect of the invention, the panel 1 has an overall thickness of from 0.5 cm to 10 cm, more preferably of from 0.7 cm to 7 cm, even more preferably of from 0.7 cm to 3.5 cm.
[0070] According to the preferred embodiment of the invention, the panel 1 of the present invention is obtained by means of a thermoforming process comprising at least the step of applying a thermal gradient and the step of applying a compression force perpendicular to the layers of the panel 1, capable of fastening the layers of the panel 1 together and of imposing a predetermined geometry on the cladding layer 3 and / or on the base layer 2 and, for the bi-facial panel, on the further cladding layer 8, as described below.
[0071] It should therefore be noted that the base layer 2 is fastened to the cladding layer 3 by means of the aforesaid thermoforming process. In further detail, the cladding layer 3 and the further cladding layer 8 are both fastened to the base layer 2 by the thermoforming process.
[0072] A further object of the present invention is a thermoforming process for manufacturing a panel for soundproofing an environment, and in particular for a panel 1 according to the present description.
[0073] The process comprises the step of providing a main layer 20 of sound-absorbing material. Preferably, the sound-absorbing material of the main layer 20 comprises an expanded polymer, more preferably a polyester.
[0074] The process comprises the step of placing an intermediate layer 40, comprising an adhesive layer 60 on a first surface 20a of the main layer 20. It is to be noted that the intermediate layer 40 may have any of the technical features set forth in the present description in relation to the intermediate layer 4 of the panel 1.
[0075] The process comprises the step of placing a cladding layer 30 on the intermediate layer 40 to define a semi-finished panel 50, illustrated in figure 4b, having a first thickness.
[0076] Preferably, prior to said step, the process provides for constraining a reinforcement layer 50a to the cladding layer 30 configured to increase its compressive strength. Advantageously, the reinforcement layer 50a allows the cladding layer 30 to be made more ductile, avoiding breakage during the further process steps described below.
[0077] The reinforcement layer 50a comprises a layer of textile material, preferably continuous, more preferably a layer of woven fibre fabric. Note that this reinforcement layer 50a uniformly covers the cladding layer 30.
[0078] Note that the cladding layer 30 is positioned on the intermediate layer 40 so as to contact the reinforcement layer 50a with the adhesive layer 60 of the intermediate layer 40.
[0079] According to one embodiment, prior to the step of placing the cladding layer 30 on the intermediate layer 40, the process comprises the step of perforating the cladding layer 30 and, optionally, the reinforcement layer 50a.
[0080] It should be noted that, in the presence of a cladding layer 30 and a reinforcement layer 50a, the process, before placing the cladding layer 30, optionally comprises the step of placing a barrier layer on the adhesive layer 60.
[0081] According to an alternative embodiment, the step of perforating the cladding layer 30 takes place subsequent to the further process steps described below. In such an embodiment, the semi-finished panel 50 does not require a barrier layer.
[0082] The process of the present invention thus comprises the step of compressing the semi-finished panel 50 by applying a thermal gradient at least on the cladding layer 30 to define a panel 1 having a second thickness less than the first thickness.
[0083] It should be noted that the process of the present invention is capable of allowing the fastening of two or more different materials by hot-melt of the adhesive layer.
[0084] It should be noted that for the purposes of the present description, prior to the step of compressing the semi-finished panel 50, the adhesive layer 60 is defined by an actual adhesive layer, having its own thickness, interposed between the main layer 20 and the reinforcement layer 50a, or alternatively between the main layer 20 and the barrier layer 50b, if present.
[0085] During compression of the semi-finished panel 50, the adhesive layer 60 partially or totally penetrates into the adjacent layers. After compression, therefore, the adhesive layer 60 is identifiable as the line of separation between the aforementioned layers.
[0086] According to the preferred aspect, the step of compressing the semi-finished panel 50 comprises the substep of imparting to the main layer 20 and / or to the cladding layer 30 a predetermined geometry, or shape.
[0087] Preferably, the step of compressing the semi-finished panel 50 comprises using a mould of a geometry corresponding to the negative of the predetermined geometry. It should be noted that this mould is adapted to compress the semi-finished panel 50, applying a thermal gradient, so as to join the different layers of the semi-finished panel 50 together and imprint the predetermined geometry.
[0088] More in detail, the step of compressing the semi-finished panel 50 provides for deforming the main layer 20, having a first density, reducing its volume, and in particular its thickness, to obtain a base layer 2 having a second density higher than the first density and having a reduced thickness with respect to the thickness of the main layer 20, in such a way as to impart the predetermined geometry to the main layer 20 and / or to the cladding layer 30. By way of example only, by means of the process of the present invention it is possible to switch from a semi-finished panel 50 having a total thickness of 10 cm to a panel 1 for soundproofing an environment having a total thickness of 2 cm.
[0089] Note that the main layer 20 undergoes a change in physical, acoustic and mechanical properties, acquiring a better sound-absorbing capacity.
[0090] According to one aspect, during hot compression, the adhesive layer 60 of the intermediate layer 40 is at least partly softened and / or melted and / or absorbed by the main layer 20 and / or the cladding layer 30 and, in particular, by the reinforcement layer 50a.
[0091] Preferably, after the step of compressing the semi-finished panel 50, the process comprises the step of perforating the cladding layer 30, and optionally the reinforcement layer 50a.
[0092] According to one embodiment, before the step of providing the main layer 20, the process comprises the step of providing a further cladding layer 80. The process further comprises the step of placing a further intermediate layer, not illustrated, on the further cladding layer 80. Consequently, the process involves placing the main layer 20 on the further intermediate layer. It is noted that for manufacturing a bi-facial system, the process substantially comprises the same steps both for the lower layers and for the layers above the main layer 20, the order of which is adapted to the final structure of the panel 1 to be manufactured.
[0093] According to the same embodiment, the step of compressing the semi-finished panel 50 provides for applying a thermal gradient on the cladding layer 30 and / or on the main layer 20 and / or on further layers placed below the main layer 20, i.e. in the opposite direction with respect to the cladding layer 30, for example the further cladding layer 80. In particular, the thermal gradient can be applied on both faces of the semifinished panel 50 to obtain a bi-facial type panel 1.
[0094] According to one embodiment, the process of the present invention provides for thermally deforming at least the cladding layer 30, and preferably also the main layer 20, according to one or more surface geometries shown, for example, in the attached figures 5a-5h.
[0095] In further detail, it should be noted that the use of unstructured, veneered or laminated wood as the material constituting the cladding layer 30, thanks to its excellent elastic properties and its high resistance to flexion and torsion, advantageously makes it possible to obtain a plastic deformation of the cladding layer 30 according to complex geometries. It should be noted that the process of the present invention can be applied to semi-finished panels 50 of large dimensions, suitable for cladding one or more walls. Advantageously, it is therefore possible to obtain panels 1 for the soundproofing of an environment that do not require joints or connection means. It should also be noted that the thermoforming process of the present invention makes it possible not only to connect and constrain the different layers of the panel 1 to each other, but also to impart at the same time a predetermined geometry to the panel, deforming the main layer 20 and the cladding layer 30, as shown in Figures 4a-4c. It should be noted that this deformation allows the predetermined geometry to be obtained without causing the breakage or damage of one of the two aforementioned layers thanks to the high flexibility of the materials used and thanks to the increase in compressive strength conferred on the cladding layer 30 by the reinforcement layer 50a.
Claims
CLAIMS1. Panel (1) for soundproofing an environment, comprising:- a base layer (2) in a first material, the first material being of the sound-absorbing type;- at least one cladding layer (3) made of a second material different from the first material and placed on the base layer (2), the cladding layer (3) having an inner surface (3a) facing the base layer (2) and an opposite outer surface (3b) configured to face a noise source to absorb and / or block sound waves generated by the noise source;- an intermediate layer (4) interposed between the base layer (2) and the cladding layer (3) and at least partly configured to fasten the base layer (2) to the cladding layer (3),- the intermediate layer (4) comprises a reinforcement layer (5a) constrained to the inner surface (3a) of the cladding layer (3); characterized in that:- the reinforcement layer (5a) comprises a layer in textile material and is configured to increase the compression resistance of the cladding layer (3),- the second material of the cladding layer being defined by veneered or unstructured wood or laminate.
2. Panel (1) according to claim 1, wherein the reinforcement layer (5a) comprises a continuous layer of textile material.
3. Panel (1) according to claim 1 or 2, further having a plurality of holes (7) obtained at least on the cladding layer (3), the holes (7) being configured to diffuse the sound waves generated by the noise source, the base layer (2) being configured to absorb the sound waves through the plurality of holes.
4. Panel (1) according to claim 3, wherein the plurality of holes (7) is obtained at least on the reinforcement layer (5a), the intermediate layer (4) comprising an adhesive layer(6) and a sound-transparent barrier layer (5b) interposed between the adhesive layer (6) and the cladding layer (3), the barrier layer (5b) having at least one substantially continuous surface.
5. Panel (1) according to claim 1, wherein at least the outer surface (3b) of the cladding layer (3) is substantially free of holes, the cladding layer (3) being configured to block the sound waves generated by the noise source and acoustically insulate the room.
6. Panel (1) according to any one of the preceding claims, wherein the base layer (2) is fixed to the cladding layer (3) by means of a thermoforming process.
7. Panel (1) according to any one of the preceding claims, wherein:- the first material of the base layer (2) is defined by a polymeric material, preferably polyester.
8. Panel (1) according to any one of the preceding claims, having a thickness comprised between 0.5 and 10 cm, preferably between 0.7 and 3.5 cm.
9. Panel (1) according to any one of the preceding claims, wherein the base layer (2) has a first surface (2a) facing the inner surface (3a) of the cladding layer (3) and a second surface (2b) opposite the first surface (2a), the panel (1) comprising:- a further cladding layer (8) placed on the second surface (2b) of the base layer (2),- a further intermediate layer (9) interposed between the base layer (2) and the further cladding layer (8) and at least partly configured to fasten the base layer (2) to the further cladding layer (8).
10. Panel (1) according to any one of the claims from 1 to 9, wherein one or more from:the first material of the base layer (2), the second material of the cladding layer (3) and the material of the reinforcement layer (5a) are of the flame-retardant type and / or treated with flame-retardant treatment.
11. Panel (1) according to any one of the claims from 1 to 10, obtained by means of a thermoforming process comprising at least the step of applying a thermal gradient and the step of applying a compression force perpendicular to the layers of the panel (1), capable of binding the layers of the panel (1) together and of applying a predetermined geometry onto the cladding layer (3) and / or onto the base layer (2).
12. Thermoforming process for making a panel (1) for soundproofing an environment, the process comprising the steps of- providing a main layer (20) of sound-absorbing material;- positioning an intermediate layer (40) comprising an adhesive layer (60) on a first surface (20a) of the main layer (20);- positioning a coating layer (30) over the intermediate layer (40) to define a semifinished panel (50) having a first thickness;- binding a reinforcement layer (50a) in textile material to the coating layer (30), the reinforcement layer (50a) being configured to increase the compression resistance of the cladding layer (30);- compressing the semi-finished panel (50) by applying a thermal gradient to at least the cladding layer (30) and / or the main layer (20) and defining a panel (1) having a second thickness less than the first thickness.
13. Thermoforming process according to the preceding claim, wherein the step of compressing the semi-finished panel (50) comprises the sub-step of imparting a predetermined geometry to the main layer (20) and / or to the cladding layer (30).
14. Thermoforming process according to the preceding claim, wherein the main layer (20) has a first density, the compression step of the semi-finished panel (50) comprising the sub-step of deforming the main layer (20), reducing the volume thereof to obtain a base layer (2) having a second density higher than the first density and imparting a predetermined geometry to the main layer (20) and / or to the cladding layer (30).
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Acoustic Pannelling Part for a Vehicle
US20100019416A1
Architectural resin panels with translucent veneer layers
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Micro-perforated wood veneer acoustic panel
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