Coverings and methods of making the same

Abstract

There is disclosed herein a panel system comprising a core comprising polyester felt; a covering shaped and configured to overlay the core; an adhesive interposed between the covering and the core to bind the covering to the core; one or more grooves defined in the core and shaped and configured to permit movement of one segment of the core relative to another segment of the core to move the core from an unfolded configuration to a folded configuration; wherein the covering is provided with a plurality of microperforations. Also disclosed are methods of fabricating such panels, and the use of such panels.

Description

[0001] COVERINGS AND METHODS OF MAKING THE SAME

[0002] Field:

[0003] The present disclosure relates generally to acoustical panels, coverings for those and other products; and, more specifically, to improved acoustical panels, coverings, methods of adhering the same, and methods of manufacturing such products.

[0004] Background:

[0005] Polyester felt (“PET Felt”) has high acoustic qualities, can be made into many shapes without extreme difficulty, is lightweight and can be produced as a 'Class A' fire-rated material. As such, it is a popular material for use in creating products including, for example, ceiling baffles, ceiling panels, wall panels.

[0006] Metals, such as aluminum, also exhibit advantageous properties for use in similar applications and articles Particular advantages of metals include rigidity and structural stability, and shaping.

[0007] In such applications and generally irrespective of panelling material, it is desirable to achieve the appearance of real wood while maintaining the advantageous properties noted above. However, known methods of achieving to achieve an at least somewhat authentic wood appearance are lacking. In PET felt applications, the felt board must be direct printed or heat transfer printed. These effects are not tremendously realistic in terms of wood-like appearance. Further, in metal embodiments, coverings lending themselves to suitable appearance have the same adhesive issues and are lacking in noise dampening.

[0008] There are known microperforated veneer coverings that are laminated to a fibreglass or mineral wool core; but, notably, not PET felt as it is relatively new to the Architectural / Decorative industry, and its uneven surface texture makes it difficult / undesirable to laminate space (which is a known method of production). In such articles, a core is impregnated with a resin prior to the veneer being laminated. Such articles are complex and typically rather expensive. Further, while exhibiting high-quality acoustical properties, aesthetic features and fire-resistance are not typically achieved to any significant degree.

[0009] Known microperforated veneers are limited to veneer surfaces and are a function of expensive processes. These also do not include perforated material on all surfaces; edges thereof commonly feature solid edge banding. In order to put the edge banding on the panel, the edge of the core (fibreglass or mineral fibre) has to be filled or sealed with a resin for the edge banding to have a solid surface to adhere to. It is a labour intensive process resulting in an expensive product. Also, this product required post-finishing (after fabrication is complete) prior to use.

[0010] U.S. Patent No. 10,132,087 discloses a panelling system; however, this is limited in applicability to flat panels and does not disclose fabrication into 3D shapes like baffles and ceiling clouds, or other even moderately complex geometries. Also, it appears that the adhesive / lamination process does not use a heat press, which our process does and helps to smooth the core material.

[0011] As such, there is a need for products and methods that alleviate or ameliorate one or more of the above-mentioned issues.

[0012] Brief Summary:

[0013] There is disclosed herein a panel system comprising a core comprising polyester felt; a covering shaped and configured to overlay the core; an adhesive interposed between the covering and the core to bind the covering to the core; one or more grooves defined in the core and shaped and configured to permit movement of one segment of the core relative to another segment of the core to move the core from an unfolded configuration to a folded configuration; wherein the covering is provided with a plurality of microperforations.

[0014] In another disclosed embodiment, the grooves comprises two grooves.

[0015] In another disclosed embodiment, the two grooves are linear, parallel to one another and position equidistant from and on opposite sides of a long axis of the core.

[0016] In another disclosed embodiment, the grooves comprises four grooves.

[0017] In another disclosed embodiment, the microperforations are circular, semi-circular, trapezoidal, hexagonal, square in shape.

[0018] In another disclosed embodiment, each perforation has a cross-sectional area less than 1mm2.

[0019] In another disclosed embodiment, the cross-sectional area of each of the perforations is substantially uniform.

[0020] In another disclosed embodiment, the four grooves comprise a first pair of grooves and a second pair of grooves.

[0021] In another disclosed embodiment, the first pair is oriented perpendicular to the second pair, and the first pair intersects with the second at four comers of an inner section of the core.

[0022] In another disclosed embodiment, the folded configuration comprises four outer segments of the core each folded to be perpendicular to the central segment.

[0023] In another disclosed embodiment, the core has a rigidity level and wherein performance of the core may be varied as a function of the rigidity level. In another disclosed embodiment, the folded configuration comprises the core appearing to have a substantially u-shaped cross-section.

[0024] In another disclosed embodiment, the cross-sectional profile of the core is maintained via an adhesive.

[0025] In another disclosed embodiment, the core adhesive comprises a cyanoacrylate adhesive.

[0026] In another disclosed embodiment, the core adhesive comprises a plurality of pin nails.

[0027] There is also disclosed herein methods for fabricating a panel. The methods include: a. adhering a covering to one or more surfaces of a polyester felt core; b. shaping the covering and core; c. defining in the covering and core one or more grooves; d. folding the covering and core about the grooves to form a panel.

[0028] In another disclosed embodiment, the adhering comprises heat pressing the covering to the core with a heat-activated adhesive interposed between the covering and the core.

[0029] In another disclosed embodiment, the shaping comprises cutting the core and covering to a desired shape.

[0030] In another disclosed embodiment, the cutting comprises computer numeric controlled (CNC) machined cutting.

[0031] In another disclosed embodiment, the defining comprises CNC knife cutting.

[0032] In another disclosed embodiment, more frequent perforations and larger perforations are provided (for better acoustic absorption). In another disclosed embodiment, smaller perforations are provided for less noticeable appearance at distance, with spacing decreased to achieve good acoustic functionality.

[0033] There is also disclosed herein use of panel systems as disclosed herein the microperforations continue around the visible faces of the panel or baffle, by way of grooving the back.

[0034] Detailed Description:

[0035] Methods disclosed herein comprise adhering decorative vinyl and / or real wood veneer to, for example and without limitation, a non-woven polyester (PET felt) board. The board is then machined and fabricated into, for example and without limitation, ceiling baffles, ceiling and wall panels and other decorative products.

[0036] The coverings and methods of deploying the same disclosed herein add the benefits of a real, or significantly more realistic, wood finish to a product that has qualities not present in real wood.

[0037] Methods and systems herein disclosed include v-notching and folding a laminated panel in order to create what may be described as a ‘self edge’ comprising a continuous covering. This eliminates any need for additional edge banding. It also allows the microperforated face to be present substantially continuously around the edge of the panel or baffle or other dimensional design. This increases the surface area of microperforation, which increases sound permeability of the article. Appearance of the article is also maintained, in that the edge banding makes wood or other finishes look plainly less authentic.

[0038] The disclosed systems and methods also facilitate simplified manufacturing, and necessitate less layering of materials. There is also the possibility hereunder of using prefinished materials, eliminating expensive post-finishing processes. Embodiments including a heat activated glue and a heated platen press, will flatten the initial texture of the core material and result in a smoother finish than a cold laminated process.

[0039] Methods include providing: a PET core, a film veneer or backer sized to a first surface of the core, an adhesive sheet interposed between the veneer and the first surface. There may additionally be provided a second film veneer or backer sized to a second surface of the core (which may be substantially opposite the first surface).

[0040] Each veneer is that heat pressed to the core such that the adhesive sheet bonds each veneer to the core. In some embodiments, each veneer may be cold-pressed with a contact cement adhesive or other cold process adhesive. Some embodiments may require thicker laminates to mitigate the uneven surface texture of the PET.

[0041] Grooves are then cut from one of the surfaces. The size, number and orientations of the grooves dictates the shapes to which the laminated felt article may be folded. For example, and as shown in Fig. 4, linear grooves equidistant from a long axis of the article permit folding into a substantially U — shaped cross-section. In the article of Fig. 4, a sound absorbing material is inserted into the channel formed when the article is folded into its U- shaped cross-section. In some embodiments, there may also be provided a channel formed to enable use of suspension hardware (i.e., to suspend the article from height).

[0042] Other groove configurations may permit shaping of different articles. For example and without limitation, as shown in Fig. 2, cutting notches from the comers of a rectangular article and cutting grooves to join such notches permits formation into a box or trough shape. One skilled in the art will appreciate that systems and methods provided herein permit groove cutting and article formation of many shapes (such as the numerous configurations shown in Fig. 2). Figure one schematically represents steps in exemplary methods disclosed herein.

[0043] As shown in Figs 3A-3B, there may be provided different product shapings. Shown in Fig 3A and Fig 3B is a tambour configuration, comprise of essentially semi-circular sections adjacent, with convex sides facing in the same direction and fastened at their concave sides. The covering may be formed in a unitary or multiple pieces.

[0044] The covering may be paced over backing with larger holes (of various shapes) in it than in the covering to balance acoustic absorption and aesthetic considerations.

[0045] As shown in Fig 4, there may be provided baffles in substantially u-shaped crosssections, with perforations of varying shapes and locations. These are provided for rigidity in certain embodiments. The covering in such embodiments may continuously cover the baffle.

[0046] In some embodiments, baffles or panels can be fastened into / onto a frame or backpanel, to make a ‘cassette’ or to supplement a larger architectural product. For example and without limitation, several baffles could be fastened to a backpanel prior to installation in order to save the separate installation of each individual baffle. The decorative panels can also be laid into a t-bar grid configuration and employed in place of a wool ceiling tile.

[0047] While various embodiments in accordance with the principles disclosed herein have been described above, it should be understood that they have been presented by way of example only, and are not limiting. Thus, the breadth and scope of the invention(s) should not be limited by any of the above-described exemplary embodiments, but should be defined only in accordance with the claims and their equivalents issuing from this disclosure. Furthermore, the above advantages and features are provided in described embodiments, but shall not limit the application of such issued claims to processes and structures accomplishing any or all of the above advantages.

[0048] It will be understood that the principal features of this disclosure can be employed in various embodiments without departing from the scope of the disclosure. Those skilled in the art will recognize, or be able to ascertain using no more than routine experimentation, numerous equivalents to the specific procedures described herein. Such equivalents are considered to be within the scope of this disclosure and are covered by the claims. Additionally, the section headings herein are provided as organizational cues. These headings shall not limit or characterize the invention(s) set out in any claims that may issue from this disclosure. Specifically, and by way of example, although the headings refer to a “Field” such claims should not be limited by the language under this heading to describe the so-called technical field. Further, a description of technology in the “Background” section is not to be construed as an admission that technology is prior art to any invention(s) in this disclosure. Neither is the “Brief Summary” to be considered a characterization of the invention(s) set forth in issued claims. Furthermore, any reference in this disclosure to “invention” in the singular should not be used to argue that there is only a single point of novelty in this disclosure. Multiple inventions may be set forth according to the limitations of the multiple claims issuing from this disclosure, and such claims accordingly define the invention(s), and their equivalents, that are protected thereby. In all instances, the scope of such claims shall be considered on their own merits in light of this disclosure, but should not be constrained by the headings set forth herein.

[0049] The use of the word “a” or “an” when used in conjunction with the term “comprising” in the claims and / or the specification may mean “one,” but it is also consistent with the meaning of “one or more,” “at least one,” and “one or more than one.” The use of the term “or” in the claims is used to mean “and / or” unless explicitly indicated to refer to alternatives only or the alternatives are mutually exclusive, although the disclosure supports a definition that refers to only alternatives and “and / or.” Throughout this application, the term “about” is used to indicate that a value includes the inherent variation of error for the device, the method being employed to determine the value, or the variation that exists among the study subjects.

[0050] As used in this specification and claim(s), the words “comprising” (and any form of comprising, such as “comprise” and “comprises”), “having” (and any form of having, such as “have” and “has”), “including” (and any form of including, such as “includes” and “include”) or “containing” (and any form of containing, such as “contains” and “contain”) are inclusive or open-ended and do not exclude additional, un-recited elements or method steps.

[0051] As used herein, words of approximation such as, without limitation, “about”, “substantial” or “substantially” refers to a condition that when so modified is understood to not necessarily be absolute or perfect but would be considered close enough to those of ordinary skill in the art to warrant designating the condition as being present. The extent to which the description may vary will depend on how great a change can be instituted and still have one of ordinary skilled in the art recognize the modified feature as still having the required characteristics and capabilities of the unmodified feature. In general, but subject to the preceding discussion, a numerical value herein that is modified by a word of approximation such as “about” may vary from the stated value by at least ±1, 2, 3, 4, 5, 6, 7, 10, 12 or 15%.

[0052] The term “or combinations thereof’ as used herein refers to all permutations and combinations of the listed items preceding the term. For example, “A, B, C, or combinations thereof is intended to include at least one of: A, B, C, AB, AC, BC, or ABC, and if order is important in a particular context, also BA, CA, CB, CBA, BCA, ACB, BAC, or CAB. Continuing with this example, expressly included are combinations that contain repeats of one or more item or term, such as BB, AAA, AB, BBC, AAABCCCC, CBBAAA, CAB ABB, and so forth. The skilled artisan will understand that typically there is no limit on the number of items or terms in any combination, unless otherwise apparent from the context.

[0053] All of the compositions and / or methods disclosed and claimed herein can be made and executed without undue experimentation in light of the present disclosure. While the compositions and methods of this disclosure have been described in terms of preferred embodiments, it will be apparent to those of skill in the art that variations may be applied to the compositions and / or methods and in the steps or in the sequence of steps of the method described herein without departing from the concept, spirit and scope of the disclosure. All such similar substitutes and modifications apparent to those skilled in the art are deemed to be within the spirit, scope and concept of the present disclosure including the appended claims.

Claims

Claims:

1. A panel system comprising: a. a core comprising polyester felt; b. a covering shaped and configured to overlay the core; c. an adhesive interposed between the covering and the core to bind the covering to the core; d. one or more grooves defined in the core and shaped and configured to permit movement of one segment of the core relative to another segment of the core to move the core from an unfolded configuration to a folded configuration; wherein the covering is provided with a plurality of microperforations; with the shape, number, diameter, spacing of the microperforations may be varied from embodiment to embodiment.

2. A system according to claim 3, wherein the grooves comprises two grooves.

3. A system according to claim 4, wherein the two grooves are linear, parallel to one another and position equidistant from and on opposite sides of a long axis of the core.

4. A system according to claim 3, wherein the grooves comprises four grooves.

5. A system according to claim 6, wherein the four grooves comprise a first pair of grooves and a second pair of grooves; wherein the first pair is oriented perpendicular to the second pair, and the first pair intersects with the second at four comers of an inner section of the core.

6. A system according to claim 7, wherein the folded configuration comprises four outer segments of the core each folded to be perpendicular to the central segment.

7. A system according to claim 1, wherein the openings are substantially all of or a mix of circular, triangular, square, oval; and wherein the openings are of all the name or a variety of cross-sectional areas.

8. A system according to claim 3, wherein the core has different densities which affect rigidity and acoustic properties.

9. A system according to claim 5, wherein the folded configuration comprises the core appearing to have a substantially u-shaped cross-section, with the fold maintained via hot melt adhesive or other adhesives (e.g., Cyanoacrylate), Pin nails.

10. A method for fabricating a panel, the method comprising: a. adhering a covering to one or more surfaces of a polyester felt core; b. shaping the covering and core; c. defining in the covering and core one or more grooves; d. folding the covering and core about the grooves to form a panel.

11. A method according to claim 12, wherein the adhering comprises heat pressing the covering to the core with a heat-activated adhesive interposed between the covering and the core.

12. A method according to claim 12, wherein the shaping comprises cutting the core and covering to a desired shape.

13. A method according to claim 12, wherein the defining comprises CNC knife-cut.

14. A system according to claim 1, wherein the core externally presents multiple faces and the perforations are present one more than one of the faces.

15. A system according to claim 1, wherein the perforations are present throughout substantially the entirety of the surface of the covering.

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