Building panel adapted to be mounted at a ceiling or wall of a room and method of manufacturing such building panel

Abstract

A textile or foil is extended between frame profile members (6) and edges thereof are fixed to a building-facing side of the frame profile members. Neighbouring frame profile members are connected at corners of the panel (1). Each corner has a slot (13) formed between opposed parts of the corner and extending at an oblique angle in relation to each one of the neighbouring frame profile members. Each corner forms an internal cavity extending laterally from either side of the slot of the corner behind opposed wall parts (18, 19) of the corner arranged at either side of the slot. A resilient member (16) is attached to the corner and extends at either side of the slot in the internal cavity of the corner of the panel, and the resilient member is adapted to retain excess textile at either side of the slot in the internal cavity of the corner.

Description

[0001] BUILDING PANEL ADAPTED TO BE MOUNTED AT A CEILING OR WALL OF A ROOM AND METHOD OF MANUFACTURING SUCH BUILDING PANEL

[0002] The present invention relates to a building panel adapted to be mounted at a ceiling or wall of a room so that a framework of the building panel has a room-facing side and a building-facing side, wherein the framework includes a peripheral frame formed by frame profile members, wherein a textile or foil is extended in a tensioned state over the room-facing side of the framework between the frame profile members, wherein each frame profile member has an outer edge connecting a room-facing side of the frame profile member with a building-facing side of the frame profile member, wherein the textile is bent about the outer edges of the frame profile members, wherein edges of the textile are fixed to the building-facing side of the respective frame profile members, wherein neighbouring frame profile members are connected to each other at respective corners of the panel, wherein each corner has a slot formed between opposed parts of the corner and extending at an oblique angle in relation to each one of the neighbouring frame profile members, wherein excess textile at a respective corner of the panel is inserted into the slot of the corner, and wherein a resilient member is arranged to, at least temporarily, retain the excess textile.

[0003] EP 1 559846 Al discloses a panel for a suspended ceiling or the like, comprising a rigid frame defining an open region covered by fabric. The frame is composed of lateral edge portions and end portions joined by corner portions. The frame is at least along portions of its periphery provided with laterally displaceable attachment members accessible from outside the frame for attachment of the fabric to the frame, where a lateral displacement of said members away from the lower peripheral edge portion of the frame results in tensioning of the fabric across the open region of the frame. The fastening of the fabric to the laterally displaceable attachment member is accomplished by means of a resilient clip inserted into a groove of the attachment member so that the fabric is pinched and thereby secured in the groove by the resilient clip. Each corner portion is provided with extensions for insertion into respective profiles of the lateral edge portions and the end portions of the frame. In order to facilitate attachment of the fabric to the corner portion, the corner portion is provided with a groove formed at a mitre angle for insertion of a corner portion of the fabric, and this portion of the fabric can furthermore be retained in the groove by means of a resilient member, for instance a piece of flexible cord of a suitable diameter. Other retaining means may be used, such as glue. However, it may not be easy to fit all the excess fabric at the corner of the panel into the groove of the corner portion. One possibility of solving this challenge may be to cut away part of the excess fabric and inserting the remaining part of the excess fabric into the groove. In this case, it may be preferred retaining the fabric in the groove by means of glue. In any case, by cutting the fabric into shape at the corner, it may not be possible to mount the same piece of fabric once again, e.g. after washing the fabric, because the edge of the fabric may have been exactly fitted to the corner of the panel and this fitting method requires a certain amount of excess fabric.

[0004] EP 3 081 113 Bl discloses a furnishing element comprising a frame having at least a first and a second wall incident to each other so as to identify an edge. A coating is associated with and superposed on said frame so as to coat at least partially said walls and said edge. The frame, at said edge, comprises an attachment element which delimits an attachment seat open in the vicinity of said first and second wall. The coating comprises at least two flaps folded and inserted inside the attachment seat, wherein the attachment seat blocks the flaps inside it against inner walls of the seat, for instance by means of teeth provided on the inner walls of the seat. The attachment element is an applied element and joined to the first and second walls of the frame at the edge identified thereby. However, in case of a relatively thicker coating, it may not be easy to fit the coating at the corner into the attachment seat. Furthermore, because the coating is cut into shape at the corner, it may not be possible to mount the same piece of coating once again, e.g. after washing the coating, because the edge of the coating may have been exactly fitted to the corner of the frame and this fitting method requires a certain amount of excess coating.

[0005] JP 2018-103582 A discloses a wall panel where a textile is stretched over a front side of a frame. The textile is attached to the frame by folding it about a peripheral edge of the frame and pressing a string or an elongated element into a groove of the back of the frame so that the textile is pressed into the groove. At the corners of the frame, excess fabric is pressed down into an inclined groove by means of a spatula. However, in case of a relatively thicker fabric, it may not be easy to fit the excess fabric at the corner into the inclined groove, and it may not be easy to remount the fabric on the frame.

[0006] GB 1 574013 describes a method of fixing textile to a wall in a similar way as described just above, whereby the textile is, however, retained in an inner locking groove and an outer secondary groove of a frame. The frame is composed by side and end frame elements connected by means of separate corner pieces. Each corner piece has an inclined groove connecting the inner and outer groove and serving to store excess textile at the corner. However, in case of a relatively thinner frame and a relatively thicker textile, it may not be easy to fit the excess fabric at the corner into the inclined groove.

[0007] US 4,920,714 describes attachment of a flexible covering material to a wall, whereby a peripheral frame has a longitudinal groove provided with pinching means in order to clamp the flexible covering material in the groove. At the corners of the frame, excess covering material is pressed into an inclined groove formed at a mitre angle of each corner. Separate corner pieces of the frame are provided which may form different angles than a right angle and which may even be rounded. However, in case of a relatively thinner frame and a relatively thicker flexible covering material, it may not be easy to fit the excess flexible covering material at the corner into the inclined groove.

[0008] WO 2017 / 196480 Al relates to stretching fabric over a frame, particularly in uses within the graphic arts. A frame for maintaining a region of a fabric piece in a substantially planar state comprises a plurality of rails preferably made of wood, each of said rails having a geometrical profile extended in a linear direction, said rails each having a first end face and a second end face, and a plurality of corner pieces. Each of said corner pieces includes a slot formed partially through said corner piece at a mitre angle to receive a pleat of surplus fabric formed when two areas of said fabric piece are turned along at seams at right angles to one another into an upright condition departing from the primary plane establishing the planar state of said fabric piece. However, in case of a relatively thinner frame and a relatively thicker fabric, it may not be easy to fit the excess fabric at the corner into said slot, and it may not be easy to remount the fabric on the frame.

[0009] The object of the present invention is to provide a building panel facilitating smooth fitting of the fabric at the corner and allowing easy removal and subsequent refitting of the tensioned textile.

[0010] In view of this object, each corner forms an internal cavity extending laterally from either side of at least part of the length of the slot of the corner behind opposed wall parts of the corner arranged at either side of the slot, the resilient member is attached to the corner and extends at either side of the slot in the internal cavity of the corner of the panel, and the resilient member is adapted to retain at least part of the excess textile at either side of the slot in the internal cavity of the corner of the panel.

[0011] In this way, by attaching the resilient member to the corner and adapting the resilient member to retain at least part of the excess textile or foil at either side of the slot in the internal cavity of the corner of the panel, it may be possible taking up and retaining, at least a major part of the excess textile at the corner, thereby ensuring a smooth finish of the textile and further allowing easy removal and subsequent refitting of the tensioned textile.

[0012] In a structurally particularly advantageous embodiment, the resilient member is adapted to pinch the at least part of the excess textile at either side of the slot between the resilient member and an internal face of the internal cavity of the corner. Alternatively, the resilient member may form a channel in which the textile may be inserted.

[0013] In an embodiment, the resilient member is adapted to pinch the at least part of the excess textile at either side of the slot between the resilient member and an internal side of either one of the opposed wall parts of the corner. In an embodiment, the resilient member is lockingly attached to the corner within the slot of the corner. Thereby, there may be no need to hold the resilient member during insertion of the textile.

[0014] In an embodiment, the resilient member is attached to the corner by means of a pin and / or screw engaging a hole in the resilient member.

[0015] In an embodiment, the resilient member has the form of a piece of sheet metal having a rounded cross-section seen in the direction of the slot. Thereby, a first part of the resilient member may abut an upper face of the internal cavity, and a second part of the resilient member may abut a lower face of the internal cavity.

[0016] In an embodiment, the resilient member has the form of a piece of sheet metal having a wave formed cross-section seen in the direction of the slot. Thereby, one or more crests of the waveform may abut an upper face of the internal cavity, and one or more troughs of the waveform may abut a lower face of the internal cavity. The textile may be inserted between a crest or a trough of the waveform and a face of the internal cavity. Thereby, a smooth insertion and / or removal of the textile may be ensured.

[0017] In an embodiment, the waveform of the cross-section of the piece of sheet metal has a central crest arranged in the slot, two troughs, and two additional crests arranged in the internal cavity of the corner at either side of the slot. The two additional crests may serve to pinch the textile and the pinching force may in this case be increased by pressing on the central crest, for instance by means of a mounting screw, whereby the central crest will be lowered, and the two troughs will tilt as they abut a lower internal face of the internal cavity, so that the outermost two additional crests will be pressed even more forcefully against an upper face of the internal cavity. The same may happen if the waveform is arranged upside down so that the three crests abut the lower internal face of the internal cavity, and the two troughs abut the upper face of the internal cavity. A pressure may be applied on the central crest simply as a result of inserting the resilient member into the internal cavity, depending on the height of the crest and troughs, respectively. In an embodiment, the resilient member is arranged symmetrically about the slot.

[0018] In an embodiment, a cover plate is fixed at the slot, thereby pinching the textile between the cover plate and edges of the slot formed by either one of the opposed wall parts of the corner. Thereby, an even stronger holding force may be applied permanently on the textile, and the resilient member may in this case serve to temporarily hold the textile in place during fitting of the textile on the panel at either side of the slot.

[0019] In a structurally particularly advantageous embodiment, the cover plate is fixed at the slot by means of a screw inserted through the cover plate and engaging a stud arranged in the slot of the corner, and the stud extends through the resilient member.

[0020] In a structurally particularly advantageous embodiment, neighbouring frame profile members are connected to each other by means of corner pieces forming at least part of the respective corners of the panel, each corner piece, at least together with the neighbouring frame profile members, forms the internal cavity of the respective corner of the panel, and each corner piece forms the opposed wall parts of the corner and the slot therebetween. Thereby assembly of the panel may be facilitated and a precise finish of each corner may be ensured.

[0021] In a structurally particularly advantageous embodiment, each edge of the textile is attached to a corresponding frame profile member by means of at least one tensioning profile member being spring-biased for displacement in a tensioning direction being lateral of said frame profile member for bringing the textile into the tensioned state. Thereby, it may be ensured that the textile is maintained tensioned with an appropriate tensioning force throughout the lifetime of the building panel. According to the present invention, it may be possible taking up and retaining a major and variable part of the excess textile at the corner, and this feature in combination with the spring-biased tensioning profile members may in particular ensure a continued smooth finish of the textile and furthermore allow easy removal and subsequent refitting of the tensioned textile. This is due to the fact that the building panel may in this way offer good flexibility when it comes to the possible overall size of the textile to be mounted, because the size of the textile may change over time, in particular as a result of washing the textile.

[0022] In a structurally particularly advantageous embodiment, each respective frame profile member forms a space between two wall parts, and the at least one tensioning profile member is guided between the two wall parts and spring-biased for displacement in the tensioning direction out of the space formed between the two wall parts. Thereby, each frame profile member may advantageously be formed by bending or roll forming a piece of sheet metal, whereby the outer edge of the frame profile member may be formed as a, preferably rounded, bent connection between the two wall parts each formed by the sheet metal.

[0023] In an embodiment, the internal cavity of each corner of the panel forms a continuation of the spaces formed between the two wall parts of the neighbouring frame profile members of the respective corner. Because a certain depth of the spaces formed between the two wall parts is required for the guidance of the tensioning profile member, the internal cavity of each corner of the panel may therefore have a corresponding certain depth which in turn may allow for even better possibility of taking up and retaining a major part of the excess textile at the corner.

[0024] The present invention further relates to a method of manufacturing a building panel adapted to be mounted at a ceiling or wall of a room so that a framework of the building panel has a room-facing side and a building-facing side. The framework includes a peripheral frame formed by frame profile members, and each frame profile member has an outer edge connecting a room-facing side of the frame profile member with a building-facing side of the frame profile member. A textile or foil is extended to a tensioned state over the room-facing side of the framework between the frame profile members by bending the textile about the outer edges of the frame profile members and by attaching each edge of the textile to a corresponding frame profile member. Neighbouring frame profile members are connected to each other at respective corners of the panel, and excess textile at each respective corner of the panel is inserted into a slot formed between opposed wall parts of the corner and is, at least temporarily, retained by a resilient member.

[0025] The method is characterised by, at each respective corner of the panel, attaching the resilient member to the corner so that it extends at either side of the slot in an internal cavity of the corner of the panel, and pressing at least part of the excess textile laterally from the slot into the internal cavity at either side of the slot so that the at least part of the excess textile is retained by means of the resilient member in the internal cavity. Thereby, the above-mentioned features may be obtained.

[0026] In an embodiment, the resilient member is inserted into the corner by displacement in the direction of the slot, and, preferably, during the insertion, the resilient member flexes at least slightly so that a stud of the corner is inserted lockingly into a hole of the resilient member. Thereby, the above-mentioned features may be obtained.

[0027] In an embodiment, a cover plate is fixed at the slot, thereby pinching the textile between the cover plate and edges of the slot formed by either one of the opposed wall parts of the corner. Thereby, the above-mentioned features may be obtained.

[0028] In an embodiment, the cover plate is fixed at the slot by inserting a screw through the cover plate so that it engages the stud of the corner. Thereby, the above-mentioned features may be obtained.

[0029] In an embodiment, the textile is extended over the room-facing side of the framework between the frame profile members by attaching each edge of the textile to the corresponding frame profile member by means of at least one tensioning profile member and by spring-biasing the tensioning profile member so that it is displaced in a lateral direction of said frame profile member and thereby brings the textile into the tensioned state. Thereby, the above-mentioned features may be obtained.

[0030] The invention will now be explained in more detail below by means of examples of embodiments with reference to the very schematic drawing, in which Fig. 1 is a cross-sectional view through an embodiment of a building panel according to the present invention, however, without the textile or foil applied to the frame;

[0031] Fig. 2 is a detail of Fig. 1 on a larger scale, however, with the textile or foil applied to the frame;

[0032] Fig. 3 is a perspective view of part of two frame profile members and a corner piece, before connection of these part to form the building panel of Fig. 1;

[0033] Fig. 4 is a perspective view of the parts of Fig. 3, after connection of the corner piece with the two frame profile members, but before attachment of a cover plate;

[0034] Fig. 5 is a perspective view corresponding to that of Fig. 4, however, after attachment of the cover plate (it is noted that the textile held by the cover plate is not illustrated);

[0035] Fig. 6 is a perspective view of a corner piece for connecting frame profile members of a building panel according to an embodiment of the present invention;

[0036] Fig. 7 is a top view of the corner piece of Fig. 6;

[0037] Fig. 8 is a side view of the corner piece of Fig. 6;

[0038] Fig. 9 is a perspective view seen from behind of the corner piece of Fig. 6, however, wherein a resilient member has been inserted into the corner piece;

[0039] Fig. 10 is a perspective view of the corner piece with the resilient member as seen in Fig. 9, however, seen from a different angle;

[0040] Fig. 11 is a perspective view of the resilient member of the corner piece as seen in Fig. 10; Fig. 12 is a top view of the resilient member of Fig. 11;

[0041] Fig. 13 is an end view of the resilient member of Fig. 11;

[0042] Fig. 14 is a perspective view seen obliquely from above of the cover plate of the corner piece as seen in Fig. 5;

[0043] Fig. 15 is a perspective view seen obliquely from below of the cover plate of Fig. 14;

[0044] Fig. 16 is a perspective view of the corner part of the peripheral frame of the building panel illustrated in Fig. 4, after placement of the framework of the building panel on a textile to be extended over the room-facing side of the framework;

[0045] Figs. 17 to 22 are perspective views of the corner part and textile illustrated in Fig. 16, illustrating different stages of the procedure of fitting the textile at the corner piece;

[0046] Fig. 23 is a cross-section through the corner piece with fitted textile seen in the direction of the arrow as indicated in Fig. 22; and

[0047] Figs. 24 and 25 are perspective views, seen from different angles of view, of a prior art corner piece for connecting frame profile members of a building panel.

[0048] In the following, generally, similar elements of different embodiments have been designated by the same reference numerals.

[0049] Fig. 1 illustrates an embodiment of a building panel 1 according to the present invention adapted to be mounted at a not shown ceiling or wall of a room so that a framework 2 of the building panel 1 has a room-facing side 3 and a building-facing side 4. For instance, if the building panel 1 as illustrated in Fig. 1 is to be used as a ceiling panel, it may be mounted, oriented as shown, under a permanent ceiling in a building and thereby form a suspended ceiling. The framework 2 includes a peripheral frame 5 formed by frame profile members 6, and a textile 7 or foil is extended in a tensioned state over the room-facing side 3 of the framework 2 between the frame profile members 6. Whereas the textile 7 or foil is not shown in Fig. 1, the textile or foil is shown in Fig. 2 illustrating a detail of Fig. 1, but with the textile 7 or foil added. It is noted that, for acoustic reasons, the peripheral frame 5 may surround one or more not shown batts of mineral wool. The building panel 1 may typically form an acoustic panel.

[0050] Each frame profile member 6 has a preferably rounded outer edge 8 connecting a roomfacing side 9 of the frame profile member 6 with a building-facing side 10 of the frame profile member 6, the textile 7 or foil is bent about the preferably rounded outer edges 8 of the frame profile members 6, and edges 20 of the textile 7 or foil are fixed to the building-facing side 10 of the respective frame profile members 6.

[0051] As seen in Fig. 2, in the illustrated embodiment, each edge 20 of the textile 7 or foil is attached to a corresponding frame profile member 6 by means of at least one tensioning profile member 11 being spring-biased for displacement in a tensioning direction DTbeing lateral of said frame profile member 6 for bringing the textile 7 or foil into the tensioned state. In the illustrated embodiment, the tensioning profile member 11 is spring- biased in the tensioning direction DTby means of an elastic spring 35, preferably a U- formed spring.

[0052] In the embodiment illustrated, as seen in Figs. 2 and 16 to 22, the tensioning profile member 11 has a longitudinal channel 44 with which said edge 20 of the textile 7 or foil is releasably connected. Each edge 20 of the textile 7 or foil is provided with a number of mutually spaced holding elements 45 arranged flexibly in relation to each other along the edge 20 of the textile 7 or foil. Each holding element 45 is adapted for insertion into the longitudinal channel 44 in a lateral insertion direction of the channel, through an opening slot of the channel. As seen, each holding element 45 is, in its final inserted position in the longitudinal channel 44, prevented from free rotation about any longitudinal axis of the channel 44 of the tensioning profile member 11. The holding elements 45 may be fixed directly to the edge 20 of the textile 7 or foil or the holding elements 45 may be fixed to a ribbon 46 mounted on the edge 20 of the textile 7 or foil, for instance by sewing, i.e. a by means of a stitch 47, or it may be attached to the edge 20 by any other suitable means, such as glue. Thereby, cutting the textile 7 or foil to size and mounting the holding elements 45 may be facilitated in that a prefabricated ribbon 46 with holding elements 45 mounted thereon may be used.

[0053] It is noted that the holding elements 45 may, as in the illustrated embodiments, be separate elements mutually spaced and distributed along the respective edge 20 of the textile 7 or foil. Thereby, good flexibility between neighbouring holding elements 45 may be achieved, and the handling of the textile 7 or foil may be easy due to the better flexibility of the edge of the textile provided with holding elements, thereby enabling creasing of the entire piece of textile. Thereby, for instance, washing of the textile 7 or foil in a washing machine may be possible before refitting the textile 7 or foil on the panel 1. Although being separate and possibly spaced elements, the holding elements 45 may be interconnected by means of flexible elements, spring-like elements or the like, in addition to the connection formed between them by means of the edge 20 of the textile 7 or foil or an edge of the ribbon 46.

[0054] Each holding element 45 may have the form of a metal element gripping over a respective edge 20 of the textile 7 or foil or the edge of the ribbon 46 attached to said edge 20 of the textile 7 or foil in the illustrated embodiments.

[0055] The ribbon 46 with the attached holding elements 45 may advantageously have the form of one of the two corresponding zipper tapes of a conventional zipper which are provided with zipper teeth. The zipper tape may be provided with individual pieces of metal moulded into shape and set on the zipper tape at regular intervals. The teeth of metal zippers may for instance be made in brass, aluminium and nickel. However, plastic materials may also be used for the teeth.

[0056] However, the mutually spaced holding elements 11 may alternatively be attached directly to the edge 8 of the textile 7 or foil. In another not shown embodiment, each edge 20 of the textile 7 or foil is provided with a not shown keder for insertion into the longitudinal channel 44 of the tensioning profile member 11. The keder may form a continuous bead or thickened part along the edge 20 of the textile 7 or foil. The keder may be trapped in the longitudinal channel 44 of the tensioning profile member 11 as a result of the tensioning force of the textile 7 or foil, or the keder may pressed into the longitudinal channel 44 by flection of the keder or of the longitudinal channel, and the keder may, possibly additionally, be held in the longitudinal channel 44 by means of friction. Although being generally continuous along the edge 20 of the textile 7 or foil, the keder may be broken at certain positions, thereby forming small spaces between keder sections, in order to ease mounting of the textile 7 or foil. The keder may be of any well-known type having for instance a circular or a flattened cross section.

[0057] As illustrated in Figs. 3 to 5, neighbouring frame profile members 6 are connected to each other at respective corners 15 of the panel 1. Each corner 15 has a slot 13 formed between opposed parts of the corner 15 and extending at an oblique angle in relation to each one of the neighbouring frame profile members 6. Excess textile 14 at a respective corner 15 of the panel 1 is inserted into the slot 13 of the corner 15, and a resilient member 16 is arranged to, at least temporarily, retain the excess textile 14.

[0058] As seen particularly well in Figs. 6 to 10, each corner 15 forms an internal cavity 17 extending laterally from either side of at least part of the length of the slot 13 of the corner 15 behind opposed wall parts 18, 19 of the corner 15 arranged at either side of the slot 13. Comparing with Figs. 1 and 2, it is understood that each one of the opposed wall parts 32, 33 of the corner 15 extends at an oblique angle in relation to a general plane of the building panel 1, said general plane extending in parallel to the extended textile 7 or foil. The resilient member 16 is attached to the corner 15 and extends at either side of the slot 12 in the internal cavity 17 of the corner 15 of the panel 1. As illustrated in Fig. 23, the resilient member 16 is adapted to retain at least part of the excess textile 14 at either side of the slot 13 in the internal cavity 17 of the corner 15 of the panel 1. By attaching the resilient member 16 to the corner 15 and adapting the resilient member 16 to retain at least part of the excess textile 14 at either side of the slot 13 in the internal cavity 17 of the corner of the panel 1, it may be possible taking up and retaining, at least a major part of the excess textile 14 at the corner 15, thereby ensuring a smooth finish of the textile 7 or foil and further allowing easy removal and subsequent refitting of the tensioned textile 7 or foil.

[0059] As seen in Figs. 3 to 10, in the illustrated embodiment, neighbouring frame profile members 6 are connected to each other by means of corner pieces 12 forming the respective corners 15 of the panel 1. Each corner piece 12 is provided with connection studs 37 for insertion into corresponding cavities of the neighbouring frame profile members 6, and the corner pieces 12 are provided with screw holes 49 for insertion of connection screws 38 which are threaded into the neighbouring frame profile members 6. Each corner piece 12 forms the internal cavity 17 of the respective corner 15 of the panel 1, and each corner piece 12 forms the opposed wall parts 18, 19 of the corner 15 and the slot 13 between the opposed wall parts 18, 19. Thereby assembly of the panel 1 may be facilitated and an accurate finish of each corner 15 may be ensured. However, in an alternative not shown embodiment, neighbouring frame profile members 6 are connected to each other by means of a mitre joint in a well-known manner.

[0060] As seen in Fig. 23, in the illustrated embodiment, the resilient member 16 is adapted to pinch the at least part of the excess textile 14 at either side of the slot 13 between the resilient member 16 and an internal face 21 of the internal cavity 17 of the corner 15. In particular, in the illustrated embodiment, the resilient member 16 is adapted to pinch the at least part of the excess textile 14 at either side of the slot 13 between the resilient member 16 and an upper face of the internal cavity 17, i.e. an internal side 22 of either one of the opposed wall parts 18, 19 of the corner 15. However, in an alternative, not shown embodiment, the resilient member 16 is adapted to pinch the at least part of the excess textile 14 at either side of the slot 13 between the resilient member 16 and a lower face of the internal cavity 17, i.e. a face opposed to the internal side 22 of either one of the opposed wall parts 18, 19 of the corner 15. In a further alternative, not shown embodiment, the resilient member 16 forms a channel in which the textile may be inserted and retained by being pinched in the channel.

[0061] Preferably, the resilient member 16 is lockingly attached to the corner 15 within the slot 13 of the corner 15. Thereby, there may be no need to hold the resilient member 16 during insertion of the textile 7 or foil into the internal cavity 17 of the corner 15.

[0062] Preferably, as illustrated in Figs. 3 to 5, the resilient member 16 is attached to the corner 15 by means of a screw 23 engaging a hole 24 in the resilient member 16. A stud 33 is arranged in the slot 13 of the corner 15, and the stud 33 extends through the hole 24 in the resilient member 16. The screw 23 is threaded into a hole in the stud 33.

[0063] According to the present invention, the resilient member 16 is preferably directly attached to the corner 15 and preferably to a corner piece 12 forming at least part of the respective corner in such a way that the resilient member 16 abuts and / or contacts at least part of the corner or corner piece 12 in the internal cavity 17 of the corner 15. However, the resilient member 16 may be attached to the corner 15 or corner piece 12 via part of the textile 7 or foil.

[0064] As illustrated in Figs. 11 to 13, the resilient member 16 may have the form of a piece of elastic sheet metal having a rounded cross-section seen in the direction of the slot 12. In particular, the resilient member 16 may have a form resembling the form of a butterfly. Thereby, a first part of the resilient member 16 may abut an upper face of the internal cavity 17, i.e. the internal side 22 of either one of the opposed wall parts 18, 19 of the corner 15, as seen in Fig. 23, and a second part of the resilient member 16 may abut a lower face of the internal cavity 17.

[0065] In particular, as seen, the resilient member 16 may have the form of a piece of sheet metal having a wave formed cross-section seen in the direction of the slot 12. Thereby, one or more crests 28, 29 of the waveform may abut an upper face of the internal cavity 17, and one or more troughs 26, 27 of the waveform may abut a lower face of the internal cavity 17. The textile 7 or foil may be inserted between a crest 28, 29 or a trough 26, 27 of the waveform and a face of the internal cavity 17. Thereby, a smooth insertion and / or removal of the textile 7 or foil may be ensured.

[0066] In particular, as seen, the waveform of the cross-section of the piece of sheet metal may have a central crest 25 arranged in the slot 13, two troughs 26, 27, and two additional crests 28, 29 arranged in the internal cavity 17 of the corner 15 at either side of the slot 13.

[0067] As seen in the figures, preferably, the resilient member 16 is arranged symmetrically about the slot 13.

[0068] As seen in Fig. 23, in the embodiment illustrated, a cover plate 30 is fixed at the slot 13, thereby pinching the textile 7 or foil between the cover plate 30 and edges 31, 32 of the slot 13 formed by either one of the opposed wall parts 18, 19 of the corner 15. Thereby, an even stronger holding force may be applied permanently on the textile 7 or foil, and the resilient member 16 may in this case serve to temporarily hold the textile 7 or foil in place during fitting of the textile 7 or foil on the panel 1 at either side of the slot 13.

[0069] In the embodiment illustrated, the cover plate 30 is fixed at the slot 13 by means of a screw 23 inserted through the cover plate 30 and engaging a stud 33 arranged in the slot 13 of the corner 15, and the stud 33 extends through the resilient member 16.

[0070] In the embodiment illustrated, each respective frame profile member 6 forms a space 41 between two wall parts 42, 43, and the at least one tensioning profile member 11 is guided between the two wall parts 42, 43 and spring-biased for displacement in the tensioning direction DTout of the space 41 formed between the two wall parts 42, 43. Thereby, each frame profile member 11 may advantageously be formed by bending or roll forming a piece of sheet metal, whereby the outer edge 8 of the frame profile member 11 may be formed as a, preferably rounded, bent connection between the two wall parts 42, 43 each formed by the sheet metal. In the embodiment illustrated, the internal cavity 17 of each corner 15 of the panel 1 forms a continuation of the spaces 41 formed between the two wall parts 42, 43 of the neighbouring frame profile members 6 of the respective corner 15. Because a certain depth of the spaces 41 formed between the two wall parts 42, 43 is required for the guidance of the tensioning profile member 11, the internal cavity 17 of each corner 15 of the panel 1 may therefore have a corresponding certain depth which in turn may allow for even better possibility of taking up and retaining a major part of the excess textile 14 at the corner 15.

[0071] As seen, a rounded outer edge 36 of each corner piece 12 forms a continuation of the rounded outer edge 8 of the neighbouring frame profile members 6 of the respective corner 15. The rounded outer edge 36 of each corner piece 12 forms a connection between the respective opposed wall parts 18, 19 of the corner piece 12 and a bottom wall 50 of the corner piece 12.

[0072] In an alternative, not shown embodiment, each corner piece 12 forms, together with the neighbouring frame profile members 6, the internal cavity 17 of the respective corner 15 of the panel 1. In this embodiment, each corner piece 12 may for instance form the opposed wall parts 18, 19 of the corner 15 and the slot 13 between the opposed wall parts 18, 19, whereas the neighbouring frame profile members 6 may form at least a part of a bottom wall 50 of the corner 15.

[0073] It is noted that although the corner piece 12 is illustrated as forming a right angle between the connected neighbouring frame profile members 6 in the typical case of the peripheral frame 5 of the building panel 1 being formed by four frame profile members 6, the corner piece 12 may just as well form different angles. For instance, if the peripheral frame 5 of the building panel 1 is formed by six frame profile members 6, each corner piece 12 may form an angle of 120 degrees. However, of course, the corner pieces 12 may also form different angles between their respective neighbouring frame profile members 6. Figs. 24 and 25 illustrate a prior art corner piece 12 for connecting frame profile members of a building panel 1. The prior art corner piece 12 has a groove 13 formed between massive wall parts 39, 40 of the corner piece 12, into which groove excess textile 14 is inserted. However, due to limited available room in the groove 13, it may not be possible to fit all the excess textile 14 at the corner of the panel 1 into this groove 13. Therefore, a part of the excess textile 14 is typically cut away, and the remaining part of the excess fabric is inserted into the groove 13. In this case, the textile may typically be retained in the groove by means of glue. However, in this way, the textile 7 or foil of the building panel 1 may not be removed from the panel 1 and attached again, for instance after washing the textile 7 or foil. This is due to the textile 7 or foil being cut closely to fit the groove 13 of the prior art corner piece 12 and due to the textile 7 or foil being glued in the groove 13.

[0074] According to an embodiment of a method of manufacturing a building panel 1 according to the present invention, the method includes extending a textile 7 or foil to a tensioned state over the room-facing side 3 of the framework 2 between the frame profile members 6 by bending the textile 7 or foil about the outer edges 8 of the frame profile members 6 and by attaching each edge 20 of the textile 7 or foil to a corresponding frame profile member 6. Furthermore, according to the embodiment of the method, excess textile 14 at each respective corner 15 of the panel 1 is inserted into a slot 13 formed between opposed wall parts 18, 19 of the corner 15 and is retained by a resilient member 16. According to the method, at each respective corner 35 of the panel 1, the resilient member 16 is attached to the corner 15 so that it extends at either side of the slot 13 in an internal cavity 17 of the corner 15 of the panel 1. Furthermore, according to the method, at least part of the excess textile 14 is pressed laterally from the slot 13 into the internal cavity 17 at either side of the slot 13 so that the at least part of the excess textile 14 is retained by means of the resilient member 16 in the internal cavity 17.

[0075] In an embodiment of the method according to the present invention, the resilient member 16 is inserted into the corner 15 by displacement in the direction of the slot 13, and, preferably, during the insertion, the resilient member 16 flexes at least slightly so that a stud 33 of the corner 15 is inserted lockingly into a hole 24 of the resilient member 16. In an embodiment of the method, a cover plate 30 is fixed at the slot 13, thereby pinching the textile 7 or foil between the cover plate 30 and edges 31, 32 of the slot 13 formed by either one of the opposed wall parts 18, 19 of the corner 15.

[0076] In an embodiment of the method, the cover plate 30 is fixed at the slot 13 by inserting a screw 23 through the cover plate 30 so that it engages the stud 33 of the corner 15.

[0077] In an embodiment of the method, the textile 7 or foil is extended over the room-facing side 3 of the framework 2 between the frame profile members 6 by attaching each edge 20 of the textile 7 or foil to the corresponding frame profile member 6 by means of at least one tensioning profile member 11 and by spring-biasing the tensioning profile member 11 so that it is displaced in a lateral direction of said frame profile member 6 and thereby brings the textile 7 or foil into the tensioned state.

[0078] Figs. 16 to 18 illustrate the steps of inserting the resilient member 16 into the corner 15 by displacement in the direction of the slot 13, whereby the resilient member 16 flexes so that the stud 33 of the corner 15 is inserted lockingly into the hole 24 of the resilient member 16. The framework 2 of the building panel 1 has been placed on a textile 7 or foil to be extended over the room-facing side of the framework. As seen, preferably, part of the corner of the textile 7 or foil has been cut away, thereby forming an oblique line between the neighbouring edges 20 of the textile 7 or foil. Thereby, the amount of excess textile 14 which has to be inserted into the internal cavity 17 has been reduced somewhat, thereby facilitating the fitting of the textile.

[0079] Fig. 19 illustrates how excess textile 14, by means of a spatula or the like, is pressed laterally from the slot 13 into the internal cavity 17 at the right side of the slot 13 so that the a part of the excess textile 14 is retained by means of the resilient member 16 in the internal cavity 17, for instance as illustrated in the cross section of Fig. 23. Fig. 20 illustrates, similarly, how excess textile 14 is pressed laterally from the slot 13 into the internal cavity 17 at the left side of the slot 13. It is noted that, preferably before fitting the excess textile 14 in the internal cavity 17 of the corner 15, the mutually spaced holding elements 45 arranged flexibly in relation to each other along the edge 20 of the textile 7 or foil have been inserted into the longitudinal channel 44 of the tensioning profile member 11, and the tensioning force of the elastic springs 35 has been applied to the tensioning profile members 11. Thereby, the textile 7 or foil has been arranged appropriately for the textile 7 or foil to be fitted at the corner 15.

[0080] Fig. 21 illustrates how the excess textile 14 is retained temporarily by means of the resilient member 16 in the internal cavity 17.

[0081] Fig. 22 illustrates how a cover plate 30 has finally been fixed in the slot 13, thereby pinching the textile 7 or foil between the cover plate 30 and edges 31, 32 of the slot 13 as also illustrated in Fig. 23. The cover plate 30 has been fixed in the slot 13 by means of a screw 23 inserted through the cover plate 30 and engaging the stud 33 attached to the corner 15 and extending through the resilient member 16. By means of the cover plate 30, an even stronger holding force may be applied permanently on the textile 7 or foil, and the resilient member 16 has mainly served to temporarily hold the textile 7 or foil in place during fitting of the textile 7 or foil on the panel 1 at either side of the slot 13. Furthermore, when the cover plate 30 is fixed in the slot 13, the mounting force of the screw 23 may, by means of the cover plate 30, compress the resilient member 16 furthermore, so that the central crest 25 is pressed in downward direction, and so that consequently, the additional crests 28, 29 to either side of the slot are, by tilting the troughs 26, 27, pressed in upward direction against the internal side 22 of the opposed wall parts 18, 19, thereby applying further pinching pressure to the excess textile 14. List of reference numbers

[0082] DTtensioning direction of tensioning profile member

[0083] 1 building panel

[0084] 2 framework of building panel

[0085] 3 room-facing side of framework

[0086] 4 building-facing side of framework

[0087] 5 peripheral frame of framework

[0088] 6 frame profile member

[0089] 7 textile or foil

[0090] 8 outer edge of frame profile member

[0091] 9 room-facing side of frame profile member

[0092] 10 building-facing side of frame profile member

[0093] 11 tensioning profile member

[0094] 12 corner piece

[0095] 13 slot

[0096] 14 excess textile or foil

[0097] 15 corner of panel

[0098] 16 resilient member

[0099] 17 internal cavity

[0100] 18, 19 opposed wall parts

[0101] 20 edge of textile

[0102] 21 internal face of internal cavity

[0103] 22 internal side of opposed wall parts

[0104] 23 screw

[0105] 24 hole of resilient member

[0106] 25 central crest

[0107] 26, 27 trough

[0108] 28, 29 crest

[0109] 30 cover plate

[0110] 31, 32 edges of slot

[0111] 33 stud of corner piece 34 hole of cover plate

[0112] 35 elastic spring for tensioning profile member

[0113] 36 rounded outer edge of corner piece

[0114] 37 connection stud of corner piece 38 connection screw for corner piece

[0115] 39, 40 massive wall parts of prior art corner piece

[0116] 41 space between wall parts

[0117] 42, 43 wall part

[0118] 44 longitudinal channel of tensioning profile member 45 mutually spaced holding elements

[0119] 46 ribbon

[0120] 47 stitch

[0121] 48 spatula

[0122] 49 screw hole of corner piece 50 bottom wall of corner piece

Claims

Claims1. A building panel (1) adapted to be mounted at a ceiling or wall of a room so that a framework (2) of the building panel (1) has a room-facing side (3) and a building-facing side (4), wherein the framework (2) includes a peripheral frame (5) formed by frame profile members (6), wherein a textile (7) or foil is extended in a tensioned state over the room-facing side (3) of the framework (2) between the frame profile members (6), wherein each frame profile member (6) has an outer edge (8) connecting a room-facing side (9) of the frame profile member (6) with a building-facing side (10) of the frame profile member (6), wherein the textile (7) is bent about the outer edges (8) of the frame profile members (6), wherein edges (20) of the textile (7) are fixed to the buildingfacing side (10) of the respective frame profile members (6), wherein neighbouring frame profile members (6) are connected to each other at respective corners (15) of the panel (1), wherein each corner (15) has a slot (13) formed between opposed parts of the corner (15) and extending at an oblique angle in relation to each one of the neighbouring frame profile members (6), wherein excess textile (14) at a respective corner (15) of the panel (1) is inserted into the slot (13) of the corner (15), and wherein a resilient member (16) is arranged to, at least temporarily, retain the excess textile (14), characterised in that each corner (15) forms an internal cavity (17) extending laterally from either side of at least part of the length of the slot (13) of the corner (15) behind opposed wall parts (18, 19) of the corner (15) arranged at either side of the slot (13), in that the resilient member (16) is attached to the corner (15) and extends at either side of the slot (13) in the internal cavity (17) of the corner (15) of the panel (1), and in that the resilient member (16) is adapted to retain at least part of the excess textile (14) at either side of the slot (13) in the internal cavity (17) of the corner (15) of the panel (1).

2. A building panel according to claim 1, wherein the resilient member (16) is adapted to pinch the at least part of the excess textile (14) at either side of the slot (13) between the resilient member (16) and an internal face (21) of the internal cavity (17) of the corner (15).

3. A building panel according to claim 1 or 2, wherein the resilient member (16) is adapted to pinch the at least part of the excess textile (14) at either side of the slot (13) between the resilient member (16) and an internal side (22) of either one of the opposed wall parts (18, 19) of the corner (15).

4. A building panel according to any one of the preceding claims, wherein the resilient member (16) is lockingly attached to the corner (15) within the slot (13) of the corner (15).

5. A building panel according to any one of the preceding claims, wherein the resilient member (16) is attached to the corner (15) by means of a pin and / or screw (23) engaging a hole (24) in the resilient member (16).

6. A building panel according to any one of the preceding claims, wherein the resilient member (16) has the form of a piece of sheet metal having a rounded cross-section seen in the direction of the slot (12).

7. A building panel according to any one of the preceding claims, wherein the resilient member (16) has the form of a piece of sheet metal having a wave formed cross-section seen in the direction of the slot (12).

8. A building panel according to claim 7, wherein the waveform of the cross-section of the piece of sheet metal has a central crest (25) arranged in the slot, two troughs (26, 27), and two additional crests (28, 29) arranged in the internal cavity (17) of the corner (15) at either side of the slot (13).

9. A building panel according to any one of the preceding claims, wherein the resilient member (16) is arranged symmetrically about the slot (13).

10. A building panel according to any one of the preceding claims, wherein a cover plate(30) is fixed at the slot (13), thereby pinching the textile (7) between the cover plate (30)and edges (31, 32) of the slot (13) formed by either one of the opposed wall parts (18, 19) of the corner (15).

11. A building panel according to claim 10, wherein the cover plate (30) is fixed at the slot (13) by means of a screw (23) inserted through the cover plate (30) and engaging a stud (33) arranged in the slot (13) of the corner (15), and wherein the stud (33) extends through the resilient member (16).

12. A building panel according to any one of the preceding claims, wherein neighbouring frame profile members (6) are connected to each other by means of corner pieces (12) forming at least part of the respective corners (15) of the panel (1), wherein each corner piece (12), at least together with the neighbouring frame profile members (6), forms the internal cavity (17) of the respective corner (15) of the panel (1), and wherein each corner piece (12) forms the opposed wall parts (18, 19) of the corner (15) and the slot (13) therebetween.

13. A building panel according to any one of the preceding claims, wherein each edge (20) of the textile (7) is attached to a corresponding frame profile member (6) by means of at least one tensioning profile member (11) being spring-biased for displacement in a tensioning direction (DT) being lateral of said frame profile member (6) for bringing the textile (7) into the tensioned state.

14. A building panel according to claim 13, wherein each respective frame profile member (6) forms a space (41) between two wall parts (42, 43), and wherein the at least one tensioning profile member (11) is guided between the two wall parts (42, 43) and spring- biased for displacement in the tensioning direction (DT) out of the space (41) formed between the two wall parts (42, 43).

15. A building panel according to claim 12 and 14, wherein the internal cavity (17) of each corner (15) of the panel (1) forms a continuation of the spaces (41) formed between the two wall parts (42, 43) of the neighbouring frame profile members (6) of the respective corner (15).

16. A method of manufacturing a building panel (1) adapted to be mounted at a ceiling or wall of a room so that a framework (2) of the building panel (1) has a room-facing side (3) and a building-facing side (4), the framework (2) including a peripheral frame (5) formed by frame profile members (6), each frame profile member (6) having an outer edge (8) connecting a room-facing side (9) of the frame profile member (6) with a building-facing side (10) of the frame profile member (6), whereby a textile (7) or foil is extended to a tensioned state over the room-facing side (3) of the framework (2) between the frame profile members (6) by bending the textile (7) about the outer edges (8) of the frame profile members (6) and by attaching each edge (20) of the textile (7) to a corresponding frame profile member (6), neighbouring frame profile members (6) being connected to each other at respective corners (15) of the panel (1), and whereby excess textile (14) at each respective corner (15) of the panel (1) is inserted into a slot (13) formed between opposed wall parts (18, 19) of the corner (15) and is, at least temporarily, retained by a resilient member (16), characterised by, at each respective corner (35) of the panel (1), attaching the resilient member (16) to the corner (15) so that it extends at either side of the slot (13) in an internal cavity (17) of the corner (15) of the panel (1), and pressing at least part of the excess textile (14) laterally from the slot (13) into the internal cavity (17) at either side of the slot (13) so that the at least part of the excess textile (14) is retained by means of the resilient member (16) in the internal cavity (17).

17. A method of manufacturing a building panel according to claim 16, whereby the resilient member (16) is inserted into the corner (15) by displacement in the direction of the slot (13), and whereby, preferably, during the insertion, the resilient member (16) flexes at least slightly so that a stud (33) of the corner (15) is inserted lockingly into a hole (24) of the resilient member (16).

18. A method of manufacturing a building panel according to claim 16 or 17, whereby a cover plate (30) is fixed at the slot (13), thereby pinching the textile (7) between the cover plate (30) and edges (31, 32) of the slot (13) formed by either one of the opposed wall parts (18, 19) of the corner (15).

19. A method of manufacturing a building panel according to claim 17 and 18, whereby the cover plate (30) is fixed at the slot (13) by inserting a screw (23) through the cover plate (30) so that it engages the stud (33) of the corner (15).

20. A method of manufacturing a building panel according to any one of the claims 16 to19, whereby the textile (7) is extended over the room-facing side (3) of the framework (2) between the frame profile members (6) by attaching each edge (20) of the textile (7) to the corresponding frame profile member (6) by means of at least one tensioning profile member (11) and by spring-biasing the tensioning profile member (11) so that it is displaced in a lateral direction of said frame profile member (6) and thereby brings the textile (7) into the tensioned state.

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