Acoustic panel assembly

Abstract

An acoustic panel assembly (1, 100, 130, 147, 148, 150) comprises a plurality of acoustic panel members (10, 110, 135, 147A, 148A, 155). A plurality of bridge portions (20) is configured to connect each of the acoustic panel members to at least one other acoustic panel member. The acoustic panel members each have at least two sidewall portions (52, 55) and an exterior face layer (70) comprising a pair of side portions (72, 75). The side portions (72, 75) of each exterior face layer (70) are configured to adhere to the sidewall portions (52, 55) of each acoustic panel member (10, 110, 135, 147A, 148A, 155). The acoustic panel assembly (1, 100, 130, 147, 148, 150) is easier to install and is applicable to a variety of wall surfaces. A method of manufacturing the acoustic panel assembly is provided.

Description

Acoustic Panel AssemblyField of the Disclosure

[0001] The disclosure relates to an acoustic panel assembly and in a particular to an acoustic panel assembly for mounting to a constructional element, such as a wall. The disclosure has been developed primarily for use in acoustic and / or reverberation control and will be described hereinafter by reference to this application.Background of the Disclosure

[0002] The following discussion of the prior art is intended to present the disclosure in an appropriate technical context and allow its advantages to be properly appreciated. Unless clearly indicated to the contrary, however, reference to any prior art in this specification should not be construed as an express or implied admission that such art is widely known or forms part of common general knowledge in the field.

[0003] Acoustic control panels are used in many building applications, such as commercial, educational, hospitality, health, museums, airports, galleries and housing. Many acoustic control products are made from wood or have finishes that mimic the appearance of wood (sometimes called “wood look”). Some of these wood and wood look acoustic products include but are not limited to perforated medium density fibreboards (MDF) veneer panels and linear batten systems, in both solid timber and wood look aluminium. These linear batten systems comprise panels made up of multiple battens held together either using what are called carrier rails or using a clip system which involves clipping individual battens into a receiving clip already fixed to a ceiling or wall. For installation, the panel product is glued and nailed in the case for the MDF, and for aluminium the panel product is screwed to the substrate (typically a furring channel) using a screw flute that is extruded into the panel.

[0004] These linear batten systems are typically either difficult to manufacture in panel form with carrier rails or slow and tedious to install using a clip system. Either way, the installed panel product is expensive. This cost is further increased when the battens are manufactured to have a high fire resistance (fire rating Group 1 under Australian and New Zealand standards), which is often desired or required as part of building regulations. This requires the linear battens to be manufactured from non-combustible materials or materials of extremely low combustibility. Also, the framing that holds theassembly of linear battens together is not aesthetic in appearance, and consequently it is difficult to produce the linear battens without displaying the unsightly framing.

[0005] It is an object of the present disclosure to overcome or substantially ameliorate one or more of the disadvantages of prior art, or at least to provide a useful alternative. It is an object of the disclosure in at least one preferred embodiment to provide an acoustic panel assembly that is easier and cheaper to manufacture, has a pleasing aesthetic appearance and is more convenient to install on site.Summary of the Disclosure

[0006] A first aspect of the disclosure provides an acoustic panel assembly comprising: a plurality of acoustic panel members; and a plurality of bridge portions configured to connect each of the acoustic panel members to at least one other acoustic panel member; wherein the plurality of acoustic panel members each have at least two sidewall portions; the plurality of acoustic panel members each comprises an exterior face layer having at least a pair of side portions; and the side portions of each exterior face layer are configured to adhere to the sidewall portions of each acoustic panel member.

[0007] In one or more embodiments, the plurality of acoustic panel members each have a cross-section or profile such that acoustic panel member defines an acute angle with at least one bridge portion. In one or more embodiments, at least one sidewall portion defines the acute angle with the at least one bridge portion.

[0008] In one or more embodiments, the plurality of acoustic panel members each have a cross-section or profile such that acoustic panel member defines a pocket or recess with at least one bridge portion. In one or more embodiments, at least one sidewall portion defines the pocket or recess with the at least one bridge portion.

[0009] In one or more embodiments, the at least one sidewall portion extends inwardly towards a base of the acoustic panel member. In one or more embodiments, the at least one sidewall portion tapers inwardly towards the base. In one or more embodiments, the at least one sidewall portion comprises a lower portion of the acousticpanel member. In one or more embodiments, the at least one sidewall portion is connected to the base.

[0010] In one or more embodiments, the base of each acoustic panel member is connected to at least one bridge portion.

[0011] In one or more embodiments, the cross-section may have any polygonal shape, including regular and irregular shapes. In one or more embodiments, the crosssection may be generally pentagonal, hexagonal, circular, oval, square, trapezoidal, rectangular or any other polygonal shape. In one or more embodiments, the crosssection may comprise a combination of the above described polygonal shapes.

[0012] In one or more embodiments, a first sidewall portion defines a first acute angle with a first bridge portion and a second sidewall portion defines a second acute angle with a second bridge portion. In one or more embodiments, the first and second acute angles are substantially the same. In one or more embodiments, the first and second acute angles are different. In one or more embodiments, a first sidewall portion defines a first pocket or recess with a first bridge portion and a second sidewall portion defines a second pocket or recess with a second bridge portion.

[0013] In one or more embodiments, the first and second sidewall portions extend inwardly towards the base of the acoustic panel member. In one or more embodiments, the first and second sidewall portions taper inwardly towards the base of the acoustic panel member. In one or more embodiments, the first and second sidewall portions comprise lower portions of the acoustic panel member.

[0014] In one or more embodiments, the side portions of the exterior face layer each have a side edge. In one or more embodiments, the side edges of the exterior face layer are configured to substantially align with edges of the sidewall portions of each acoustic panel member adjacent or connected to the base.

[0015] In one or more embodiments, each bridge portion comprises one or more openings for absorbing sound.

[0016] In one or more embodiments, the exterior face layer is selected from the group comprising: vinyl film, olefin film, paper and textiles. In one or more embodiments, theexterior face layer has a printed finish. In one or more embodiments, the printed finish is selected from the group comprising: woodgrain, real wood veneer, leather, leather look vinyl and vinyl. In one or more embodiments, the exterior face layer has a surface finish, such as stone, real wood veneer or other decorative finish.

[0017] In one or more embodiments, the acoustic panel assembly comprises one or more connecting members configured to connect the acoustic panel assembly to another acoustic panel assembly. In one or more embodiments, there are at least two connecting members are configured to interconnect with each other. In one or more embodiments, the at least two connecting members have complementary shapes. In one or more embodiments, the at least two connecting members are configured to receive one or more fasteners. In one or more embodiments, a first connecting member comprises a tongue and a second connecting member comprises a groove.

[0018] In one or more embodiments, the plurality of acoustic panel members and the plurality of bridge portions are at least integrally formed. In one or more embodiments, the plurality of acoustic panel members, the plurality of bridge portions and the one or more connecting members are integrally formed. In one or more embodiments, the plurality of acoustic panel members and the plurality of bridge portions, optionally with the one or more connecting members, are extruded as a single unit. In one or more embodiments, the one or more openings are formed after extrusion of the plurality of acoustic panel members and the plurality of bridge portions, optionally with the one or more connecting members.

[0019] In one or more embodiments, the plurality of acoustic panel members, the plurality of bridge portions, the one or more connecting members and the one or more openings are integrally formed. In one or more embodiments, the plurality of acoustic panel members, the plurality of bridge portions, the one or more connecting members and the one or more openings are additively manufactured as a single unit.

[0020] In one or more embodiments, the acoustic panel assembly comprises an extruded metal, preferably aluminium. However, other lightweight materials may be used for the acoustic panel assembly, such as [are there any alternatives?].

[0021] A second aspect of the disclosure provides a method of manufacturing the acoustic panel assembly of the first aspect, comprising:producing a plurality of acoustic panel members connected by a plurality of bridge portions; applying a film to the plurality of acoustic panel members; and cutting the film to form an exterior face layer for each acoustic panel member.

[0022] In one or more embodiments, the film applying step comprises placing the film over or on the plurality of acoustic panel members. In one or more embodiments, the film is arranged on the plurality of acoustic panel members such that loops are formed in each space between the plurality of acoustic panel members.

[0023] In one or more embodiments, the cutting step comprises cutting the film along a line in each loop to create a plurality of film sheets, each having side portions and side edges. In one or more embodiments, the line is substantially parallel to a longitudinal axis of the acoustic panel members.

[0024] In one or more embodiments, the method comprises wrapping the side portions of each film sheet around portions of each acoustic panel member to form the exterior face layer of each acoustic panel member. In one or more embodiments, the method comprises wrapping the side portions of each film sheet around the sidewall portions of each acoustic panel member to hide the side edges.

[0025] In one or more embodiments, the producing step comprises extruding the plurality of acoustic panel members and the plurality of bridge portions. In one or more embodiments, the producing step comprises additively manufacturing the plurality of acoustic panel members and the plurality of bridge portions.

[0026] In one or more embodiments, the method comprises forming one or more openings into the plurality of bridge portions. In one or more embodiments, the forming step comprises punching the one or more openings into the plurality of bridge portions. In one or more embodiments, the forming step comprises cutting or machining the one or more openings into the plurality of bridge portions. In one or more embodiments, the forming step comprises additively manufacturing the one or more openings in the plurality of bridge portions with the plurality of acoustic panel members and the plurality of bridge portions as part of the producing step.

[0027] In one or more embodiments, the method comprises applying a protective coating to the acoustic panel assembly. In one or more embodiments, the protectivecoating applying step is performed after the punching step. In one or more embodiments, the protective coating applying step is performed before the film applying step. In one or more embodiments, the protective coating applying step comprises anodising the acoustic panel assembly.

[0028] One or more embodiments of the second aspect may have the features of one or more embodiments of the first aspect of the disclosure stated above, where applicable.

[0029] Unless the context clearly requires otherwise, throughout the description and the claims, the words “comprise”, “comprising”, and the like are to be construed in an inclusive sense as opposed to an exclusive or exhaustive sense; that is to say, in the sense of “including, but not limited to”.

[0030] Furthermore, as used herein and unless otherwise specified, the use of the ordinal adjectives "first", "second", "third", etc., to describe a common object, merely indicate that different instances of like objects are being referred to, and are not intended to imply that the objects so described must be in a given sequence, either temporally, spatially, in ranking, or in any other manner.Brief Description of the Drawings

[0031] Preferred embodiments of the disclosure will now be described, by way of example only, with reference to the accompanying drawings in which:

[0032] Figures 1A and 1B are a perspective views of an acoustic panel assembly according to one embodiment of the disclosure;

[0033] Figures 1C and 1D are top plan and cross-sectional views, respectively, of the acoustic panel assembly of Figures 1A and 1 B;

[0034] Figures 2A and 2B are perspective views of an acoustic panel assembly according to another embodiment of the disclosure;

[0035] Figures 2C and 2D are top plan and cross-sectional views, respectively, of the acoustic panel assembly of Figures 2A and 2B;

[0036] Figure 3A and 3B are perspective views of an acoustic panel assembly according to a further embodiment of the disclosure;

[0037] Figures 3C and 3D are top plan and cross-sectional views, respectively, of the acoustic panel assembly of Figures 3A and 3B;

[0038] Figures 4A and 4B are cross-sectional views of other embodiments of the acoustic panel assembly;

[0039] Figure 5 is a perspective view of an acoustic panel assembly according to yet another embodiment of the disclosure;

[0040] Figure 6 is a partial close up perspective view of the acoustic panel assembly of Figure 5;

[0041] Figure 7 is a underneath plan view of the acoustic panel assembly of Figure 5;

[0042] Figure 8 is a perspective view of the acoustic panel assemblies of Figures 1 A to 4B;

[0043] Figure 9 is a schematic drawing illustrating one step in manufacturing the acoustic assembly of Figures 1A to 1D according to a further embodiment of the disclosure; and

[0044] Figure 10 is a schematic drawing illustrating another step in manufacturing the acoustic assembly of Figures 1A to 1D according to this further embodiment.Preferred Embodiments of the Disclosure

[0045] The present disclosure will now be described with reference to the following examples which should be considered in all respects as illustrative and non-restrictive. Although the disclosure has been described with reference to specific examples, it will be appreciated by those skilled in the art that the disclosure may be embodied in many other forms. In the Figures, corresponding features within the same embodiment or common to different embodiments have been given the same reference numerals.

[0046] Referring to Figures 1A to 1 D, an acoustic panel assembly 1 is shown according to one embodiment of the present disclosure. The acoustic panel assembly 1 comprises a plurality of acoustic panel members in the form of linear battens 10 and a plurality of bridge portions 20 configured to connect each of the acoustic panel members to at least one other acoustic panel member. Each bridge portion 20 comprises one or more openings for absorbing sound, which in this embodiment take the form of elongate closed slots 30. The slots 30 may be arranged at regular or irregular intervals along the length of the bridge portions 20. The slots 30 in this embodiment are provided along the entire length of the bridge portions 20. In other embodiments, the slots 30 may be located at specific locations or clustered or grouped at particular areas of the bridge portions 20.

[0047] The acoustic panel assembly 1 has connecting members 40 and 42 for connecting the acoustic panel assembly to other acoustic panel assemblies and provide locations for receiving one or more fasteners (not shown) to fix the acoustic panel assembly to a constructional element, such as a wall or ceiling. Generally, the interconnected acoustic panel assemblies 1 form a larger acoustic panel assembly intended to cover an entire surface of the constructional element. In this embodiment, the connecting members take the form of a tongue 40 and a groove 42 for receiving the tongue of an adjacent acoustic panel assembly, as best shown in the embodiment of Figure 6. The tongue 40 may have a recessed area, such as a screw flute, for receiving one or more fasteners. However, it will be appreciated that the connecting members may take other forms, but preferably have complementary shapes to enhance their connection. For example, the connecting members 40, 42 may adopt common joint arrangements, such as mortise and tenon, dowels and lap joints.

[0048] The linear battens 10 generally have a cross-section or profile 50 such that each batten defines an acute angle a with a bridge portion 20a. In this embodiment, the battens 10 each have sidewall portions 52, 55 that extend inwardly towards a base 57 of the batten, preferably forming a recess or pocket 58. The sidewall portions 52, 55 are lower portions of the battens 10 and are preferably connected to the base 57.

[0049] In this embodiment, the sidewall portions 55 also defines an acute angle p with another bridge portion 20b. The angle is the same as angle a, to provide a symmetrical appearance for the batten 10. However, in other embodiments, the angle a may be different to the angle p. The angles a, p are acute to ensure that subsequentcovering of the battens 10 with a surface finish may be performed without showing the edges of the finish, as discussed in more detail below.

[0050] The sidewall portions 52, 55 preferably taper inwardly toward the base 57.This creates pockets 58 on either side of each batten 10, as well as the acute angles a, p with the bridge portions 20a, 20b, as best shown in Figure 6. While the pockets 58 have been illustrated in relation the embodiment of Figure 6, all the other embodiments of the batten assemblies preferably share this feature. Also, in other embodiments, only one of the sidewall portions 52, 55 extends or tapers inwardly toward the base. For example, the batten 10 above the groove 42 may have only one inwardly extending sidewall portion.

[0051] The cross-section 50 is formed by the two sidewall portions 52, 55, the base 57 and a curved top portion 60. The curved top portion 60 provides a rounded appearance for the battens 10 to suit a desired aesthetic appearance. Thus, the cross-section 50 is composed of a combination of polygonal shapes, being an arcuate or circular shape (top portion 60) combined with an open trapezoidal shape (sidewall portions 52, 55 and base 57). It will be appreciated that the batten may have any polygonal shape, including regular and irregular shapes, or combinations of polygonal shapes to meet a desired aesthetic appearance for the battens. For example, the cross-section 50 may be generally pentagonal, hexagonal, circular, oval, square, trapezoidal, rectangular or any other polygonal shape, as well as combinations of these shapes.

[0052] The battens 10 also have an exterior face layer 70 with at least a pair of side portions 72, 75, preferably with respective side edges 82, 85, as best shown in Figure 10. The side portions 72, 75 are configured to adhere to the sidewall portions 52, 55 of the batten 10, and are preferably glued to the sidewall portions. Generally, the exterior face layer 70 is glued to each batten 10. The exterior face layer 70 generally provides an aesthetic or decorative appearance for the battens 10. The inwardly tapering sidewall portions 52, 55 ensure that the side edges 82, 85 are not visible upon installation of the batten system 10, and instead are tucked into the pockets 58. This ensures that the battens 10 retain the pleasing aesthetic or decorative appearance of the exterior face layer 70, since no seams or cut edges are visible, and emulate the appearance of whatever finish is provided by the exterior face layer.

[0053] The exterior face layer 70 can be selected from vinyl film, olefin film, paper and textiles, but is preferably made of olefin film. In this embodiment, the exterior face layer 70 has a woodgrain or real wood veneer finish. However, in other embodiments, a variety of printed finishes may be chosen. Examples of other printed finishes are leather, leather look vinyl and vinyl. However, other appropriate surface finishes may be used, including stone, real wood veneer or other decorative finishes. Other embodiments of the exterior face layer 70 comprise similar films to olefin, such as vinyl, paper and textiles.

[0054] In some embodiments, the exterior face layer width can vary in the range of 0.1mm to 0.4mm. Generally, as the exterior face layer 70 is relatively very thin, it presents a minimal fuel load that can be burnt, such that it does not adversely affect the fire rating of the acoustic panel assembly 1 , which is maintained at Group 1. In other embodiments, the exterior face layer 70 may comprise perforations to maintain or enhance the acoustic performance of the acoustic panel assembly 1.

[0055] Since the exterior face layer 70 may be provided with various surface finishes, the acoustic panel assembly 1 can be integrated with the other walls and / or ceiling of any rooms or building structures for an aesthetically appealing appearance. Thus, the acoustic panel assembly 1 has a wider range of aesthetically pleasing surface finishes without compromising its acoustic and reverberation control characteristics or its fire safety rating.

[0056] To install the linear batten assembly 1, it is placed against the surface of a constructional element, such as a wall or ceiling. A first batten assembly 1 is attached to the constructional element by inserting suitable fasteners (nails, screws, etc.) through the screw flutes of the tongue 40, preferably attaching the batten assembly to a furring channel of the constructional element (not shown). The furring channel may create an airgap between the batten assembly 1 and the constructional element. A second batten assembly 1 is then connected to the fixed first batten assembly by inserting the tongue 40 of the second batten assembly into the groove 42 of the fixed first batten assembly and repeating the fastening process. Consequently, the batten assemblies 1 are quickly and conveniently installed, requiring less labour, especially when compared to previous installation methods, such as mounting clips to the wall and then mounting the battens to the clips. The batten assembly 1 also retains the desired linear batten look or appearance sought with these types of acoustic panels, without the unsightlyappearance of prior art framing elements. The side edges 82, 85 of the exterior face layer 70 are hidden from view by being attached to the sidewall portions 52, 55 in the pocket or recess 58, and thus provide the battens 10 with an appearance of being individual battens as opposed to appearing as a single moulded look that is more artificial and thus less aesthetically pleasing in appearance. In addition, this arrangement also keeps the area between the battens 10 open for the purpose of sound absorption, which is also facilitated by the slots 30. Moreover, it is easy to cut angles and curves on the ends of the batten assembly 1. In addition, the slots 30 along the length of the bridge portions 20 provide sufficient flexibility to the bridge portions 20 to allow the batten assembly 1 to bend around curves (such as in a curved wall or corners).

[0057] Optionally, the rear or back surface of the batten assembly 1 may have an acoustic textile fitted to it to assist with reverberation control when fitted to a wall or ceiling, preferably with either an air gap, acoustic insulation or both, behind the linear batten assembly. The acoustic textile may also have a black finish to give the grooves 42 a consistent black look and further disguise the slots 30.

[0058] Referring to Figures 2A to 2D, another embodiment of the present disclosure is shown, where the acoustic panel assembly is also a linear batten assembly 100 with battens 110. However, the cross-section or profile 120 of the battens 110 is different to the cross-section 50 of the battens 10. Instead the cross-section 120 of each batten 110 has a slanted or inclined top portion 122 with an angled sidewall portion 125. This crosssection 120 is commonly referred to as a “shark’s nose”. The battens 110 still have the inwardly tapering lower sidewall portions 52, 55, base 57, bridge portions 20, slots 30, and connecting tongue 40 and groove 42. Consequently, the linear batten assembly 100 is functionally the same as the acoustic panel assembly 1 of Figures 1A to 1D, so its function will not be described to avoid repetition.

[0059] Referring to Figures 3A to 3D, a further embodiment of the present disclosure is shown, where the acoustic panel assembly is also a linear batten assembly 130 with battens 135. Again, the primary difference is that the cross-section or profile 140 of the battens 135 is different to the cross-sections 50, 120 of the battens 10, 110. The crosssection 140 of each batten 135 has a flat top portion 141 with an angled upper sidewall portions 142, 145. The upper angled sidewall portions 142, 145 connect to the lower sidewall portions 52, 55, respectively. Thus, the cross-section 140 has a hexagonal shape. The battens 135 also have the inwardly tapering lower sidewall portions 52, 55,base 57, bridge portions 20, slots 30, and connecting tongue 40 and groove 42. Hence, the linear batten assembly 130 is functionally the same as the assemblies 1 , 100 of Figures 1A to 1D and 2A to 2D. Thus, how the batten assembly 130 works will not be described to avoid repetition.

[0060] Figures 4A and 4B illustrate alternative cross-sectional profiles for the batten assembly. Figure 4A shows a batten assembly 147 having battens 147A with a cross- sectional profile 147B comprising a flat top portion 147C and two straight sidewall portions 147D. Figure 4A shows a batten assembly 148 having battens 148A with a cross-sectional profile 148B comprising a flat top portion 148C and two straight sidewall portions 148D. The battens 147A, 148A still have the inwardly tapering lower sidewall portions 52, 55, base 57, bridge portions 20, slots 30, and connecting tongue 40 and groove 42. Consequently, the linear batten assemblies 147, 148 are functionally the same as the acoustic panel assemblies 1 , 100, 130 of Figures 1A to 3D, so their function will not be described to avoid repetition

[0061] Referring to Figures 5 to 7, yet another embodiment of the present disclosure is shown, where the acoustic panel assembly is again a linear batten assembly 150 with battens 155. Again, the primary difference is that the cross-section or profile 160 of the battens 155 is different to the cross-sections 50, 120, 140, 147B, 148B of the battens 10, 110, 135, 147A, 148A. The cross-section 160 of each batten 155 has a flat top portion 161 with an angled upper sidewall portions 162, 165. The upper angled sidewall portions 162, 165 connect to the lower sidewall portions 52, 55, respectively. Thus, the crosssection 160 has a hexagonal shape, the same at the cross-section 140 of the battens 135. However, the upper sidewall portions 162, 165 have angles less acute that the upper sidewall portions 142, 145, resulting in the battens 155 being “taller” than the battens 135. That is, the battens 155 tend to extend further outwardly from the assembly 150 compared to the battens 135, as best shown in Figure 8. The battens 155 have the inwardly tapering lower sidewall portions 52, 55, base 57, bridge portions 20, slots 30, and connecting tongue 40 and groove 42 shared by the other assemblies of Figures 1A to 4B. Referring to Figure 7, the linear batten assembly 150 is shown from underneath to better illustrate the base 57, bridge portions 20 and slots 30. Hence, the linear batten assembly 150 is functionally the same as the assemblies 1, 100, 130, 147, 148 of Figures 1A to 4D. To avoid repetition, a description of how the batten assembly 150 works will be omitted.

[0062] Referring to Figure 8, the linear batten assemblies 1, 100, 130, 150 are shown together to highlight the differences in their respective cross-sections 50, 120, 140, 160, as well as the presence of the common features of inwardly tapering lower sidewall portions 52, 55, base 57, bridge portions 20, slots 30, and connecting tongue 40 and groove 42.

[0063] The linear batten assemblies 1 , 100, 130, 147, 148, 150 may be used in the construction of a wall, ceiling or other building feature, and is preferably used in the acoustic control of a room or building, especially reverberation control. In other embodiments, the linear batten assemblies 1, 100, 130, 147, 148, 150 may be installed on the surface of a constructional element, such as a wall or ceiling, without having to be applied to the surface of a component of the constructional element before it is constructed or assembled. This provides versatility in application of the linear batten assemblies 1, 100, 130, 147, 148, 150 to a variety of surfaces, irrespective of whether they are part of individual elements for later construction or assembly or have been assembled or constructed into a composite object.

[0064] The present disclosure also provides a method of manufacturing the acoustic panel assemblies 1 , 100, 130, 147, 148, 150. The method comprises producing a plurality of acoustic panel members connected by a plurality of bridge portions. In the above descried embodiments, the plurality of acoustic panel members 10, 110, 135, 147A, 148A, 155 and the plurality of bridge portions 20 are integrally formed, preferably by extruding them as a single unit. This extrusion process would also form the complementary connecting members, which in this embodiment are the tongue 40 and groove 42.

[0065] The slots 30 are then formed in the bridge portions 20, preferably after extrusion. The slots 30 may be created by cutting, machining or punching, although punching is preferred. In this embodiment, the slots 30 are 15mm long and 5mm wide at 20mm centres. A protective coating is then applied to the assembly 1, 100, 130, 147, 148, 150, which in this embodiment comprises anodising the surfaces of the battens 10, 110, 135, 147A, 148A, 155, bridge portions 20 and connecting members 40, 42. The coating may also serve a decorative purpose; for example by anodising the battens 10, bridge portions 20 and connecting members 40, 42 the colour black, this ensures a uniform appearance for the batten assembly 1 and helps hide the bridge portions and slots 30 in the final installation by giving the bridge portions and slots some depth. Inaddition, by anodising after punching the slots 30, the edges of the slots are also black. It is preferable to use anodising instead of powder coating as the adhesive used for the exterior face layer (discussed below) has a better bond with the anodised surface. Of course, a different colour to black may be chosen, such as brown or other colour, if desired, to blend the acoustic panel assemblies 1, 100, 130, 147, 148, 150 to the colour or intended colour of the wall or ceiling.

[0066] It will be appreciated that in other embodiments, the acoustic panel members, bridge portions and connecting members can be manufactured separately and then subsequently joined. However, it is preferred that the acoustic panel members, bridge portions and optionally the connecting members are manufactured as a single unit for convenience and lower costs. Similarly, the bridge portions can be manufactured with openings preformed in the bridge portions. Alternatively, the acoustic panel members, bridge portions and the connecting members can be printed using an additive manufacturing process, either together or as individual components. Again, the openings can be formed post-additive manufacturing process or as part of the additive manufacturing process. Other forms of protective coating may be applied to the acoustic panel assembly, such as powder coating.

[0067] Generally, the acoustic panel members, bridge portions and optionally the connecting members are composed of an extruded metal, preferably lightweight so the acoustic panel assembly can be more easily installed and places less strain on the building or constructional element, yet still be sufficiently strong and provide acoustic and reverberation control. It is preferred that aluminium is used for the acoustic panel members, bridge portions and optionally the connecting members, but other lightweight materials may be used for the acoustic panel assembly. For example, the acoustic panel members, bridge portions and optionally the connecting members can be made of MDF. In this case, the MDF is moulded to a profile and drilled with one or more elongated slots, the MDF being black. However, this moulding process would be slower compared to the extrusion process. It would also have a lower fire rating compared to aluminium. Another example of a lightweight material would be an extruded wood plastic composite (WPG).

[0068] Figures 9 and 10 show how the exterior face layer 70 is applied to the linear batten assembly 1 of Figures 1 A to 1 D as part of the method of manufacturing the acoustic panel assembly. In this process 200, a surface covering is applied to the acoustic panel assembly 1 after extrusion of the battens 10, bridge portions 20 andconnecting members 40, 42, and punching the openings 30 in the bridge portions. The surface covering takes the form of an olefin film sheet 210 in this embodiment and is intended to eventually form the exterior face layer 70 of each batten 10. The film sheet 210 has an adhesive pre-applied to its rear or back surface prior to placement on the battens. In this embodiment, the adhesive is a glue, preferably a polyurethan reactive (PUR) glue.

[0069] The sheet of film 210 is placed on or over the battens 10 and preferably wrapped around the battens 10 but is not fully wrapped. Instead, the film sheet 210 is preferably arranged such that loops 220 are formed in each space 230 between the battens 10, as best shown in Figure 9. In this embodiment, fixed blades 240 each cut the sheet of film 210 at each loop 220 along lines substantially parallel to a longitudinal axis of each batten 10 to create a plurality of individual film sheets, each having side portions 72, 75 and preferably side edges 82, 85, as best shown in Figure 10. Other embodiments may use other cutting devices to slice or cut the film 210 at each loop 220.

[0070] As shown in Figure 10, the side portions 72, 75 of the film sheet 210 are then wrapped around the sidewall portions 52, 55 of each batten 10. This wrapping process is preferably performed by pressure rollers 260. Consequently, the top portion 60 and sidewall portions 52, 55 are covered by the exterior face layer 70, with the side edges 82, 85 of the exterior face layer 70 being tucked underneath the visible top portion and in the pockets 58.

[0071] As a consequence of this process, the acoustic panel assemblies 1, 100, 130, 147, 148, 150 are quicker and easier to manufacture compared to previously known methods, requiring less labour. There is no need to separately mounting the battens 10, 110, 135, 147A, 148A, 155 to carrier rails or clips, which would be ordinarily done manually. Moreover, a more pleasing aesthetic appearance can be obtained, since the separate exterior face layers 70 give the battens 10, 110, 135, 147A, 148A, 155 the appearance of being individual battens or acoustic panel members, thus avoiding the batten assemblies 1, 100, 130, 147, 148, 150 having a solid moulding or artificial look or appearance created with a single exterior face layer applied to the battens. The battens 10, 110, 135, 147A, 148A, 155 and the bridge portions 20 may also be anodised black so that the gaps in between the battens are black to achieve a uniform appearance and assist in disguising the slots 30 to achieve a more pleasing appearance, as discussed above.

[0072] It will further be appreciated that any of the features in the preferred embodiments of the disclosure can be combined together and are not necessarily applied in isolation from each other. For example, to achieve a desired look, the battens 10, 110, 130, 147A, 148A, 150 can each have different appearances or be used in various combinations together to achieve a desired pattern or appearance, such as a set of battens alternating between the rounded battens 10 and the shark nose battens 110. Similar combinations of two or more features from the above described embodiments or preferred forms of the disclosure can be readily made by one skilled in the art.

[0073] The embodiments of this disclosure confer the advantages of providing an acoustic panel assembly that is easier and quicker to install with less labour, due to the use of bridge portions connecting the acoustic panel members and associated openings for sound absorption. The acoustic panel assembly also has a more aesthetically appealing appearance as the separate exterior face layers for each acoustic panel member gives each acoustic panel member an individual and natural appearance. In addition, the acoustic panel assembly may be quickly and easily manufactured and ensures that the desired fire rating can be retained, unlike the prior art. Also, the acoustic panel assembly can be applied on site over new surfaces or retrofitted to existing surfaces, making it more versatile over similar products. In all these respects, the embodiments of the disclosure represent a practical and commercially significant improvement over the prior art.

Claims

Claims1. An acoustic panel assembly comprising: a plurality of acoustic panel members; and a plurality of bridge portions configured to connect each of the acoustic panel members to at least one other acoustic panel member; wherein the plurality of acoustic panel members each have at least two sidewall portions; the plurality of acoustic panel members each comprises an exterior face layer having at least a pair of side portions; and the side portions of each exterior face layer are configured to adhere to the sidewall portions of each acoustic panel member.

2. The acoustic panel assembly of claim 1, wherein the plurality of acoustic panel members each have a cross-section or profile such that the acoustic panel member defines an acute angle with at least one bridge portion.

3. The acoustic panel assembly of claim 1, wherein the plurality of acoustic panel members each have a cross-section or profile such that the acoustic panel member defines a pocket or recess with at least one bridge portion.

4. The acoustic panel assembly of claim 1, wherein the plurality of acoustic panel members each have at least one sidewall portion that defines an acute angle with the at least one bridge portion.

5. The acoustic panel assembly of claim 1, wherein the plurality of acoustic panel members each have at least one sidewall portion that defines a pocket or recess with the at least one bridge portion.

6. The acoustic panel assembly of claim 4 or 5, wherein the at least one sidewall portion extends inwardly towards a base of the acoustic panel member7. The acoustic panel assembly of claim 6, wherein the base of each acoustic panel member is connected to the at least one bridge portion.

8. The acoustic panel assembly of any one of claims 4 to 7, the at least one sidewall portion comprises a lower portion of the acoustic panel member.

9. The acoustic panel assembly of any one of claims 6 to 8, wherein the at least one sidewall portion is connected to the base.

10. The acoustic panel assembly of claim 1, wherein the plurality of acoustic panel members each have a first sidewall portion and a second sidewall portion, and the first and second sidewall portions extend inwardly towards the base of the acoustic panel member.

11. The acoustic panel assembly of claim 1 , wherein the plurality of acoustic panel members each have a first sidewall portion defining a first pocket or recess with a first bridge portion and a second sidewall portion defining a second pocket or recess with a second bridge portion.

12. The acoustic panel assembly of any one of the preceding claims, wherein the side portions of the exterior face layer each have a side edge, wherein the side edges of the exterior face layer are configured to substantially align with edges of the sidewall portions of each acoustic panel member adjacent or connected to the base.

13. The acoustic panel assembly of any one of the preceding claims, wherein each bridge portion comprises one or more openings for absorbing sound14. The acoustic panel assembly of any one of the preceding claims, wherein the acoustic panel assembly comprises one or more connecting members configured to connect the acoustic panel assembly to another acoustic panel assembly and provide locations for receiving one or more fasteners, wherein there are at least two connecting members configured to interconnect with each other.

15. A method of manufacturing the acoustic panel assembly of any one of the preceding claims, comprising the steps of: producing a plurality of acoustic panel members connected by a plurality of bridge portions; applying a film to the plurality of acoustic panel members; and cutting the film to form an exterior face layer for each acoustic panel member.

16. The method of claim 15, wherein the producing step comprises extruding the plurality of acoustic panel members and the plurality of bridge portions.

17. The method of claim 15 or 16, comprising punching, cutting or machining one or more openings into the plurality of bridge portions; anodising the acoustic panel assembly; or any combination thereof.

18. The method of any one of claims 15 to 17, wherein the film applying step comprises applying a sheet of film to the plurality of acoustic panel members to form the exterior face layer and arranging the sheet of film on the plurality of acoustic panel members such that loops are formed in each space between the plurality of acoustic panel members.

19. The method of claim 18, comprising cutting the sheet of film along a line in each loop to create a plurality of film sheets, each having side portions and side edges.

20. The method of claim 19, comprising wrapping the side portions of each film sheet around sidewall portions of each acoustic panel member to hide the side edges.

Images