Acoustical Panel Frame Using Aluminum Composite Laminate

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Solution Overview

Problem

Existing acoustical panel frames are often heavy, aesthetically limited, and difficult to reproduce, especially when made of metal, and face challenges in consistent dimensionality and aesthetic matching after damage, while wood panels are costly and hard to manufacture uniformly.

Innovation Solution

The use of aluminum composite laminate substrates for acoustical panel frames, which are lightweight, dimensionally stable, and receptive to printing, combined with die-cutting, hole punching, and folding grooves to create a frame that can be easily assembled and customized with digital or screen printing, meeting ASTM E84 smoke and fire ratings.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If metal framing panels are used, then reproducibility is improved, but weight increases and aesthetic appeal deteriorates

Engineering Contradiction:

ImprovereproducibilityVSAvoidweight

Core Design Contradiction:

Ease of manufactureVSWeight of moving object

Solution Approach 1:

The patent employs aluminum composite laminate substrate combining aluminum and polymer layers to achieve lightweight properties while maintaining structural integrity and dimensional stability, resolving the contradiction between metal strength and weight

Inventive Principle:

Principle #40Composite materials

2Shape

If wood panels are used, then aesthetic appeal is improved, but manufacturing precision deteriorates

Engineering Contradiction:

Improveaesthetic appealVSAvoiddimensional consistency

Core Design Contradiction:

ShapeVSManufacturing precision

Solution Approach 1:

The aluminum composite laminate provides uniform dimensional properties and stability while accepting various surface treatments and printing methods to achieve aesthetic appearance, decoupling manufacturing precision from aesthetic quality

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent applies digital printing and screen printing to the aluminum composite substrate to create various surface finishes and patterns, allowing aesthetic customization without compromising manufacturing precision

Inventive Principle:

Principle #32Color changes

3Shape

If wood panels are used, then aesthetic appeal is improved, but cost increases

Engineering Contradiction:

Improveaesthetic appealVSAvoidcost

Core Design Contradiction:

ShapeVSQuantity of substance

Solution Approach 1:

The aluminum composite laminate provides a cost-effective alternative to expensive wood panels while maintaining aesthetic appeal through printing and surface treatment capabilities

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The combination of aluminum and polymer layers creates a material that is both aesthetically versatile and economically advantageous compared to solid wood

Inventive Principle:

Principle #40Composite materials

4Ease of manufacture

If metal paneling frames are used, then reproducibility is improved, but surface finish versatility deteriorates

Engineering Contradiction:

ImprovereproducibilityVSAvoidsurface finish versatility

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The aluminum composite laminate substrate accepts digital printing and screen printing processes, enabling diverse surface finishes and patterns while maintaining consistent manufacturing quality

Inventive Principle:

Principle #32Color changes

Solution Approach 2:

The aluminum composite material provides a versatile platform that combines manufacturing consistency with surface treatment flexibility

Inventive Principle:

Principle #40Composite materials

Data Source

PatentUS10640971B1Acoustical panel frame

Publication Date: 2020.05.05 VOMELA SPECIALTY CO

AI summary

An acoustical panel apparatus includes a laminate panel substrate that is receptive to ink printing operations. The substrate may be provided with folding grooves to form an apertured base, a sidewall, and an inner wall which together define a receptacle. An acoustical tuning body is positionable at the receptacle to attenuate at least one of sound transmissions and sound reflections from sound passing through the apertures in the base. A mounting bracket is attached to the panel to secure the acoustical tuning body at the receptacle and for mounting the panel substrate to a wall or ceiling.