Acoustical Building Panel With Press-Formed Recess for Monolithic Seams

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Solution Overview

Problem

Existing surface covering systems, such as drywall, are poor at controlling noise within a room environment while maintaining a monolithic appearance.

Innovation Solution

The development of an acoustical building panel with a fibrous panel featuring a central portion and a perimeter portion, where the perimeter portion has a recess press-formed into it, creating a seam channel when panels are mounted. This system includes a seam concealment sub-system and a coating to achieve a monolithic appearance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Shape

If drywall-based surface covering systems are used to achieve a monolithic appearance, then aesthetic appeal is improved, but acoustic performance deteriorates

Engineering Contradiction:

Improvemonolithic appearanceVSAvoidnoise control

Core Design Contradiction:

ShapeVSObject-affected harmful factors

Solution Approach 1:

The panel is divided into a central portion and a perimeter portion with different densities. The central portion has lower density for acoustic absorption, while the perimeter portion has higher density for structural integrity and seam formation. This segmentation allows the panel to simultaneously achieve monolithic appearance and acoustic performance.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the panel have different material properties. The central portion is designed with lower density fibrous material optimized for acoustic absorption, while the perimeter portion uses higher density material for structural support and to create the recess profile. This local differentiation resolves the contradiction between appearance and acoustic function.

Inventive Principle:

Principle #3Local quality

2Object-affected harmful factors

If acoustical panels are used to control noise, then acoustic performance is improved, but aesthetic appearance deteriorates due to visible seams and grid

Engineering Contradiction:

Improvenoise reductionVSAvoidseam visibility

Core Design Contradiction:

Object-affected harmful factorsVSShape

Solution Approach 1:

The recess is press-formed into the panel during manufacturing, creating a pre-configured profile that anticipates the need for seam concealment. This preliminary action allows the recess to define a seam channel that can be filled to create a monolithic appearance, eliminating the need for post-installation grid or visible seam treatments.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

A seam concealment subsystem is introduced as an intermediary element that fills the seam channels formed by the recesses of adjacent panels. This mediator component hides the seams between panels while maintaining the acoustic performance of the fibrous panel material, resolving the contradiction between acoustic function and aesthetic appearance.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Shape

If recess is press-formed into perimeter portion, then seam channel formation is improved for monolithic appearance, but manufacturing complexity increases

Engineering Contradiction:

Improveseam channel formationVSAvoidpress-forming process

Core Design Contradiction:

ShapeVSEase of manufacture

Solution Approach 1:

The density parameter of the fibrous material is varied between the central and perimeter portions during panel formation. By controlling the density distribution and press-forming depth, the recess is created in a single manufacturing step without requiring complex multi-stage processing. This parameter control resolves the contradiction between achieving the desired seam channel shape and maintaining manufacturing simplicity.

Inventive Principle:

Principle #35Parameter changes

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The acoustical building panel effectively reduces noise within a room environment while maintaining a seamless, monolithic appearance, addressing the limitations of traditional drywall-based systems.

Implementation Method 1

a fibrous panel comprising: a central portion having a first major surface; a perimeter portion circumscribing the central portion; a recess press-formed into the perimeter portion

Methodology Applied

Scientific EffectAcoustic absorption: Acoustic Absorption

Data Source

PatentUS12221784B2Acoustical building panel, monolithic surface covering system incorporating an acoustical building panel, and methods of forming and installing the same

Publication Date: 2025.02.11 AWI LICENSING LLC

AI summary

An acoustical building panel is disclosed that comprises a fibrous panel comprising: a central portion having a first major surface; a perimeter portion surrounding the central portion; a recess press-formed into the perimeter portion, the recess circumscribing the first major surface and comprising a recess floor surface; a second major surface opposite the first major surface; and side edge surfaces that define a perimeter of the fibrous panel and extend from the second major surface to the recess floor surface.