SOUND-ABSORBING PANEL WITH MODIFIABLE SIZE AND/OR SHAPE AND ASSOCIATED MANUFACTURING METHOD

Abstract

A sound-absorbing panel comprising a padding layer with a first face, a second face and an edge, a fabric and fastening members for fixing the fabric to the padding layer, is described, wherein the padding layer comprises a layer of heat-bonded synthetic fibers, wherein the density of the fibers in the proximity of the first face and in the proximity of the second face is greater than the density of the fibers in the central zone of the padding layer, wherein the fabric is arranged so as to adhere to the first face and to the edge of the padding layer and form fabric flaps along the second face, wherein the fastening members are removable fastening members and are configured to fix at least one of the fabric flaps to the padding layer along the second face.

Claims

1. A sound-absorbing panel comprising a padding layer with a first face, a second face and an edge, a fabric and fastening members for fixing the fabric to the padding layer, wherein the padding layer comprises a layer of heat-bonded synthetic fibers, wherein the density of the fibers in the proximity of the first face and in the proximity of the second face is greater than the density of the fibers in the central area of the padding layer, wherein the fabric is arranged so as to adhere substantially to the first face and to the edge of the padding layer and to form fabric flaps along the second face, wherein the fastening members are removable fastening members and are configured to fix at least one of the fabric flaps to the padding layer along the second face, wherein the fastening members comprise at least one screw.

2. The sound-absorbing panel of claim 1, wherein the edge is a sharp-cut edge.

3. The sound-absorbing panel of claim 1, wherein the fastening members do not comprise glue or adhesive.

4. The sound-absorbing panel of claim 1, wherein the fastening members are discrete fastening members.

5. The sound-absorbing panel of claim 1, wherein the fastening members comprise one or more of the following: nails, metal staples, staples made of non-metallic material, snap-fasteners, buttons and eyelets or rubber bands.

6. The sound-absorbing panel according to claim 1, wherein at least one fabric flap is fixed with at least one first screw in the proximity of a first end thereof and a second screw in the proximity of its second end.

7. The sound-absorbing panel of claim 6, wherein the at least one fabric flap is also fixed with one or more staples.

8. The sound-absorbing panel according to claim 1, wherein the fabric is shaped as an open box and comprises a bottom, edges and flaps.

9. The sound-absorbing panel according to claim 1, wherein the fabric is made by interweaving an elastic texturized yarn and comprises polyester.

10. A method of modifying the shape and/or size of a sound-absorbing panel, comprising: providing a sound-absorbing panel according to claim 1, wherein the sound-absorbing panel comprises a first shape and a first size; removing one or more of the fastening members and temporarily uncovering a part of the edge of the padding layer; cutting a portion of the padding layer; covering again the uncovered part of the edge with the fabric; and fixing again the fabric by means of one or more fastening members, thus obtaining a sound-absorbing panel with a second shape and/or a second size.

11. The method of claim 10, wherein the step of fixing again the fabric is carried out using, at least in part, the fastening members with which the fabric was originally fixed to the padding layer.

12. The method of claim 10, wherein the step of cutting a portion of the padding layer comprises the step of cutting the padding layer with a straight-blade cutting member, for example a cutter knife.

13. The method of claim 10, further comprising the step of cutting off the excess fabric.

14. A method for manufacturing a sound-absorbing panel according to claim 1, comprising: providing a padding layer with a first face, a second face and an edge, wherein the padding layer comprises a layer of heat-bonded synthetic fibers, wherein the density of the fibers in the proximity of the first face and in the proximity of the second face is greater than the density of the fibers in the central area of the padding layer; providing a fabric shaped so as to form a bottom of shape and size substantially corresponding to the first face, and edges of shape and size substantially corresponding to the edges, and flaps which extend from said edges; coupling the padding layer to the fabric; and applying fastening members so as to fix the fabric to the padding layer along the second face, wherein said fastening members comprise at least one screw screwed into the thickness of the padding layer from the second face.

15. The method of claim 14, wherein the step of applying fastening members comprises applying at least one staple and/or other removable fastening members.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0050] FIG. 1 shows, by way of example, a portion of a padding layer while it is being partially lined with a fabric according to the present invention;

[0051] FIG. 2 shows, in schematic form, a portion of fabric for lining a padding layer according to the present invention;

[0052] FIG. 3 shows, in schematic form, the portion of fabric while it is being fixed to the padding layer according to the invention;

[0053] FIG. 4 shows, in schematic form, the portion of fabric fixed to the padding layer according to a method of the present invention;

[0054] FIG. 5 shows, in schematic form, a cross-section through the padding layer with the fabric and two screws for fixing the fabric to the padding layer;

[0055] FIG. 5a shows, in schematic form, a further cross-section through the padding layer with the fabric and two screws for fixing the fabric to the padding layer;

[0056] FIG. 5b shows, in schematic form, a further cross-section through the padding layer with the fabric and two screws for fixing the fabric to the padding layer;

[0057] FIG. 6 shows, by way of example, the rear face of a sound-absorbing panel according to the present invention;

[0058] FIG. 7 shows, in schematic form, the step during which the fabric is partially removed so as to allow cutting of a part of the padding layer, for example using a cutter knife; and

[0059] FIG. 8 shows, in schematic form, the step where the fabric is being fixed again to the rear face of the padding layer.

DETAILED DESCRIPTION

[0060] According to the present invention a sound-absorbing panel suitable for being modified in terms of its shape and/or its size is described. A method for modifying the shape and/or the size of a sound-absorbing panel is also described.

[0061] A sound-absorbing panel according to the present invention may be used on its own or in combination with other sound-absorbing panels in order to form structures suitable for installation in various environments in order to improve the acoustics thereof. They may be used to form walls, partitions, ceilings, false ceilings or the like. They may also be used to form furniture or parts of furniture, such as chairs, tables, sofas, bookshelves or the like.

[0062] For the purposes of the present description and the claims, it must be understood that, except where otherwise indicated, all the numbers which express values, quantities, percentages and the like are to be interpreted as being preceded, in each case, by the term about. Furthermore, all the ranges include every combination of the end values indicated within the range and include all the sub-ranges, which may also not be specifically indicated in the present description.

[0063] The sound-absorbing panel 1 according to the present invention may assume any shape. For example, a rectangular, square, round, regular polygon or irregular polygon shape.

[0064] According to the present invention and as will be described below, a padding layer 10 of heat-bonded synthetic fibers, a fabric 20 and fastening devices 31, 32 for fixing the fabric 20 to the padding layer 10 are provided.

[0065] The padding layer 10 comprises a first face 11 and a second face 12. Viewed in cross-section the padding layer 10 (according to embodiments) has a substantially constant cross-section. See in this connection FIGS. 5, 5a and 5b.

[0066] According to the present invention, the padding layer 10 comprises (or is essentially composed of) heat-bonded synthetic fibers.

[0067] In one embodiment, the heat-bonded synthetic fibers comprise polyester fibers.

[0068] Preferably, the fibers have a diameter of between 20 ?m (micron) and 50 ?m (micron), preferably a diameter of between 30 ?m (micron) and 35 ?m (micron).

[0069] The fibers can be used in a temperature range of between ?40? C. and +80? C.

[0070] Preferably, the fibers are non-toxic and non-irritants. Furthermore they may be able to be fully recycled.

[0071] According to the present invention, the density of the fibers in the proximity of the first face 11 and in the proximity of the second face 12 is greater than the density of the fibers in the central zone 13. The greater density of the padding layer 10 in the proximity of the outer faces 11 and 12 makes them more rigid and imparts rigidity to the panel 1. Furthermore, as will be clarified below, the fastening devices 31, 32 may be firmly fastened in order to fix the fabric 20 to the padding layer 10.

[0072] According to embodiments, the padding layer 10 is not delimited by a rigid edge which has a smaller thickness (and therefore a high fiber density and consequently is rigid). For example, the padding layer 10 terminates substantially with a sharp-cut edge. For the purposes of the present description and the attached claims, the expression sharp-cut will mean that the padding layer is cut at 90? (as shown in FIG. 5) or has a cut otherwise inclined, as shown in FIGS. 5a and 5b. The angle of inclination of the cut may be a few degrees or greater, such as 30?, 45? or 60?. Among the inclined cuts, the preferred angle is 45?. A cut is sharp-cut irrespective as to any chamfer or rounding along the first face 11 and/or the second face 12.

[0073] According to embodiments, the padding layer 10 comprises an edge which has a smaller thickness (with a high fiber density and rigid) along a perimetral section. For example, the edge with a smaller thickness may be provided along one or two sides of the panel 1, in the case where the panel has a polygonal shape.

[0074] The sound-absorbing panel 1 according to the invention also comprises a fabric 20. According to embodiments, the fabric 20 is fixed at least to one face (11 or 12) of the padding layer. According to embodiments, the fabric is fixed only to one face (12) of the padding layer 10.

[0075] Although, as mentioned above, the padding layer 10 is substantially symmetrical when viewed in cross-section, and therefore a visible face and an opposite face is not identifiable, the fabric 12 is applied to the padding layer 10 so as to define a visible face and a face opposite thereto.

[0076] In other words, the fabric 20 is applied so as to cover completely a first face 11 which, accordingly, is defined as being the visible face, typically exposed to the sound source. The fabric 20 is preferably applied so as to cover at least partly the edges 15 of the padding layer 10. More preferably, the fabric 20 is applied so as to cover completely the edges 15 of the padding layer 10 so as to cover and not expose the sections of the padding layer 10. According to embodiments, the fabric 20 is applied so as to cover, at least in part, the second face 12, namely the face opposite to the face 11 which defines the visible face of the panel 1. According to embodiments, the fabric 20 is applied so as to cover, substantially entirely, the second face 12, namely the face opposite to the visible face.

[0077] Preferably, the fabric 20 is not fastened to the first face 11 of the padding layer. Preferably, in any case, the fabric 20 is not fastened to the first face 11 with adhesive or the like.

[0078] Preferably, the fabric 20 is not fastened to the edge 15 of the padding layer 10. Preferably, in any case, the fabric 20 is not fastened to the edge 15 of the padding layer 10 with adhesive or the like.

[0079] According to embodiments, the fabric 20 is fastened to the padding layer 10 along the second face 12. According to embodiments, the fabric 20 is fastened to the padding layer 10 substantially only along the second face 12, opposite to the first face 11.

[0080] The fabric 20 is fastened to the second face 12 by means of one or more devices such as screws, nails, staples made of metal (or other material), strips of Velcro? or the like or strips of double-sided tape, or a combination thereof. The fabric 20 may also be fastened by means of snap fasteners, buttons and eyelets or a combination thereof. The fabric may also be fastened by means of rubber bands.

[0081] According to embodiments, the fabric 20 is not fastened by means of adhesive or, alternatively, the fabric is not only fastened by means of adhesive.

[0082] Preferably, the fabric 20 is made of polyester.

[0083] For example, the fabric 20 is made by interweaving an elastic texturized yarn with a yarn count of 750 dtex along warp and weft. The structure may be formed by 1600 threads and 1500 wefts per meter with a cr?pe weave. The weight per square meter may be 300 g. In one embodiment, the fabric is of the Trevira CS flame-retarding type.

[0084] According to one embodiment, the fabric has the following properties: [0085] specific strength of between 527 and 1552 [Pa s/m]; and [0086] mass porosity of between 66% and 79%.

[0087] Preferably, the fabric has a specific strength of between 723 and 1213 [Pa s/m] and mass porosity of between 74% and 77%.

[0088] Preferably, the warp of the fabric comprises between 5 and 70 threads per centimeter.

[0089] More preferably, the warp of the fabric comprises between 5 and 40 threads per centimeter.

[0090] Even more preferably, the warp of the fabric comprises between 15 and 40 threads per centimeter.

[0091] Preferably, the weft of the fabric comprises between 5 and 70 threads per centimeter.

[0092] More preferably, the weft of said fabric comprises between 5 and 40 threads per centimeter.

[0093] Even more preferably, the weft of said fabric comprises between 12 and 22 threads per centimeter.

[0094] According to embodiments, as shown in various figures, the fabric 20 is arranged so as to adhere to (or be substantially directly facing) the first face 11 and the edges 15 and is folded over onto the second face 12. For example, the fabric 20 may be shaped as an open box, namely with a bottom 21, edges 25 and flaps 22. Each flap 22, preferably, is separately fastened to the second face 12. For example, each flap 22 is fastened by means of screws 31 and/or metal staples 32. Advantageously, a flap 22 may be fastened to the padding layer 10 and also the other layer 22, for example by means of metal staples 32.

[0095] The sound-absorbing panel 1 according to the invention is configured to be modified. In particular, the shape and/or the size of the sound-absorbing panel 1 according to the present invention may be changed so as to adapt it better to the requirements of the site where it will be installed. The modification may be performed before transportation to the installation location or also on-site if the need to modify the panel should arise at that moment (or if it is important to ensure that the panel is modified in the correct manner).

[0096] For example, a rectangular panel 1 with side L1 and height H1 may be modified so as to obtain a rectangular panel with shorter side L2, i.e. L2<L1, or a square panel, i.e. with L2=H1.

[0097] The person performing the modification must remove the fabric 20 by the amount need to expose the padding layer 10 in the zone where the cut is to be made (broken line 16 in FIG. 7). For example, the person may remove the screws 31 and then remove the metal staples 32, raising the fabric flap to the height required. The padding layer 10 may then be cut. Thereafter the fabric 20 may be repositioned, fastening it to the padding layer 10 in a similar manner to the way in which it was fastened before modification (or in another way). For example, the fabric may be fixed again using the same screws 31 which will remain screwed to the fabric and so do not risk falling to the ground and being lost. Typically the metal staples which should remain attached to the fabric must be removed and replaced. In FIG. 7 the metal staples 32 have not yet been removed. Obviously, according to the present invention, the screws could be replaced.

[0098] Obviously, the fabric flap 22 corresponding to the side where the cut was made will be longer. Said flap may be kept longer, as shown in FIG. 8, or may be cut so as to have the same length as the other flaps 22.

[0099] The padding layer may be cut at angle of 90? or may be inclined (i.e. not perpendicular) at a different angle so as form a trapezium-shaped panel. This may be necessary when the wall to which the panel will be fixed does not have level walls. The inclination may be only a few degrees, for example less than 5?, or a greater angle, for example 5?, 10? or 15?.

[0100] Cutting of the padding layer 10 may be performed using any suitable tool. For example, it may be performed using a strong cutter knife 40 or straight-edge blade.

[0101] Reciprocating blades, circular blades or reciprocating circular blades may also be used, provided, preferably, that they do not have teeth.

[0102] Advantageously, therefore, the sound-absorbing panel according to the invention may be shaped so as satisfy the specific requirements for its use. The panel, owing to the variable density and in particular owing to the greater density in the proximity of the outer faces, is sufficiently rigid and self-supporting. No frame is required and therefore modification of the frame is not necessary, as instead the case in the known sound-absorbing panels.

[0103] The length of the screws is preferably proportional to the thickness of the panel. According to embodiments, the screws have a length not smaller than about one third of the panel thickness. According to embodiments, the screws have a length not smaller than about half the panel thickness. According to embodiments, the screws have a length not smaller than about two thirds of the panel thickness.