UNDERLAYMENT

Abstract

A composite comprising a core, a first cover layer and a second cover layer, wherein the core is provided from an uncut flat body, wherein the core is a three dimensional structure having a first main surface and a second main surface, the first cover layer is in contact with the first main surface creating multiple contact areas and the second cover layer is in contact with the second main surface creating multiple contact areas, wherein the multiple contact areas between the first cover layer and the first main surface are offset in x-direction and y-direction to the multiple contact areas between the second cover layer and the second main surface, characterized in that the first cover layer and the second cover layer are different.

Claims

1. A composite comprising: a core, a first cover layer (101) and a second cover layer, wherein the core is provided from an uncut flat body, wherein the core is a three dimensional structure having a first main surface and a second main surface, the first cover layer is in contact with the first main surface creating multiple contact areas and the second cover layer is in contact with the second main surface creating multiple contact areas, wherein the multiple contact areas between the first cover layer and the first main surface are offset in x-direction and y-direction to the multiple contact areas between the second cover layer and the second main surface, wherein the first cover layer and the second cover layer are different.

2. The composite according to claim 1, wherein a first intermediate layer is located between the first cover layer and the first main surface and/or a second intermediate layer is located between the second cover layer and the second main surface.

3. The composite according to claim 2, wherein the first intermediate layer and/or the second intermediate layer is a continuous layer, a discontinuous layer, a film, a slit film, an adhesive, a hotmelt, a woven fabric, a nonwoven fabric, a continuous fiber web, a discontinuous fiber web, and/or a foam.

4. The composite according to claim 2, wherein the first intermediate layer and/or the second intermediate layer has a weight of at most 1200 g/m.sup.2, preferably of at most 300 g/m.sup.2, even more preferably of at most 200 g/m.sup.2 even more preferably of at most 150 g/m.sup.2, even more preferably of at most 100 g/m.sup.2, and most preferably of at most 50 g/m.sup.2.

5. The composite according to claim 1, wherein the first cover layer and/or the second cover layer is a foam, a textile fabric, a sheet of material, a laminate of two or more layers, or any combination thereof.

6. The composite according to claim 1, wherein the first cover layer and/or the second cover layer has a weight of at most 1200 g/m.sup.2, preferably of at most 500 g/m.sup.2, more preferably of at most 250 g/m.sup.2, even more preferably of at most 125 g/m.sup.2, even more preferably of at most 60 g/m.sup.2, and most preferably of at most 40 g/m.sup.2.

7. The composite according to claim 5, wherein the textile fabric comprises fibers and is preferably a woven, a knitted fabric, a spun-laid nonwoven, a carded nonwoven, an air-laid nonwoven, a wet-laid nonwoven, a meltblown nonwoven, a layer of unidirectional fibers, a net, a scrim, a two-dimensional entangled mat of extruded filaments, or any combination thereof.

8. The composite according to claim 7, wherein the fibers of the textile fabric are monofilaments, multifilament yarns, mono-component fibers, two mono-component fibers and/or bicomponent fibers.

9. The composite according to claim 1, wherein the uncut flat body is plastically deformed.

10. The composite according to claim 9, wherein the core is obtained from the plastically deformed uncut flat body by folding.

11. The composite according to claim 1, wherein the core has a three-dimensional form comprising a honeycomb structure, a trapezoidal structure or a structure comprising cylindrical and/or truncated cone like projections.

12. The composite according to claim 10, wherein the cells comprised in the honeycomb structure have a diameter of 1 mm to 60 mm, preferably of 2 to 40 mm, and more preferably of 2 to 30 mm, even more preferably of 2 to 20 mm, and most preferably of 3 to 10 mm and/or honeycomb cells have a height of 1 mm to 60 mm, preferably of 2 mm to 30 mm, and more preferably of 3 to 20 mm, and most preferably of 3 to 10 mm.

13. The composite according to claim 10, wherein the core comprises half-hexagonal cell walls, is folded such that the cell walls are not fully vertical and is preferably rollable.

14. The composite according to claim 13, wherein two in machine direction consecutive half hexagonal cells form an angle of up to 110°, preferably between 1° and 90°, more preferably between 15° and 80°, even more preferably between 30° and 75°, and most preferably between 35° and 70°.

15. The composite according to claim 13, wherein the half-hexagonal cells comprised in the core structure have a diameter of 1 mm to 60 mm, preferably of 2 to 40 mm, and more preferably of 2 to 30 mm, even more preferably of 2 to 20 mm, and most preferably of 3 to 10 mm and/or the half-hexagonal cells have a height of 1 mm to 60 mm, preferably of 2 mm to 30 mm, and more preferably of 3 to 20 mm, and most preferably of 3 to 10 mm.

Description

[0148] The object is also solved by a ceiling system comprising a ceiling surface covering and the composite according to the embodiments disclosed herein above.

[0149] FIG. 1: Schematic cross sectional view of a composite according to the invention.

[0150] FIG. 2: Schematic cross sectional view of a composite according to a preferred embodiment of the invention.

[0151] FIG. 3: Schematic cross sectional view of a relaxed honeycomb structure.

[0152] FIG. 4: Schematic top view of a honeycomb cell.

[0153] FIG. 5: Schematic perspective view of a part of a honeycomb cell of a relaxed honeycomb structure.

[0154] FIG. 6 Schematic cross sectional view of a fully folded honeycomb cell of a honeycomb structure.

[0155] FIG. 7: Schematic perspective view of a part of a relaxed honeycomb structure

[0156] FIG. 1 shows a schematic cross sectional view of a composite according to the invention comprising a core 102 provided from an uncut flat body, a first cover layer 101, which is in contact with the first main surface (not shown) of the core 102 and a second cover layer 103, which is contact with the second main surface (not shown) of the core 102.

[0157] FIG. 2 shows a schematic cross sectional view of a composite comprising a relaxed honeycomb structure 202 as a core, a first cover layer 201, which is in contact with the first main surface (not shown) of the relaxed honeycomb structure 202, and a second cover layer 203, which is in contact with the second main surface (not shown) of the relaxed honeycomb structure 202. Further, the composite 200 comprises void volumes 204a/b between the cover layers 201 and 203 and the relaxed honeycomb structure 202. The machine direction MD is indicated by an arrow.

[0158] FIG. 3 shows a side view of a relaxed honeycomb structure 302, which has an angle α between two in machine direction consecutive half honeycomb cells 306 and 307. Thereby, the two half honeycomb cells are folded such that an angle α is established by the corner points 308a-c and 308d-f. The machine direction MD and cross direction CD are indicated by arrows.

[0159] FIG. 4 shows a schematic top view of a honeycomb cell 400. In this honeycomb cell 400 the diameter d is the perpendicular distance between two parts 401a of two consecutive half hexagonal cell walls of the honeycomb structure in machine direction, which are oriented parallel to each other. The machine direction MD and cross direction CD are indicated by arrows.

[0160] FIG. 5 shows a schematic perspective view of a part of a honeycomb cell of a relaxed honeycomb structure 500 comprising a kink 503 and a cell wall of the half hexagonal cell walls of the relaxed honeycomb structure 501, which is oriented parallel to the kink 503. The diameter of the honeycomb cells of the relaxed honeycomb structure is determined by measuring the diameter d.sub.half between the kink 503 and the cell wall of the half hexagonal cell of the relaxed honeycomb structure 501, which is perpendicular to the kink 503 and perpendicular to the plane of the cell wall 501, and sum up the diameters d.sub.half of two half hexagonal cells, which share the same kink 503. The partially dashed lines 502 indicates the half hexagonal cell of the relaxed honeycomb structure. The machine direction MD and cross direction CD are indicated by arrows.

[0161] FIG. 6 shows a schematic cross sectional view of a fully folded honeycomb cell of a honeycomb structure 600 comprising a connecting area 602 and honeycomb cell walls 601. The height of the fully folded honeycomb cell 600 is measured as the perpendicular distance between the plane of connecting area 604 and the end of the honeycomb walls 601. The machine direction MD and cross direction CD are indicated by arrows.

[0162] FIG. 7 shows a part of a relaxed honeycomb structure 700 half hexagonal honeycomb cells 701 having a height h and a half diameter d.sub.half. Also the relaxed honeycomb structure 700 comprises kinks 703 and connecting areas 704. The machine direction MD and cross direction CD are indicated by arrows.