• 专利附录
  • 专利说明
  • 权利要求
  • 类似技术
  • 同族专利
  • 引用文献
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    • 专利摘要:
    Fig. 1 A sound-absorbing assembly (10) is provided, comprising: - a support plate (30); and - a woven or knitted upper fabric layer (20) that is adhered directly to the flat side (35) of the support plate (30) facing the chamber. The thickness (22) of the upper fabric layer of the woven or knitted upper layer (20) is in the range of 1/7 to 1/12 of the support plate thickness (32). FIG. 1
    公开号:BE1022769B1
    申请号:E2015/5719
    申请日:2015-11-05
    公开日:2016-08-31
    发明作者:Eecke Kristoff Dries Koen Ver
    申请人:Triplaco Nv；
    IPC主号:
    专利说明:

    Field of the Invention The present invention relates generally to a sound-absorbing assembly and a method of manufacturing such a sound-absorbing assembly. More specifically, the invention relates to sound-absorbing assemblies for use as, for example, plate-shaped building elements, also called building panels, ceiling panels, wall panels, partition panels, etc.
    Background of the invention. Such a sound-absorbing assembly is known, for example, from DE19839973. This describes a sound-absorbing assembly for use as a plate-shaped building element. The sound-absorbing assembly comprises a support plate structure which is formed by a perforated plate of about 6 to 30 mm thick, made of a solid material such as metal, wood, chipboard, MDF plate, flattening board, synthetic material or plaster. This support plate structure comprises a pattern of support plate holes or a grid with holes that occupy 10-90% of the surface. The support plate holes in the support plate structure are relatively large, for example in the range of 2 mm to 30 mm. The sound-absorbing assembly further comprises a microperforated sheet or thin plate disposed on one of the plate surfaces of the support plate structure. The microperforated sheet or thin plate comprises microbones with diameters of less than 2 mm with the holes occupying less than 4% of the total area. It is known from DE19839973 that the support plate holes and microgoles work together to form a Helmholtz resonator structure.
    [03] DE19839973 shows that when a non-woven material or fabric with a suitable flow resistance is used as a porous layer that is placed or stretched on one side of the perforated support plate structure with the large support plate holes, as shown in Figure 4 of DE19839973, entails disadvantages. According to DE19839973 there is thus the disadvantage that this non-woven material or fabric easily becomes dirty when it is placed on the side facing the space to be damped, and moreover the hole pattern and / or the frame of the carrier plate holes remain visible. According to DE19839973 it is therefore essential to use a microperforated sheet that is not made of a fabric or a non-woven material on top of the support plate structure.
    However, such a microperforated sheet, which is manufactured, for example, as a high pressure laminate or HPL, for example on top of a support plate structure that is manufactured as MDF, even if provided with relatively small microperforations in the form of holes or slots, causes a regular and typically repetitive pattern that is clearly visible. In addition, drilling or milling holes or slots in such high-quality materials is a process that requires high-performance and high-precision tools not to damage the surface around the micro-perforations. This limits the efficiency and increases the costs of manufacturing such a sound-absorbing assembly.
    [05] A manufacturing process for a sound-absorbing assembly in which a porous fabric is glued to a rigid panel body with openings. The pores of the fabric are thereby substantially smaller than the openings in the panel body. To allow suitable air flow through the fabric to the openings in the panel body, the glue is applied by means of a nozzle in a rotating pattern around these openings. Such a complicated process for applying the glue limits the efficiency and increases the cost of the manufacturing process for such a sound-absorbing assembly.
    [06] Therefore, there is still a need for a simpler, more robust, high-performance sound-absorbing assembly that overcomes the above-described problems and that can be manufactured more efficiently.
    Summary of the invention [07] According to a first aspect of the invention, a sound-absorbing assembly is provided, comprising: - a support plate comprising: - a support plate thickness, between the flat side facing the chamber and the opposite flat side facing the wall, in the range of 5 mm to 30 mm; - a plurality of support plate openings extending through the support plate from the flat side facing the chamber to the flat side facing the wall, comprising an opening width in the range of 4 mm to 12 mm and a center-to-center distance in the range from 110% to 500% of the opening width; and - an upper fabric layer which is adhered directly to the flat side of the support plate facing the chamber and which consists of a woven or knitted fabric;
    CHARACTERIZED THAT the thickness of the upper fabric layer is in the range of 1/7 to 1/12 of the support plate thickness.
    [08] In this way, surprisingly, improved sound absorption values are obtained over comparable sound-absorbing assemblies that use a micro-perforated sheet or thin plate comprising microgoles as the top layer. In this specific thickness range of the woven upper layer, the pores of the fabric cause an optimized Helmholtz resonator-like effect. In addition to the Helmholtz resonator-like effect, the more irregular structure of the fabric and its yarns, when compared to a flat microperforated sheet, causes a more optimized dispersion and damping of the sound pressure waves. In addition, the visual appearance of the sound-absorbing panel is improved since the pores of the woven upper layer do not lead to a characteristic repetitive pattern, and this specific thickness range of the woven upper layer ensures that the support plate openings and / or the support plate frame are no longer clearly visible when the sound-absorbing assembly is mounted against a wall, ceiling, or other suitable surface in a room. Similar advantages can also be realized by means of a knitted upper fabric layer with the same range for the ratio between the thickness of the knitted upper fabric layer and the support plate thickness.
    According to an embodiment, a sound-absorbing assembly is provided, characterized in that: the support plate thickness is in the range of 6 mm to 12 mm; and - the thickness of the woven upper layer is 1/8 to 1/10 of the support plate thickness.
    [10] In this way, the Helmholtz resonator-like effect of the support plate and the woven upper layer is further optimized, leading to optimized sound attenuation values. Alternatively, a knitted upper layer with a thickness of the upper fabric layer in the range of 1/8 to 1/10 of the support plate thickness can be provided.
    [11] According to a further embodiment, a sound-absorbing assembly is provided, characterized in that the woven upper fabric layer comprises yarns with a thickness in the range of 50% to 120%, preferably 80% to 100%, of the thickness of the woven upper low.
    [12] In this way, a suitable woven upper fabric layer will comprise a suitable percentage of holes and sufficient corrugation at the level of the warp threads and weft threads to obtain an improved sound damping effect. It is clear that the thickness of the yarn of the woven upper fabric layer means the cross-sectional dimension of the yarn.
    For example, in the case of a monofilament yarn with a circular cross section, the thickness of the yarn refers to the diameter of the yarn. However, when the cross-section of the yarn has an alternative cross-section such that, if woven between the fabric of the woven upper fabric layer, the dimension of the cross-section of the yarn in the direction transverse to the plane of the woven fabric deviates considerably from the size of this cross-section in the direction of the plane of the woven fabric, the thickness of the yarn refers to the cross-sectional dimension of the yarn generally transverse to the plane of the woven fabric.
    [13] Alternatively, a knitted upper fabric layer can be provided and preferably the yarns have a similar ratio between their thickness and the thickness of the knitted upper layer as with a woven fabric; thus a suitable percentage of holes and sufficient corrugation is provided at the level of the knitted yarns to achieve an improved sound damping effect.
    [14] According to a further embodiment, a sound-absorbing assembly is provided, characterized in that the yarns comprise a monofilament yarn. For example: - a monofilament yarn comprising a coating, for example a monofilament glass yarn comprising a co-extruded polymer coating; - a monofilament polymer yarn; - a monofilament glass fiber yarn; or - any other suitable monofilament yarn.
    [15] Such monofilament yarns guarantee good structural stability for the woven upper fabric layer and moreover guarantee an optimum percentage of holes and sufficient corrugation at the level of the warp threads and weft threads in order to obtain a sound damping effect.
    [16] According to a further embodiment, a sound-absorbing assembly is provided, characterized in that the yarns comprise one or more of the following: - a yarn comprising a monofilament glass fiber core and at least one coating comprising polyvinyl chloride or polyethylene or any other suitable polymer or combination thereof; - a filament yarn, preferably a synthetic monofilament yarn, for example a monofilament yarn comprising at least one suitable polymer or suitable combination of polymers, for example polyvinyl chloride, a polyester; - a filament glass fiber yarn, preferably a monofilament glass fiber yarn.
    [17] Although generally spun or filament yarns, natural or synthetic yarns, for example synthetic multifilament yarns, multifilament fiberglass yarns, cotton yarns, wool yarns, etc. are possible, the specific yarns mentioned above guarantee a sound-absorbing assembly comprising an upper layer with excellent product stability, good moisture and impact resistance, scratch and shock resistance, it is easy to wash etc. because it includes a simple and robust structure and improved sound-absorbing parameters.
    According to a further embodiment, a sound-absorbing assembly is provided, characterized in that the woven upper layer comprises a percentage of holes in the range of 0.5% to 7%, preferably in the range of 1% to 5%.
    [19] In this way the Helmholtz resonator-like effect of the support plate openings in the support plate and the openings between the warp and weft threads of the woven upper layer is further optimized, leading to optimized sound attenuation values.
    According to a further embodiment, a sound-absorbing assembly is provided, characterized in that the woven upper layer comprises a weaving pattern comprising a density in the range of 5 to 12, preferably 6 to 10 warp threads and / or weft threads per centimeter.
    [21] In this way, a simple and robust woven upper layer can be realized which contributes to optimum acoustic properties of the sound-absorbing assembly since it comprises a sufficiently high percentage of holes and a sufficiently high level of corrugations of the yarn.
    [22] According to a further embodiment, a sound-absorbing assembly is provided, characterized in that the sound-absorbing assembly further comprises a wall-cavity layer between the flat side of the carrier plate facing the wall and the wall, which, if mounted, has a thickness which is in the range of 15 mm to 70 mm, preferably in the range of 18 mm to 55 mm.
    [23] Thanks to this wall cavity, an optimum amount of further sound-damping material can be placed between the flat side of the carrier plate facing the wall and the wall.
    [24] According to a further embodiment, a sound-absorbing assembly is provided, characterized in that the wall-cavity layer comprises one or more of the following: - a mineral wool; a synthetic wool, for example a suitable polymer wool, for example a polyester wool with a density in the range of 300 g / m2 to 750 g / m2; - a synthetic foam, for example a synthetic foam comprising melamine, polyethylene, polyurethane, etc .; and that the support plate comprises one or more of the following: - an MDF plate; - a plasterboard.
    [25] In this way, a sound-absorbing assembly comprising a weighted sound absorption coefficient can be realized in accordance with the ISO 11654 standard, also known as Alfa-W, of 0.7 or more, or even 0.9 for a sound-absorbing assembly with a limited support plate thickness of, for example, only 8 mm.
    [26] The use of synthetic wool or foam preferably makes it possible to apply it during manufacture to the wall-facing side of the sound-absorbing assembly, thereby obtaining a more efficient assembly process.
    According to a further embodiment, a sound-absorbing assembly is provided, characterized in that the sound-absorbing assembly further comprises a back cover layer, the thickness of the back cover layer being in the range of 0.1 mm to 5 mm, preferably in the range from 0.2 mm to 2 mm.
    [28] In this way, the acoustic parameters of the sound-absorbing assembly are further improved.
    According to a further embodiment, a sound-absorbing assembly is provided, characterized in that the back cover layer comprises a non-woven fabric, preferably a non-woven fabric comprising glass fibers with a weight in the range of 50 g / m2 to 75 g / m2 and a fiber diameter in the range of 7 μm to 15 μm.
    [30] Such a non-woven fabric can perform its acoustic function on the wall-facing side of the support plate where it is no longer visible and where it can be easily applied.
    According to a further embodiment, a sound-absorbing assembly is provided, characterized in that the woven upper fabric layer is glued directly to the flat side of the support plate facing the chamber by means of an adhesive layer whose thickness is in the range of 10% up to 30% of the thickness of the woven upper layer.
    [32] In this way, optimum adhesion of the woven upper layer is guaranteed, while reducing the risk of the adhesive layer filling the pores of the upper fabric layer and thus reducing the percentage of holes.
    According to a further embodiment, a sound-absorbing assembly is provided according to any one of the preceding claims, characterized in that the sound-absorbing assembly further comprises mounting a mounting frame which is arranged between the flat side of the carrier plate facing the wall and that the support plate is mounted on the mounting frame by means of nails: - the size of the head being less than 150% of the thickness of the yarns of the woven upper fabric layer; and - protruding from the flat side facing the chamber over a distance shorter than 80%, preferably shorter than 60%, of the thickness of the woven upper layer.
    [34] In this way, the sound-absorbing assembly can be efficiently mounted on a support frame without the risk of damaging the woven upper fabric layer and without leaving visual traces as the nail visually disappears between and / or under the yarns of the woven fabric. Such nails can for instance be applied by means of a suitable air pressure gun for an efficient and consistent placement of the nails. It is clear, however, that alternative mounting systems or combinations of mounting systems are possible, preferably with little or no visual traces of the mounting means or of any connecting means between adjacent sound absorption panels, for example one or more of the following systems: - tongue and groove mounting and / or connection; - a click mounting and / or connection, preferably a click mounting and / or connection under tension; - mounting or connecting by means of gluing, for example gluing using a polyurethane glue; - etc.
    [35] According to a second aspect of the invention, a method is provided for manufacturing the sound-absorbing assembly according to the first aspect of the invention, characterized in that the method comprises the following sequential steps: - applying, by means of an adhesive application roller of an adhesive layer on the flat side of the support plate facing the chamber, the thickness of the adhesive layer being in the range of 10% to 30% of the thickness of the woven upper layer; - placing the woven upper fabric layer on top of the adhesive layer on the flat side of the support plate facing the chamber; - temporarily exerting pressure by passing the support plate with the applied adhesive layer and the woven upper fabric layer placed thereon between pressing rollers, so that the layer thickness is reduced by a thickness in the range of 50% to 90%, preferably in the range of 75% to 85%, of the thickness of the woven upper layer.
    [36] In this way, the improved sound-absorbing assembly can be manufactured by a simple and efficient process of applying glue.
    [37] According to an embodiment, a manufacturing method is provided, characterized in that the adhesive layer preferably comprises a self-adhesive polyurethane adhesive.
    [38] In this way, the curing of the glue is further optimized and focused on the specific parts of the yarns of the fabric that are pressed into the glue in a simple and efficient manner and with sufficient pressure.
    Brief description of the drawings [39] Figure 1 is a schematic representation of a cross-section of an embodiment of a sound-absorbing assembly according to the invention; Figure 2 is a schematic representation of a plan view of an embodiment of a woven fabric that forms an upper layer of the embodiment of the sound-absorbing assembly of Figure 1; Figure 3 is an enlarged schematic representation of a cross-section of a fragment of the sound-absorbing assembly of Figure 1, including the embodiment of the woven fabric of Figure 2; Fig. 4 is a schematic representation of an embodiment of the sound-absorbing assembly, similar to that of Fig. 1, on a smaller scale, further showing an embodiment of mounting means; and [43] Figures 5 and 6 respectively show a table and a graphical representation of sound absorption values of specific embodiments of the sound-absorbing assembly.
    Detailed Description of the Embodiment (s) [44] Figure 1 is a schematic representation of a cross-section of an embodiment of a sound-absorbing assembly 10. As shown, the sound-absorbing assembly comprises a support plate 30. As will be explained in more detail below, the support plate 30 is provided with a large number of support plate openings 33 and therefore it can be referred to as a perforated plate. A suitable material from which such a perforated plate 30 can be manufactured is, for example, an MDF plate (Medium-Density Fiberboard) provided with a plurality of support plate openings 33. It is clear that other suitable materials are possible to manufacture such a perforated support plate. for example, a suitable plasterboard provided with a plurality of support plate openings 33 which is preferred over an MDF or other wood-based board due to the better fire-resistant properties. The carrier plate 30 according to this embodiment comprises a carrier plate thickness 32 of, for example, 8 mm. It is clear that the support plate thickness 32 of the support plate 30 is the distance between the flat side 35 facing the chamber and the opposite flat side 37 facing the wall. It is clear that, according to alternative embodiments, alternative support plate thicknesses can be used as long as these are generally in the range of 5 mm to 30 mm and preferably in the range of 6 mm to 12 mm. These dimensions provide a Helmholtz resonator-like effect, as will be explained in more detail below.
    The embodiment of the carrier plate of Figure 1 comprises a plurality of carrier plate openings 33 as shown. As shown, these carrier plate openings 33 extend through the carrier plate 30 from the flat side 35 facing the chamber to the flat side 37 facing the wall. According to this embodiment, the multiple number of support plate openings has a cylindrical shape with a diameter 34 of 6 mm. However, it is clear that alternative shapes for the cylindrical shape are possible, for example suitable slots with a width of 6 mm, conically drilled or milled shapes etc. It is clear that still further alternative embodiments for the openings etc. are possible, as long as the opening width 34 of these support plate openings 33, in other words the diameter in the case of a cylindrical opening or the width in the case of a longitudinal slot-shaped opening, is generally in the range of 4 mm to 12 mm. As is further illustrated, according to this embodiment, the center-to-center distance 36, in other words the distance between the central longitudinal axes of two adjacent cylindrical support plate openings 33 is 8 mm. It is clear that in this way a sufficiently thick wall thickness is obtained for the structural walls 31 of the support plate 30 between the support plate openings 33. However, it is clear that alternative embodiments are possible, as long as the center-to-center distance 36 is generally in the range is from 110% to 500% of the opening width 34. According to the illustrated embodiment, the multiple number of support plate openings 33 can be provided, for example, by means of a triangular, square or other suitable drilling pattern for holes of 6 mm diameter through the support plate 30 with a center-to-center distance 36, sometimes also referred to as a center distance, of 8 mm. It is clear that, although only an enlarged portion of the portion of the sound-absorbing panel 10 is depicted, the length and width of this sound-absorbing panel 10 is different orders of magnitude greater than the opening width 34 of its support plate openings 33 and thus a large number of support plate openings 33 of for example 6 mm diameter, a sound-absorbing panel 10 with a width and length of, for example, larger than 1 m is provided.
    It is clear that still further embodiments of the supporting plate 30 are possible, for example plaster supporting plates, for example of the type generally known as Gyptone or Rigitone, which comprise, for example, plasterboard with dimensions of length x width x thickness of about 1998 x 1188 x 12.5 mm, comprising circular carrier plate openings 33 of, for example, 6 mm, 8 mm or 10 mm and a center-to-center distance 36 of 18 mm, 18 mm or 23 mm respectively for the respective types referred to as Rigitone 6/18, Rigitone 8/18 or Rigitone 10/23. These support plate openings 33 are arranged in a square drill pattern so as to result in an opening degree of 8.7%; 15.5% or 14.8%. However, it is clear that alternative embodiments comprising alternative dimensions are possible with regard to the length, width, thickness and size of the openings in the plate. According to a specific alternative embodiment, the length x width can for example be 3030 mm x 1280 mm.
    [47] As shown, a woven upper fabric layer 20 is directly adhered to the flat side 35 of the support plate 30 facing the chamber. As will be described in more detail below, it is clear that this woven upper fabric layer 20 consists of a woven fabric. Since the woven upper fabric layer 20 thus comprises only a woven fabric, a simple and efficient construction and manufacture of the sound-absorbing assembly 10 can be realized. According to the illustrated embodiment, the thickness 22 of the woven upper layer 20 is 1 mm. However, it is clear that alternative embodiments are possible as long as the thickness 22 of the woven upper layer is in the range of 1/7 to 1/12 of the backing plate thickness 32.
    [48] In this way, the combination of the specific support plate openings 33 and the porosity of the woven upper layer 20 as well as this specific ratio of the thickness of the woven upper layer to the support plate provides an optimum Helmholtz resonator-like effect, while the The wavy structure of the woven fabric of the woven upper fabric layer 20, as well as the more or less round circumference of the yarns of the woven fabric improve the dispersion, damping and absorption of sound pressure waves.
    [2] Figure 2 is a more detailed top view of an embodiment of the woven upper fabric layer 20. As shown, the woven upper fabric layer 20 comprises a simple 1-to-1 braiding pattern of warp threads 24 and weft threads 26. As shown, suitable openings 28 created between these respective yarns 24, 26 of the woven upper fabric layer 20. According to this embodiment, the yarns 24, 26 are yarns comprising a monofilament glass fiber core and at least one polyvinyl chloride coating, for example, a co-extruded PVC coating can be used. chosen. Alternative embodiments of the yarn are possible, for example a monofilament polyvinyl chloride or polyester yarn, or other suitable filament polymer yarns. According to still further alternatives, the yarn can be, for example, filament-glass fiber yarn. Although in general any suitable filament or spun yarn and / or synthetic or natural yarn can be used, yarns such as the aforementioned monofilament yarn are preferred since they also provide good mechanical properties 10 when used as woven upper fabric layer 20, such as an increased resistance to scratches, shocks, good impact resistance and because they are moisture-resistant and allow a simple and efficient cleaning of the woven upper fabric layer of the sound-absorbing assembly if dirt is present. According to this embodiment, as shown more clearly in Figure 3, the diameter 24D of the yarn 24 is 0.5 mm, which is approximately equal to 50% of the thickness 22 of the woven upper layer 20. Alternative embodiments of the weave pattern are possibly, such as a 2/2 braid pattern, or any other suitable weaving pattern that can be defined for the specific shed forming device of the weaving machine, which, for example, uses suitable weaving frames or even more complex patterns that use, for example, a jacquard mechanism.
    Preferably, the woven upper layer 20 comprises a weave pattern comprising a density in the range of 5 to 12, preferably 6 to 10 warp threads 24 and / or weft threads 26 per centimeter. According to one embodiment referred to as "Chocolate", 8 warp threads and 8 weft threads per centimeter are provided in a 2/2 braid pattern. According to an alternative embodiment referred to as "Sepia", 6 warp threads per centimeter and 10 weft threads per centimeter are provided. As will be explained in further detail below, this leads to a suitable percentage of holes, i.e. the ratio of the area of the holes 28 to the area covered by the warp threads 24 and the weft threads 26, for the woven upper layer 20, which according to specific tested embodiments of the sound-absorbing assembly 10, an Alfa-W value of 0.9 leads to. The specific yarns used in these embodiments referred to as "Chocolate" and "Sepia" are monofilament yarns comprising a glass fiber core and a co-extruded bi-color polyvinyl chloride coating with a diameter of 0.5 mm.
    It is clear that alternative embodiments of such a woven upper layer 20 are possible, for example comprising a percentage of holes in the range of 0.5% to 7%, preferably in the range of 1% to 5%.
    As shown in more detail in Figure 3, the percentage of holes is mainly determined by the ratio between the diameter 24D of the yarns 24, 26, the diameter or width 28D of the openings 28 between the yarns 24, 26, the weave pattern and the respective density of the warp threads and weft threads. A suitable percentage of holes and a suitable level of corrugation of the yarns 24, 26 of the woven upper layer 20 can generally be realized when the woven upper fabric layer 20 comprises yarns 24, 26 with a thickness 24T in the range of 30% to 120% of the thickness 22 of the woven upper layer. According to the embodiment shown in Figure 1, the thickness 22 of the woven upper layer is 1 mm and the thickness 24T of the yarns 24, 26, which according to this embodiment corresponds to the diameter 24D of the circular cross-section of the yarns 24 , 26, equal to 0.5 mm so as to correspond to a 50% ratio. It is clear, for example from Figure 3, that the thickness 24T of the yarn 24, 26 generally refers to the cross-sectional size of the yarn 24, 26, which is generally transverse to the plane of the woven fabric 20 If according to alternative embodiments, the woven fabric 20 would comprise yarns 24, 26 with a non-circular cross-section, such as a cross-section that looks more like a square, ellipse, etc., the thickness 24T of the yarn 24, 26 of the woven fabric would 20 are generally determined by the maximum cross-sectional size of the yarn in the direction that is generally transverse to the plane of the woven fabric.
    [52] As is apparent from Figure 3, the thickness of the adhesive layer should preferably be sufficiently large to ensure a secure connection between the wavy yarns of the woven upper layer 20 and the side 35 of the support plate 30 facing the chamber. According to the embodiment shown in Figure 1, a polyurethane glue of the type referred to as PUR 706.1, produced by KebChemie MG, is applied. Becker GmbH under the trade name KLEIBERIT. It comprises a polyurethane base, a density of 1.1 g / cm3 and is self-adhesive, which means that it hardens when sufficient pressure is applied. According to this embodiment it is applied in an amount of 80 g / m2. It is clear that alternative embodiments for the adhesive layer 100 are possible, as long as preferably the woven upper fabric layer 20 is applied directly to the flat side 35 of the support plate 30 facing the chamber. glued by means of this adhesive layer 100, the thickness 100D of which is in the range of 10% to 30% of the thickness 22 of the woven upper layer. As clearly shown in Figure 3, this allows the adhesive layer to cover a substantial portion of the wavy yarns 24, 26 when they are closest to the flat side 35 of the support plate 30 facing the chamber, while the diameter 28D of the openings 28 remains unchanged.
    [53] As further illustrated, according to the embodiment of Figure 1, the sound-absorbing assembly 10 further comprises a back cover layer 40. The back cover layer 40, as shown, comprises a back cover layer thickness 42 that is in the range of 0.1 mm to 5 mm, preferably in the range of 0.2 mm to 2 mm. The back cover layer 40 according to this embodiment comprises, for example, a non-woven fabric, preferably a non-woven fabric comprising glass fibers with a weight in the range of 50 g / m2 to 75 g / m2 and a fiber diameter in the range of 7 μm to 15 μm. For example, a fiberglass mat referred to as MJ70B, manufactured by Saint-Gobain Vetrotex, of 70 g / m2 and comprising glass fibers with a diameter of 11 μm.
    As further illustrated, according to the embodiment of Figure 1, the sound-absorbing assembly 10 further comprises a wall-cavity layer 50 between the flat side 37 of the carrier plate 30 facing the wall and the wall 60 in the mounted state. It is clear that according to the embodiment shown in Figure 1, in which preferably, but optionally, a back cover layer 40 is attached to the flat side 37 of the carrier plate 30 facing the wall, this means that the wall cavity layer 50 is positioned between this rear cover layer 40 and the wall 60 against which the carrier plate is mounted. It is also clear that the term wall must be interpreted very broadly as any suitable surface against which the sound-absorbing assembly can be attached, for example any suitable surface of a room, for example the walls, the ceiling, the floor, etc. regardless of the material of this wall, for example a surface consisting of stone, wood, glass, etc. The thickness 52 of the wall-cavity layer is in the range of 15 mm to 70 mm, preferably in the range of 18 mm to 55 mm. According to one embodiment, the wall cavity layer 50 has a thickness 52 of 50 mm and is filled with mineral wool. According to a further embodiment, the wall-cavity layer 50 has a thickness 52 of 20 mm and is filled with a synthetic wool or a synthetic foam, which is preferably already provided on the flat side 37 of the carrier plate 30 facing the wall. during manufacture and before the confirmation operation. Such a synthetic wool may, for example, comprise a suitable polymer wool, such as a polyester wool with a density in the range of 300 g / m2 to 750 g / m2. A suitable synthetic foam comprises, for example, a foam comprising melamine, polyethylene, polyurethane, etc. the wall cavity layer 50 is preferably completely filled with such a mineral or synthetic wool or a synthetic foam, it is clear that in general alternative embodiments are possible in which, for example, the wall cavity layer 50 is only partially filled with such materials.
    [55] As shown in more detail in Figure 4, according to the embodiment of Figure 1, the sound-absorbing assembly 10 further comprises a mounting frame 70 which is mounted in mounted condition between the flat side 37 of the carrier plate 30 facing the wall and the wall 60. The support plate 30, as shown, is attached to the mounting frame by means of suitable nails 72. Preferably, these nails 72 have a head size that is less than 150% of the thickness 24D of the yarns 24, 26 of the woven upper tissue layer 20. Preferably, the nails 72 are inserted by means of, for example, a hammer or a suitable air gun, so that the nails 72 protrude from the flat side 35 facing the chamber over a distance that is less than 80%, preferably less than 60 %, of the thickness 22 of the woven upper layer. According to this embodiment with a thickness 22 of the woven upper layer of 1 mm, this means 0.3 mm. In this way the nails 72 are no longer visible. Preferably, the nails 72 penetrate the upper tissue layer 20 and preferably they even extend their heads beyond the flat side 35 facing the chamber into the support plate 30, since this further reduces the risk of visibility of the nails. In this way, the sound-absorbing assembly 10 can be attached to the mounting frame 70 on the side facing the chamber without causing damage or leaving visual traces of the mounting means.
    Figures 5 and 6 show, respectively, a table and a graphical representation of sound absorption values of specific embodiments of the sound-absorbing assembly 10, which are very similar to the embodiment described with reference to Figure 1, with a support plate thickness 32 preferably in the range from 6 mm to 12 mm; and a thickness 22 of the woven upper layer 20 in the range of 1/8 to 1/10 of the support plate thickness 32.
    [57] The left-hand column A in Figure 5, labeled 200, with sound absorption coefficients or Alfa-s and the corresponding graph with diamond-shaped reference points in Figure 6, refer to an embodiment with a thickness 22 of the 1 mm woven top layer of the "Sepia" - execution of the fabric referred to above, combined with a support plate thickness 32 of 8 mm and a drilling pattern for the support plate openings with a diameter 34 for the openings 33 of 6 mm and a center-to-center distance 36 of 8 mm, comprising the MJ70B - back cover layer 40 referred to above and a wall-cavity layer 50 with a thickness of 50 mm filled with mineral wool. As shown, this embodiment leads to a weighted sound absorption coefficient in accordance with the ISO 11654 standard, also called Alfa-W, of 0.9.
    [58] In the second column B of Figure 5, labeled 201, and the corresponding graph with square reference points in Figure 6, a second embodiment of sound absorption coefficients or Alfa-s is depicted. This embodiment is identical to that with respect to column A, except that now an embodiment with a thickness 22 of 1 mm of the woven upper layer of the "Chocolate" embodiment of the fabric referred to above is used. As shown, this embodiment leads to a weighted sound absorption coefficient in accordance with the ISO 11654 standard, also called Alfa-W, of 0.9.
    [59] The third column C in Figure 5, labeled 202, and the corresponding graph with triangular reference points in Figure 6, depicts a third comparative embodiment of sound absorption coefficients or Alfas. This embodiment is identical to that with respect to column B, except that now instead of the non-woven MJ70B back cover layer 40, a woven fabric is used as the back cover layer and the support plate has a support plate thickness 32 of 16 mm. As shown, this embodiment results in a weighted sound absorption coefficient in accordance with the ISO 11654 standard, also called Alfa-W, of 0.85. This corresponds to a ratio of the thickness 22 of the woven upper layer 20 of 1 mm which is 1/16 of the support plate thickness 32 of 16 mm. In general, when a thicker carrier plate is used, a higher sound absorption coefficient is expected, but as shown in this embodiment, the ratio of upper layer thickness 22 to carrier plate thickness 32 being outside the optimum range of 1/7 to 1/12, the measured Alfa-W of 0.85 is surprisingly lower than the Alfa-W of 0.9 of the first and second embodiments described above and which have a support plate thickness 32 of only 8 mm, but a ratio within the optimum range of 1/7 to 1/12.
    [60] In the fourth column D in Figure 5, labeled 203, and the corresponding graph with cross-shaped reference points in Figure 6, a fourth embodiment of sound absorption coefficients or Alfa-s is depicted. This embodiment is identical to that with respect to column A, except that now an embodiment with a wall-cavity layer 50 with a thickness of 20 mm filled with polyester wool with a density in the range of 300 g / m2 to 750 g / m2 is used. As shown, this embodiment results in a weighted sound absorption coefficient in accordance with the ISO 11654 standard, also called Alfa-W, of 0.6. This is still a high Alfa-W value given that the limited thickness of the full sound-absorbing assembly is limited to approximately 30 mm so as to reduce the volume occupied on the peripheral walls of the room to be equipped with such sound-absorbing assemblies .
    [61] The fifth column E in Figure 5 and the corresponding graph with dotted reference points in Figure 6 depict a fifth comparative embodiment of sound absorption coefficients or Alfa-s and labeled 204. This embodiment is identical to that with respect to column A, except that now an embodiment with a thickness 22 of 0.57 mm of the woven upper layer is used of an embodiment of the fabric sold under the trade name Alkenz Soleye Fabrics Sunshadow 3000 N 1%. This woven upper layer comprises a woven fabric comprising: - Monofilament polymer yarns comprising a combination of 25% polyester and 75% polyvinyl chloride; - A weave pattern comprising a 2/2 braid pattern with 7 warp threads per centimeter and 5 weft threads per centimeter; - A weight of 520 g / m2.
    As shown, this embodiment results in a weighted sound absorption coefficient according to the ISO 11654 standard, also called Alfa-W, of 0.3. In other words, it is clear that such comparative embodiments with a ratio between the thickness 22 of the woven upper layer and the support plate thickness 32 of 0.75 mm / 8 mm, which reaches about 1/14 outside the optimum of 1/7 to 1/12 is a good reference for the first and second embodiments that include a ratio that falls within this optimum range, since these embodiments have the same support plate thickness of 8 mm. Surprisingly, a ratio that satisfies this optimum range of 1/7 to 1/12 results in a clear and strong increase in the sound absorption coefficient of the sound-absorbing assembly.
    The sound-absorbing assembly 10 can be made by a simple and robust production process in which the woven upper fabric layer 20 is glued to the flat side 35 facing the chamber by means of an efficient roller coater. First, the adhesive layer 100 is applied by means of an adhesive application roller of the roller coater on the flat side 35 of the carrier plate 30 facing the chamber. According to this embodiment, the adhesive layer thickness 100D is approximately 0.2 mm if 80 g / m2 of adhesive is applied for a thickness 22 of the woven upper layer of 1 mm. However, alternative embodiments are possible as long as the adhesive layer thickness 100D is in the range of 10% to 30% of the thickness 22 of the woven upper layer. Consequently, the woven upper fabric layer 20 is placed on top of the adhesive layer 100 on the flat side 35 of the carrier plate 30 facing the chamber. fabric layer 20 between the press rollers. These press rolls are positioned so that the layer thickness is reduced by a thickness in the range of 50% to 90%, preferably in the range of 75% to 85% of the thickness 22 of the woven upper layer 20. According to the embodiment of Figure 1, for a thickness 22 of the woven upper layer of 1 mm, an adhesive layer thickness 100D of 0.2 mm and a support plate thickness 32 of 8 mm, the thickness with 8 mm, or 80% of the thickness 22 of the woven upper layer , reduced.
    [63] It is furthermore clear that, due to the relatively large dimensions of the support plate openings 33, the adhesive layer 100 will only be applied to the flat side 35 of the structural walls 31 of the support plate 30 facing the chamber through the adhesive application roller. As already explained above, the adhesive layer 100 preferably comprises a self-adhesive polyurethane adhesive.
    It is clear that still further embodiments for the sound-absorbing assembly 10 are possible, more specifically instead of an upper fabric layer 20 consisting of a woven fabric, use can be made of a knitted fabric 20, as long as generally the thickness 22 of the upper layer of the knitted upper fabric layer 20 is in the range of 1/7 to 1/12 of the support plate thickness 32. Referring generally to the embodiments and optimizations described above and insofar as appropriate when reference is made to a woven upper fabric layer, a woven upper layer, a thickness of a woven upper layer, etc., generally similar embodiments and optimizations can be provided with a knitted fabric 20 with similar openings 28 between similar yarns. In general, therefore, the embodiments described above can alternatively also be described with a knitted upper layer and a thickness of the knitted upper layer. Therefore, in general, the term upper fabric layer and thickness of the upper fabric layer may be interpreted as referring to both alternatives of a woven fabric or a knitted fabric. However, it is clear that a woven fabric is preferred since it offers better structural stability and wear resistance.
    [65] It is furthermore clear that if reference is made to the upper fabric layer of the sound-absorbing assembly, this means that, in the mounted state, this upper fabric layer forms the flat side of the sound-absorbing assembly facing the chamber. It is thus clear that no further layers or planar elements are provided which, when mounted, cover this upper fabric layer of the sound-absorbing assembly on the side facing the chamber.
    [66] Woven fabric in the context of this application refers to a textile that is formed by a weaving process performed on a weaving machine by interweaving warp threads and weft threads.
    [67] When reference is made in the context of this application to monofilament yarn, reference is made to a yarn preferably comprising a thick, single, continuous and / or relatively long filament as opposed to spun yarn.
    [68] Mineral wool, also known as mineral fiber, rock wool, artificial mineral fiber or MMMF and artificial glass fiber or MMVF, is a name in the context of this application for fiber materials produced by spinning molten minerals or synthetic minerals such as slag and ceramics or to pull.
    [69] If reference is made to a chamber 35 face plate 20 of the support plate 20, this means the surface 35 facing the most likely location of sound generating sources in the chamber when the sound absorbing assembly is against a wall, ceiling or other suitable peripheral part of a room is attached.
    [70] Where reference is made in the context of this application to sound absorption coefficients or Alfa-s, this refers to sound absorption coefficients or Alfa-s values measured in accordance with the standards EN ISO 354: 2003 and / or EN ISO 11654: 1997 . These measurements were performed in a reverberation room with a volume V = 296.9 m3 and a total area of Stot = 278.2 m2. At a temperature of T = 10.4 ° C in an empty space and T = 10.6 ° C with test element present. At an atmospheric pressure of p = 100.7 kPa and a relative humidity of hr = 68.6%. The surface area of the test element is 10.82 m2.
    [71] When reference is made in the context of this description to a weighted sound absorption coefficient, this refers to a weighted sound absorption coefficient in accordance with the ISO 11654 standard, also known as Alfa-W. The ISO 11654 standard describes how frequency dependent sound absorption coefficients of octave bands from 250 Hz to 4 kHz are converted into a single digit, namely the Alfa-W value.
    [72] Although the present invention has been illustrated with reference to specific embodiments, it will be apparent to those skilled in the art that the invention is not limited to the details of the foregoing illustrative embodiments, and that the present invention may be practiced with various modifications and modifications without leaving the scope of the invention. The present embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being described by the appended claims and not by the foregoing description, and all modifications falling within the meaning and scope of the claims, are therefore included here. In other words, it is assumed that this covers all changes, variations or equivalents that fall within the scope of the underlying basic principles and whose essential attributes are claimed in this patent application. In addition, the reader of this patent application will understand that the words "comprising" or "include" do not exclude other elements or steps, that the word "a" does not exclude a plural, and that a single element, such as a computer system, a processor or other integrated unit can fulfill the functions of different tools mentioned in the claims. Any references in the claims should not be construed as limiting the claims in question. The terms "first", "second", "third", "a", "b", "c" and the like, when used in the description or in the claims, are used to distinguish between similar elements or steps and do not necessarily describe a sequential or chronological order. Similarly, the terms "top", "bottom", "over", "under" and the like are used for the purposes of the description and do not necessarily refer to relative positions. It is to be understood that those terms are interchangeable under proper conditions and that embodiments of the invention are capable of functioning in accordance with the present invention in sequences or orientations other than described or illustrated above.
    权利要求:
    Claims (15)
    [1]
    CONCLUSIONS
    A sound-absorbing assembly (10), comprising: - a support plate (30) comprising: - a support plate thickness (32), between the flat side (35) facing the chamber and the opposite flat side (37) facing the wall , in the range of 5 mm to 30 mm; - a plurality of support plate openings (33) extending through the support plate (20) from the flat side (35) facing the chamber to the flat side (37) facing the wall, comprising an opening width (34) in the range of 4 mm to 12 mm and a center-to-center distance (36) in the range of 110% to 500% of the opening width (34); and - an upper fabric layer (20) that is adhered directly to the flat side (35) of the support plate (30) facing the chamber and which consists of a woven or knitted fabric; CHARACTERIZED THAT the thickness (22) of the upper fabric layer (20) is 1/7 to 1/12 of the support plate thickness (32).
    [2]
    A sound-absorbing assembly (10) according to claim 1, characterized in that: - the support plate thickness (32) is in the range of 6 mm to 12 mm; and - the thickness (22) of the upper fabric layer (20) is 1/8 to 1/10 of the support plate thickness (32).
    [3]
    A sound-absorbing assembly (10) according to claim 1 or 2, characterized in that the upper fabric layer (20) comprises yarns (24, 26) with a thickness in the range of 80% to 120% of the thickness (22) of the upper tissue layer.
    [4]
    A sound-absorbing assembly (10) according to any one of the preceding claims, characterized in that the yarns (24, 26) comprise a monofilament yarn.
    [5]
    A sound-absorbing assembly (10) according to any one of the preceding claims, characterized in that the yarns (24, 26) comprise one or more of the following: - a yarn comprising a monofilament glass fiber core and at least one polymer coating; - a filament yarn, preferably a monofilament yarn comprising at least one polymer; - a monofilament glass fiber yarn.
    [6]
    A sound-absorbing assembly (10) according to any one of the preceding claims, characterized in that the upper fabric layer (20) comprises a percentage of holes in the range of 0.5% to 7%, preferably in the range of 1% up to 5%.
    [7]
    A sound-absorbing assembly (10) according to any one of the preceding claims, characterized in that the upper fabric layer (20) consists of a woven fabric and said woven upper fabric layer (20) comprises a weave pattern with a density in the range of 5 to 12, preferably 6 to 10, warp threads (24) and / or weft threads (26) per centimeter.
    [8]
    A sound-absorbing assembly (10) according to any one of the preceding claims, characterized in that the sound-absorbing assembly (10) further comprises a wall-cavity layer (50) between the flat side (37) of the carrier plate facing the wall (30) and the wall (60), wherein the wall-cavity layer in mounted condition has a thickness (52) in the range of 15 mm to 70 mm, preferably in the range of 18 mm to 55 mm.
    [9]
    A sound-absorbing assembly (10) according to claim 8, characterized in that the wall-cavity layer (50) comprises one or more of the following: - a mineral wool; - a synthetic wool; - a synthetic foam, and that the support plate (30) comprises one or more of the following: - an MDF plate; - a plasterboard.
    [10]
    A sound-absorbing assembly (10) according to claim 8 or 9, characterized in that the sound-absorbing assembly (10) further comprises a back cover layer (40), wherein the thickness (42) of the back cover layer is in the range of 0.1 mm up to 5 mm, preferably in the range of 0.2 mm to 2 mm.
    [11]
    A sound-absorbing assembly (10) according to claim 10, characterized in that the back cover layer (40) comprises a non-woven fabric, preferably a non-woven fabric comprising glass fibers with a weight in the range of 50 g / m2 to 75 g / m2 and a fiber diameter in the range of 7 μm to 15 μm.
    [12]
    A sound-absorbing assembly (10) according to any one of the preceding claims, characterized in that the upper fabric layer (20) is glued directly onto the flat side (35) of the support plate (30) facing the chamber by means of an adhesive layer (100) with a thickness (100D) in the range of 10% to 30% of the thickness (22) of the upper fabric layer.
    [13]
    A sound-absorbing assembly (10) according to any one of the preceding claims, characterized in that the sound-absorbing assembly (10) further comprises mounting a mounting frame (70) disposed in mounted position between the flat side facing the wall (37) of the support plate (30) and the wall (60), and that the support plate (30) is mounted on the mounting frame by means of nails (72): - whose head size is less than 150% of the thickness (24T) of the yarns (24, 26) of the upper fabric layer (20); and - protruding from the flat side (35) facing the chamber over a distance shorter than 80%, preferably shorter than 60%, of the thickness (22) of the upper fabric layer.
    [14]
    A method for manufacturing the sound-absorbing assembly according to one of the preceding claims, characterized in that the method comprises the following sequential steps: - applying, by means of an adhesive application roller, an adhesive layer (100) to the chamber-facing flat side (35) of the support plate (30), the thickness (100D) of the adhesive layer being in the range of 10% to 30% of the thickness (22) of the upper fabric layer; - placing the upper fabric layer (20) on top of the adhesive layer (100) on the flat side (35) of the support plate (30) facing the chamber; and - temporarily exerting pressure by allowing the support plate (30) with the applied adhesive layer (100) and the upper fabric layer (20) placed thereon between pressing rollers, so that the layer thickness of this assembly is reduced by a thickness in the range of 50% to 90%, preferably in the range of 75% to 85%, of the thickness (22) of the upper fabric layer of the woven upper layer (20).
    [15]
    A manufacturing method according to claim 14, characterized in that the adhesive layer (100) comprises a self-adhesive polyurethane adhesive.
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    EP15160097.0|2015-03-20|
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