Acoustics – Sound-modifying means – Sound absorbing panels
Reexamination Certificate
1999-11-02
2001-10-23
Dang, Khanh (Department: 2837)
Acoustics
Sound-modifying means
Sound absorbing panels
C181S287000, C181S295000, C181S030000
Reexamination Certificate
active
06305495
ABSTRACT:
This present invention is a molded panel or board formed of flexible mats of continuous or chopped strands of high performance filaments for use as decorative surfacing panels for acoustical ceiling systems.
BACKGROUND
The surfacing panels of the present invention have been developed particularly to provide a new decorative surface for existing acoustical tile or panel systems such as where the tiles or panels, because of age have become soiled by heat, light and dust as well as other contaminants circulating in the ceiling area such as at air conditioning outlets and inlets or where the acoustical units have become damaged in use over a prolonged period.
BRIEF DESCRIPTION OF THE INVENTION
The panels of the invention are thin and lightweight such that they can be readily lifted and maneuvered by a person, even a non-skilled person, and have a degree of flex such that they can be pushed into an existing acoustical grid system in underlying relation with existing tiles in the system. That is the surfacing panels are made to have a degree of springiness so that they can be flexed or bowed slightly to permit their being pushed into place for support and coverage of the exposed surfaces of panels of an existing panel system without removal of panels from the system. A wide range of decorative surfaces can be provided on the surfacing panels to replace the appearance of panels already in place. In this regard, if desired the surfacing panels of the invention can be installed merely to change the decor of the ceiling in a dwelling space such as in a home or office.
The panels are dimensionally stable with a degree of stiffness and rigidity and a strength to weight ratio such that they can underlie and span the surface expanse of existing panels without sagging. In this regard, if because of age a curvature exists in a panel to be covered such that a surfacing panel would tend to be pushed downward due to contact with an overlying panel, the surfacing panel can be molded with a slight concavity or bow on its underside so that in a sense it becomes pre-stressed against the weight of an overlying panel. That is, the weight of the panel on the upper side of the panel can act to straighten the bowed surfacing panel into desired planar alignment in the system. With this design capability the surfacing panel has the feature of lending itself to even a lighter weight construction and adaptability to use for decorative purposes.
To attain desired lightweight and strength, the panels it has been found can be made basically of two thin layers of flexible mats of continuous filament strands such as mats of non-woven, randomly swirled continuous glass filament strands or randomly oriented chopped segments of continuous strands interbonded such as by a polyester binder. The two layers of strand mats are combined in interbonded relation by a lightweight dry thermoplastic adhesive such as is available in the form of a non-woven fibrous webbing.
The exposed top layer of the panels can be selected to provide any of a wide range of desired decorative appearances. In this regard for example the top layer having a color providing a desired aesthetic appearance can be a nubby or other textured woven or non-woven fiber fabric or a non-woven chopped strand mat as of glass filaments. Another type of decorative top layer that can be incorporated in the panel for example, is a layer of vinyl film or other resin film such as Mylar which can be of a selected desired color. Such a film can also be provided with a printed configuration for decoration to still further enhance the aesthetic appearance of the product. The top layer in addition to providing decorativeness adds to the strength of the combination.
The amount of dry adhesive web material effective to bond the basic strand mats, for example, can be of light weight in the order of 0.17 oz/sq. yd and make up as low as 2 percent of the final product weight. The individual mats in the panel by way of example, can be of thickness of about {fraction (1/16)}th inch and have a weight of approximately 0.0235 pounds per square foot. A vinyl outer exposed surface can be bonded to the two interbonded layers of strand mat by application of heat and pressure or the combination or also by a layer of web adhesive compatible with the vinyl material. A film face of resin as pointed out above can be of any number of colors, and patterns can be imprinted on the film surface to expand the range of aesthetics. The film layer can act as a drum like membrane for sound transmission and/or can be provided with perforations to allow sound passage through the thin exposed surface of the panel.
If a nubby surface is provided on the panel, the surfacing layer, by way of example, can have a thickness in the order of 30 mils and have a weight of approximately 0.1 lb. per sq ft. The complete panel assembly made up of two interbonded layers of strand mat, for example, can have a thickness of about 60 mils but with a nubby surfacing material the panel assembly can have a thickness dimension of about 90 mils. The strength to weight ratio of the assembly is such that because of the lightweight of the relatively high strength interbonded mats and their decorative surfacing, the panels do not sag. The product eliminates the need for removing existing ceiling panels, thereby reducing the cost of installation of what once installed, appears to be an entirely new ceiling system. The panels of the invention thus not only rejuvenate old and worn ceiling systems but in addition permit provision of an entirely different appearance when redecoration of a dwelling space is desired.
The terms panel and tile as used herein are interchangeable as commonly used in that both are applicable usually to surface units in acoustical support systems in dwelling spaces.
An object of the invention is to provide an economical method and means for renovating or redecorating existing ceiling tile systems.
Another object of the invention is to provide a surfacing panel of lightweight which will not overburden the frequently not too structurally strong grid support system and having a degree of manual flex such that it can be readily pushed into place in an existing ceiling grid system in underlying relation with an existing ceiling panel.
A further object of the invention is to provide a surfacing panel of lightweight and strong enough to bear the weight, if necessary, an existing tile supported in a tile support system.
Still another object of the invention is to provide a surfacing panel for existing acoustical tile systems which when installed does not diminish acoustical properties of the system but in some instances can even enhance the acoustical properties of the system.
A principal feature of the invention is the capability of the surfacing panels to economically provide an entirely new appearance to a ceiling tile system without requiring removal of existing tiles.
Another feature of the invention is the wide range of decorative selections which can be provided on the surfacing panel, including a wide range of different surface textures and colors from which a selection can be made.
Still another feature of the invention is the springiness and flex characteristics of the panel which allows it to be bowed to facilitate its being pushed into place under a panel in a grid support system.
A further feature of the invention is the capability of providing a surfacing panel which can be made or cut to dimensions matching panels or tiles in an existing panel or tile support system.
Other objects and features which are believed to be characteristic of my invention are set forth with particularity in the appended claims. My invention, however, both in organization and manner of construction, together with further objects and features thereof, may be best understood by reference to the following description taken in connection with the accompanying drawings.
REFERENCES:
patent: 3021247 (1962-02-01), Stephens
patent: 4642951 (1987-02-01), Mortimer
patent: 5547743 (1996-08-01), Rumiesz, Jr. et al.
Capaul Corporation
Dang Khanh
Sokol Law Office
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