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Патент USA US3027974

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United States Patent 0 M1C6
William A. Jack, Hampton, NJ” assignor to Johns-Man
ville Corporation, New York, N.Y., a corporation of
New York
Filed Dec. 23, 1957, Ser. No. 764,825
15 Claims. (Cl. 181-33)
Patented Apr. 3, 1962
vention shown in FIG. 4, along line 5-~5 of FIG. 4;
FIG. 6 is a pictorial view, partly in cross section, of
apparatus utilized in making an acoustical product of the
instant invention.
Referring to FIGS. 1 and 2, the novel acoustical prod
uct of the present invention comprises a relatively very
thin layer or veneer 1 of acoustical material having
?ssured completely therethrough a plurality of irregular '
more particularly, it relates to a method of cutting ?s 10 ?ssures 2 in an irregular pattern. The layer 1 is com
posed of very soft and very loose textured acoustical
sured patterns in very soft, loose textured blankets of
material of approximately 1/2” thickness and having a
acoustical materials, to a method of fabricating novel
This invention relates to decorative acoustical panels;
density of approximately 1 pound per cu. ft.; other light
weight, loose-textured acoustical materials, may of course,
Heretofore, it has been known to utilize sand blasting 15 be substituted for the particular material recited. The
acoustical panels using these ?ssured blankets, and to the
novel panels produced thereby.
or other forms of abradin0 means to ?ssure a design into
veneer 1 is cemented, or otherwise secured or plied, to
an acoustical board through a template having the de
a base or backing 4 consisting of an imperforatc panel;
sired ?ssured pattern perforated therein. Utilizing such
the ?nal product resembles somewhat any unitary panel,
a procedure, an attractive and e?cient acoustical product
made from the much denser acoustical materials, ?ssured
is produced which has a plurality of rather deep, irregu~ 20 only partially therethrough.
lar ?ssures therein. When such a procedure is attempt
A modi?cation of the invention illustrated in FIGS.
ed to be used with acoustical blankets of the same thick
ness but of a very loose texture and of a very light weight,
the ?nal product resembles somewhat the product pre
viously produced by said procedure. However, in view
1 and 2 has a plurality of such soft acoustical materials
cemented, or otherwise secured together, with ?ssures 12
in layer or veneer 11 mating with corresponding ?ssures
16 in layer or veneer 15 (FIG. 3), i.e., a plurality of simi
of the loose texture of these very light weight acoustical
lar blankets, identically ?ssured, are mated together with
blankets, the abrading sand, peach stone particles, steel
the group of ?ssures on one panel aligned with the corre
shot, or walnut shell particles are embedded in the side
walls of the ?ssures and are di?icult to remove. The
sponding group on the other panels.
abrading material left behind after the ?ssuring of the
produce a ?ssured acoustical panel somewhat similar to
that illustrated in FIGS. 1 and 2. The use of at least
panels, consequently, adulterates the ?ssured panels and
detracts from its esthetic appearance.
An object of this invention therefore is to utilize very
light and very loose textured acoustical material in a
novel manner, i.e., by producing an acoustical panel of
This plied construc
tion is further cemented or glued to a base member 14 to
a pair of similarly ?ssured blankets, mated together, is
to produce an acoustical panel having relatively deep
?ssures therein, which gives the appearance of great
depth to each of the aligned ?ssures 12, 16 thereby pro
ducing a marked shadow effect.
The form of the invention shown in FIGS. 4 and 5
?ssured acoustical panels utilizing inexpensive acoustical
is somewhat akin to that illustrated in FIG. 3. How
ever, the blanket 35 of FIGS. 4 and 5 has ?ssured there
materials and to obtain results which, heretofore, have
only been obtained with the more expensive and dense 40 through a pattern different from the pattern in blanket
31 so that the ?ssures are only partially superposed, or
form of acoustical materials.
Still a further object of this invention is to utilize
in register, or blanket 35 may have the identical pattern
certain classes of acoustical materials in a manner never
of layer 31 abraded therein, in which case the two layers
are displaced slightly from each other to present a con—
used before to produce a novel type of acoustcal panel
which, heretofore, this class of materials was not thought 45 struction wherein the plurality of ?ssures 32 in blanket
31 are at least partly out of registry with the ?ssures 36
capable of producing.
of blanket 35 and are arranged in an irregular manner
Another object of this invention is a novel method of
with respect thereto, so that there is an irregular overlap
fabricating a ?ssured type, acoustical panel from light
or superposition of ?ssures 32 upon ?ssures 36, giving
weight and loose textured acoustical materials.
In brief, the invention resides in ?ssuring a pattern 50 thereby an added esthe'tic eifect. As in the construc
tion of FIG. 3, backing 34 is adhered to the veneer 35
into a relatively very thin, loose textured blanket of
which in turn is adhered to the veneer 31 to produce the
acoustical material comprising, e.g., a felt of mineral,
?nished panel.
synthetic or vegetable ?bers by the use of a template
The apparatus illustrated in FIG. 6 comprise a metal
placedupon the blanket, and cementing this ?ssured
such materials with a ?ssured appearance.
An additional object of this invention is to produce
blanket on a base panel, which may or may not be of
acoustical construction, to produce the ?nal acoustical
These and other objects will be readily apparent from
the above brief description and from an examination of
the following more detailed description and appended
drawings wherein:
FIG. 1 is a plan view of an acoustical panel formed
according to the instant invention;
template 5 having cutouts 6 therein of the desired shape
to be ?ssured through the blankets, and such cavity out
lines are cut through the adjacent panel 1 by an abrading
blast 8, composed of a mixture of compressed air and
an abrasive, originating from a blasting nozzle 7. The
abrading may also be performed by particles centrifugal
ly ?ung from a spinning wheel (not shown). When the
abrading operation has been performed the acoustical
panel has cut therein, through its entire thickness, a plu
rality of ?ssures ‘2.
To give the loose textured and very
_ FIG. 2 is a cross-sectional view of the panel of FIG. 1 65 light weight ?bers more body or rigidity, the panel 1 of
along line 2—~2 thereof;
FIG. 2, the panels 11, 15 of FIG. 3, and the panels 31,
FIG. 3 is a cross-sectional view, similar to FIG. 2,
of a second form of the instant invention;
FIG. 4 is a plan view of a third form of the instant
3 (shown only in FIG. 2) by cementing the layer of pa
35 of FIG. 5 may be provided with a backing of paper
per 3 on the rear face of each of the panels prior to
70 ?ssuring. This paper backing 3 may be retained in the
FIG. 5 is a cross-sectional view of the form of the in
assembling of each of the modi?cations as it is well hid
of loose textured acoustical blanket, placing a template
den from view and has cut therethrough the same ?ssured
design as the adjacent veneer panels, the ?ssures being
having irregular apertures therein over the paper and
blanket, abrading through the template apertures and
completely through said paper and blanket, and plying
cut through the paper backing by the abrading process
described above.
the combined paper and blanket to an imperforate base
The materials used for the veneer construction may
be of light weight mineral wool, light weight glass wool,
glass ?ber textile scrap, synthetic or vegetable ?ber, or
of other light weight ?brous material having a thickness
of approximately 1/2" and a density of approximately 1
prising, placing a template having irregular apertures
6. A method for fabricating an acoustical product com
therein over at least one layer of relatively thin, loose
The backing material, as for example the backing 4 in
FIG. 2, may be of relatively inexpensive ?ber board or
board manufactured from the commonly known mineral
wools, or it may be manufactured from any known mate
textured, acoustical blanket, abrading through the tem
plate apertures, and completely through the at least one
layer, and plying at least one such blanket layer to an
imperforate base panel.
7. An acoustical panel comprising, an imperforate base
rial not having appreciable sound absorbing qualities. 15 panel, an acoustical veneer of loose textured ?bers plied
The type of backing material used depends upon the
acoustical requirements, and the amount or thickness of
such backing naturally depends upon the type of con
struction utilized. Thus, if the construction of FIGS. 3,
4, and 5 were used, a somewhat thinner layer of backing 20
thereto, said veneer having a plurality of irregular ?ssures
therein completely through said veneer.
8. The panel or" claim 7, wherein said veneer comprises
a plurality of similar blankets having identical ?ssures
therethrough and in at least partial registry with each
9}. In an acoustical panel construction comprising, an
imperforate base panel, a plurality of loose textured,
A preferred form of acoustical panel, made according
acoustical panels of similar dimensions as the base panel
to my invention, has the backing 4 of FIGS. 1 and 2,
for example, composed of light Weight and very loose 25 secured to the base panel and to each other, each of said
loose textured. acoustical panels having a plurality of ir
textured material of the same construction and composi
would be adhered to the veneer than the thickness of back
ing layer as shown in FIGS. 1 and 2.
regular ?ssures therethrough.
tion as used for the veneer 1. This combination pro
duces a panel having a clean ?ssured appearance similar
to that obtained with acoustical materials of much greater
density. In this construction also, the relatively inexpen
sive form of acoustical materials is used throughout there
by utilizing a very light and loose textured acoustical
10. The panel construction of claim 9 wherein the ?s
sures in each loose textured panel are similar to the ?s
30 sures in a mating loose textured panel, and identical ?s
sures are superposed in registry upon each other to there
by obtain a deep shadow effect.
11. In an acoustical panel construction, an imperforate
material in a manner not contemplated before.
If desired the veneer may be painted or treated with
base panel, an acoustical veneer secured thereto com
the acoustical properties to any great extent while it does
posed of a material having loose textured ?bers and hav
ing a very low density, said veneer having a plurality of
improve the esthetic values somewhat as a particular room
design or color may be selected in accordance with per
sonal tastes.
irregular shaped and irregularly spaced ?ssures therein.
veneer construction is backed by a layer of paper to
?cations may suggest themselves to one skilled in the
ing a plurality of irregularly shaped and irregularly spaced
some other form of covering.
This does not decrease
12. The panel construction of claim 11, wherein the
Having thus described my invention in rather full de 40 impart greater strength to the veneer construction. I
13. The panel construction of claim 11, wherein the
tail, it will be understood that these details need not be
veneer includes a plurality of blankets, each blanket hav
strictly adhered to and that various changes and modi
?ssures therein.
14. The panel construction of claim 13 wherein the
by the subjoined claims.
?ssures in each blanket are superposed upon and regis
What I claim is:
tered with identical ?ssures in the adjacent blanket.
1. A method for fabricating an acoustical product com
15. The panel construction of claim 13, wherein the
prising, placing a template having irregular apertures
?ssures in one of the blankets of one panel are displaced
therein over a relatively thin layer of loose textured
acoustical blanket having a density of approximately one 50 from the ?ssures of an adjacent blanket of the same panel,
so as to be only partly aligned therewith.
pound per cubic foot, abrading through the template
art, all falling within the scope of the invention as de?ned
apertures and completely through the blanket, and plying
the blanket to an imperforate base panel.
2. The method of claim 1, further including securing
a second blanket, made in a similar manner as the ?rst
blanket, in plied relation to the ?rst blanket, and secur
ing together the plied construction and the base panel.
3. The method of claim 2, further including the step
of aligning the ?ssures in the ?rst blanket at least in
part with the corresponding ?ssures in the second blanket
in the plying of said blankets, to obtain thereby a deep
?ssure etfect.
4. In a method for fabricating an acoustical, ?ssured
type panel, the steps of abrading a plurality of ?ssures
completely through a relatively thin layer of light weight 65
acoustical material through a template having the desired
pattern cut out therein, and plying the thin layer to a
References Cited in the ?le of this patent
prising, securing a paper covering to a relatively thin layer
second, imperforate layer of acoustical material.
5. A method for fabricating an acoustical product com
Trader ______________ _._ Sept. 15,
Rosenblatt ___________ _.. Mar. 18,
Weiss _______________ __ Nov. 24,
Kellett ______________ __. Mar. 20,
Lambert _____________ __ Aug. 10,
Ericson _____________ .._ Oct. 19,
Gessler et a1. _________ __ Dec. 14,
Gessler et al. _________ .... July 31,
De Vries _____________ __ July 14,
Holtsford ____________ __ Mar. 12,
Proudfoot ____________ ..._ May 7,
Heine _______________ _. Mar. 4,
Australia ____________ __ Sept. 21, 1954
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