CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to co-pending U.S. Provisional Patent Application

No. 61/525,294 filed August 19, 2011, the entire content of which is incorporated herein by reference.

FIELD OF THE INVENTION

[0002] The present invention relates to panels, and more particularly to panels for covering a wall, ceiling, or the like.

BACKGROUND OF THE INVENTION

[0003] Buildings of all types, including commercial, residential, and public buildings, require ceiling structures of some type to create an appropriate appearance within a building. In some buildings, a suspended ceiling system, which supports individual ceiling tiles or panels, may be installed. Fiberboard-based panels have high acoustic absorption, but must be replaced regularly when used in high moisture, high stress, or sterile environments. Vinyl or other synthetic panels, which are easier to install, do not need to be replaced as regularly as fiberboard- based panels because vinyl or synthetic panels provide enhanced durability from physical stress, are resistant to mold and mildew, and can be easily cleaned and/or sterilized. However, vinyl or synthetic panels may have reduced acoustic performance and therefore may not provide noise attenuation and comfort as may be desired by building occupants.

SUMMARY OF THE INVENTION

[0004] The present invention provides, in one aspect, a composite panel structure adapted to be supported relative to a mounting surface. The composite panel structure includes a panel having a first surface and a second surface defining therebetween a thickness of the panel. The panel also has a plurality of perforations arranged in a hexagonal pattern and spanning the thickness of the panel. The perforations provide acoustic transparency to the panel. The composite panel structure further includes a film positioned adjacent the first surface of the panel to attenuate sound waves reflected from the panel.

[0005] Other features and aspects of the invention will become apparent by consideration of the following detailed description and accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0006] FIG. 1 is a schematic side view of a panel in accordance with the invention.

[0007] FIG. 2 is an enlarged view of the panel of FIG. 1, illustrating a hexagonal perforation pattern in the panel.

[0008] FIG. 3 is a schematic side view of a composite panel structure in accordance with a first embodiment of the invention.

[0009] FIG. 4 is an enlarged view of the composite panel structure of FIG. 3, illustrating a hexagonal perforation pattern in a panel of the composite panel structure.

[0010] FIG. 5 is a schematic side view of a composite panel structure in accordance with a second embodiment of the invention.

[0011] FIG. 6 is an enlarged view of the composite panel structure of FIG. 5, illustrating a hexagonal perforation pattern in a panel of the composite panel structure.

[0012] FIG. 7 is a graph illustrating random incidence sound absorption coefficients in a small reverberation room over a range of frequencies for the panel of FIG. 1 and the composite panel structures of FIGS. 3 and 5.

[0013] Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. DETAILED DESCRIPTION

[0014] FIGS. 1 and 2 illustrate a panel 1 for creating a wall, ceiling, or like structure in the interior of a building. Alternatively, the panel 1 may be used on the exterior of a building. The panel 1 includes a first surface 4 in facing relationship with an upper ceiling structure 8 (or, alternatively, another interior mounting surface within a building) and a second surface 12 facing away from the upper ceiling structure 8. The first surface 4 of the panel and the upper ceiling structure 8 define therebetween an air gap having a length L ₀ of about 16 inches. The length L ₀ of the air gap may change depending upon the desired acoustical performance of the panel 1. In the illustrated construction, the panel 1 is substantially square having a nominal dimension of 2 feet by 2 feet. Alternatively, the panel 1 may be configured having any of a number of different shapes and dimensions. The first and second surfaces 4, 12 define therebetween a thickness T ₀ of about 4 mm. Alternatively, the thickness To of the panel 1 may be greater or less than 4 mm. The panel 1 is rigid and is self-supporting (e.g., within a suspended ceiling system), and is made of a plastic material (e.g., rigid polyvinyl chloride, ABS, high-impact polystyrene, etc.).

Alternatively, the panel 1 may be made of a foam or a porous, cellular material (e.g., extremely low-density rigid polyvinyl chloride, low density polystyrene, cellular ABS, etc.).

[0015] The panel 1 also includes a plurality of perforations 16 spanning the thickness To of the panel 1 and arranged in a regular 60° hexagonal pattern 20 such that the panel 1 appears visually opaque from a distance (e.g., 3 feet or more; see FIG. 2). Alternatively, the perforations 16 may occur in a different hexagonal pattern, a non-hexagonal pattern, or an irregular pattern. The hexagonal pattern 20 shown in FIG. 2 has an edge length Eo of 5.5 mm, and the perforations 16 are located at the respective vertices of the hexagonal pattern 20 and in the center of the hexagonal pattern 20. Alternatively, the edge length E ₀ may be greater or less than about 5.5 mm depending upon the size of the perforations 16. In the illustrated construction, the diameter Do of the perforations 16 is about 1 mm, and the perforations 16 collectively define an open area within the panel 1 of about 3%.

[0016] With reference to FIGS. 1 and 2, the panel 1 functions to allow acoustic (i.e., sound) waves from an environment to pass through the perforations 16 in the panel 1 and be absorbed rather than be reflected back into the environment, thereby decreasing the noise level and improving the comfort of occupants in the environment. The panel 1 , being made of a synthetic material, is unlike fiberboard-based panels in that it allows easy installation of the panels 1 , enhanced durability of the panel 1 from physical stress, resistance to growth of mold and mildew on the panel 1 , and ease of cleaning and/or sterilizing of the panel 1. By

incorporating perforations 16, the panel 1 reduces noise levels and maintains the advantages of a conventional synthetic panel over a fiberboard-based panel.

[0017] FIG. 3 illustrates a composite panel structure 128 in accordance with a first embodiment of the invention for creating a wall, ceiling, or like structure in the interior of a building, or covering the exterior of a building. Like components are shown with like reference numerals, plus "100." The composite panel structure 128 includes a panel 101 and an insulation layer 132 positioned adjacent a first surface 104 of the panel 101. Alternatively, the insulation layer 132 may be coupled to the first surface 104 of the panel 101 (e.g., using an adhesive). The insulation layer 132 includes a first surface 136 in facing relationship with the first surface 104 of the panel 101 and a second surface 140 facing away from the first surface 104 of the panel 101. The first and second surfaces 136, 140 of the insulation layer 132 define therebetween a thickness Ti of about 0.5 inches. Alternatively, the thickness Ti of the insulation layer 132 may be greater or less than 0.5 inches. The insulation layer 132 is made of a porous, polyester insulation material. Alternatively, the insulation layer 132 may be made of any of a number of different insulating materials.

[0018] The panel 101 includes a plurality of perforations 1 16 spanning the thickness T ₃ of the panel 101 , which is substantially similar to the thickness To of the panel 1 , and arranged in a regular 60° hexagonal pattern 120 (FIG. 4). The hexagonal pattern 120 shown in FIG. 4 has an edge length Ei of 10.5 mm. Alternatively, the edge length Ei may be greater or less than about 10.5 mm depending upon the size of the perforations 1 16. In the illustrated construction, the diameter Di of the perforations 1 16 is about 3.8 mm, and the perforations 1 16 collectively define an open area within the panel 101 of about 12%.

[0019] With reference to FIGS. 3 and 4, the composite panel structure 128 functions to allow acoustic (i.e., sound) waves from an environment to pass through the perforations 1 16 in the panel 101 and to encounter the insulation layer 132. The insulation layer 132 absorbs some of the sound waves and reduces the sound waves that are reflected back into the environment, thereby decreasing the noise level and improving the comfort of occupants in the environment. The panel 101, being made of a synthetic material, is unlike fiberboard-based panels in that it allows easy installation of the panels, enhanced durability of the panel from physical stress, resistance to growth of mold and mildew on the panel, and ease of cleaning and/or sterilizing of the panel. By incorporating perforations 116 in the panel 101 and the insulating layer 132, the composite panel structure 128 reduces noise levels and maintains the advantages of a

conventional synthetic panel over a fiberboard-based panel.

[0020] FIGS. 5 and 6 illustrate a composite panel structure 228 in accordance with a second embodiment of the invention for creating a wall, ceiling, or like structure in the interior of a building, or covering the exterior of a building. Like components are shown with like reference numerals, plus "200." The composite panel structure 228 includes a panel 201 and a film 244 positioned adjacent a first surface 204 of the panel 201. The film 244 includes a first surface 248 in facing relationship with the first surface 204 of the panel 201, and a second surface 252 facing away from the first surface 204 of the panel 201. The first and second surfaces 248, 252 of the film 244 define therebetween a thickness T ₂ of about 0.0015 inches. Alternatively, the thickness T ₂ of the film 244 may be greater or lesser than 0.0015 inches. The film 244 is made of a plastic material (e.g., polyvinyl chloride). Alternatively, the film 244 may be made from a non-plastic material (e.g., a fabric).

[0021] The film 244 also includes a plurality of microperforations (not shown) spanning the thickness T ₂ of the film 244 and having a diameter between about 100 microns and about 300 microns. Preferably, the microperforations include a diameter of about 250 microns. The density of the microperforations in the film 244 is between about 20 perforations/cm ² and about 80 perforations/cm ² . Preferably, the density of the microperforations in the film 244 is about 50 perforations/ cm ² .

[0022] The panel 201 includes a plurality of perforations 216 spanning the thickness T ₄ of the panel 201, which is substantially similar to the thickness T ₀ of the panel 1, and arranged in a regular 60° hexagonal pattern 220. The hexagonal pattern 220 shown in FIG. 6 has an edge length E ₂ of 13.5 mm. Alternatively, the edge length E ₂ may be greater or less than 13.5 mm depending upon the size of the perforations 216. In the illustrated construction, the diameter D ₂ of the perforations 216 is about 6.35 mm, and the perforations 216 collectively define an open area within the panel 201 of about 20%. In an alternative construction, the diameter D ₂ of each of the perforations 216 may be between about 4 mm and about 8 mm, and the perforations 216 may collectively define an open area within the panel 201 between about 10% and about 30%.

[0023] In the composite panel structure 228 of FIG. 5, an outer perimeter of the film 244 is adhered via an adhesive to an outer perimeter of the panel 201. The adhesive is applied to about the outer one inch of the perimeter of the panel 201. The remaining interior of the film 244 remains unadhered or unattached to the panel 201. A middle or central portion of the film 244 "pillows-up" when sound waves pass through the perforations 216 in the panel 201, and the sounds waves are captured between the film 244 and the panel 201. Note that the extent to which the film 244 is shown "pillowed-up" in FIG. 5 is exaggerated for purposes of illustration. The sound waves may also diffuse through the microperforations in the film 244 to reduce or attenuate the sound waves that are reflected back into an environment. In an alternative construction of the structure 228, the outer perimeter of the film 244 may be adhered via an adhesive to an edge surface of the panel 201 having a length equivalent to the thickness T ₄ of the panel 201 such that no portion of the film 244 is attached to the first surface 204 of the panel 201.

[0024] With reference to FIG. 5, the composite panel structure 228 functions to allow acoustic (i.e., sound) waves from an environment to pass through the perforations 216 in the panel 201 and then encounter the film 244. The sound waves diffuse through the

microperforations in the film 244 to reduce or attenuate the sound waves that are reflected back into an environment, thereby decreasing the noise level and improving the comfort of occupants in the environment. The panel 201 , being made of a synthetic material, is unlike fiberboard- based panels in that it allows easy installation of the panels, enhanced durability of the panel from physical stress, resistance to growth of mold and mildew on the panel, and ease of cleaning and/or sterilizing of the panel. By incorporating perforations 216 in the panel 201 and the film 244, the composite panel structure 228 reduces noise levels and maintains the advantages of a conventional synthetic panel over a fiberboard-based panel. [0025] The graph in FIG. 7 depicts the random incidence sound absorption coefficient in a small reverberation room over a range of frequencies for the panel 1 shown in FIG. 1, the composite panel structure 128 shown in FIG. 3, and the composite panel structure 228 shown in FIG. 5. Tests were conducted in accordance with ASTM C423-08a with an ASTM E795-00 type "E" mounting at a mounting depth of 16 inches. The test conditions were as follows: the temperature was 73 °F-76 °F, the relative humidity was 86-70%, and the barometric pressure was 969 hPa. The second surface 12, 112, 212 of the respective panels 1, 101, 201 (i.e., the surface that would be facing the environment) faced the acoustic waves. The panel 1 displayed the lowest sound absorption coefficient across a range of frequencies, while the composite panel structure 128 displayed the highest sound absorption coefficient except at higher frequencies. The composite panel structure 228 displayed an intermediate sound absorption coefficient except at higher frequencies, where the structure 228 had a higher sound absorption coefficient than the panel 1 and the structure 128. The data in FIG. 7 indicates that the presence of a film or an insulating layer increases the acoustic absorption performance of a perforated panel.

[0026] Various features of the invention are set forth in the following claims.