WO1990012934A1 - Ceiling panel and method of manufacture - Google Patents

Ceiling panel and method of manufacture Download PDF

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Publication number
WO1990012934A1
WO1990012934A1 PCT/FI1990/000114 FI9000114W WO9012934A1 WO 1990012934 A1 WO1990012934 A1 WO 1990012934A1 FI 9000114 W FI9000114 W FI 9000114W WO 9012934 A1 WO9012934 A1 WO 9012934A1
Authority
WO
WIPO (PCT)
Prior art keywords
fabric
panel
ceiling
underiayer
fibers
Prior art date
Application number
PCT/FI1990/000114
Other languages
French (fr)
Inventor
Kari Hynninen
Antti Jalonen
Simo Laakso
Matti Salo
Original Assignee
Ahlström Eristeet Oy
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Ahlström Eristeet Oy filed Critical Ahlström Eristeet Oy
Publication of WO1990012934A1 publication Critical patent/WO1990012934A1/en
Priority to NO91914197A priority Critical patent/NO914197L/en

Links

Classifications

    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B9/00—Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation
    • E04B9/04—Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation comprising slabs, panels, sheets or the like
    • E04B9/0407—Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation comprising slabs, panels, sheets or the like being stiff and curved
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B9/00—Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B9/00—Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation
    • E04B9/04—Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation comprising slabs, panels, sheets or the like
    • E04B9/045—Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation comprising slabs, panels, sheets or the like being laminated

Definitions

  • the present invention relates to a ceiling panel capable of bending into the shape of a curve and a method of manufacturing such.
  • glasswool panels installed with the help of support moulding are generally used in ceilings.
  • a flat ceiling is not difficult to make, but construction of a curved ceiling is complicated.
  • curved ceilings have been made of pressed-to-shape pieces, the manufacture of which calls for expensive moulds and the transport of which is difficult. Furthermore, fitting the pieces together in the assembly stage sets great demands on the dimensional accuracy of the pieces.
  • An object of the invention is to provide a panel capable of bending into the shape of a curve, by means of which panel the drawbacks described above can be avoided. Another object is to provide a method of manufacturing such panel.
  • the ceiling panel according to the invention is mainly characterized in that it comprises a mineral wool layer containing fibers bonded together, the direction of extension of the fibers being mainly perpendicular to an underlayer/layer fabric attached to one side of the fiber layer.
  • the method according to the invention for manufacturing ceiling panels is mainly characterized in that a mineral wool mat which is coated on both sides thereof with an underiayer fabric and the fibers of which mat have been caused to rise from a horizontal position to a mainly vertical position at the manfufacturing stage of the mat, is cut along its centerline into two layers and that the layers cut apart from each other are cut into panels of a suitable size.
  • the fiber structure is, for technical reasons, primarily parallel to the surface of the panel, which is why the compression strength of the panel is low in the direction perpendicular to the plane of the panel.
  • the panel according to the invention is manufactured from a mineral wool sheet, the main portions of the fibers of which axe, in the ⁇ mani'fcic-turing stage -with *the panel regarded lying in a horizontal position, forced to rise fxom the hitherto normal, horizontal disposition to a substantially vertical disposition in such a manner that the fibers proceed steeply wavelike in the base sheet when viewing the profile of the base sheet. This is brought about by decreasing the speed of the mineral wool mat between the top and the bottom wires used in the manufacturing prior to conveying the mat into the heat treatment oven for hardening of the bonding agents.
  • This "shrink" panel is already coated on both sides thereof in the processing stage with an underiayer fabric (25 - 50 g/m 2 glass tissue) which provides an even base for final coating of the panel.
  • the underiayer fabric is attached to the base sheet by means of the resin contained in the base sheet.
  • the base sheet is made twice as thick as that required for the final product plus working allowance.
  • This base sheet which is coated on both sides thereof with an underiayer fabric and which naturally is stiff in this stage, is sawn along its centerline into two layers. In that way, one surface of both layers is coated with an underiayer fabric, which provides an even base for the final coating.
  • the fibers are mainly in the vertical position.
  • the final product After sawing, the final product has, due to the presence of vertical fibers, sufficient compression strength and solidity so that the panel can be installed to rest freely on mouldings.
  • the sawing of the base sheet in two since the sawing of the base sheet in two is effected mainly perpendicularly to the fibers, the tensile and compression forces are not subjected to the fibers in the direction of the fibers when the sheet is being bent, but perpendicularly to the fibers. Thus, the sheet bends well because of lack of horizontal bonds in the back thereof.
  • the base sheet layers sawn apart are laminated with a final coating fabric on that side -which is coated with an underiayer fabric.
  • Fig. 1 is a cross-sectional illustration of a stage of manufacture of a ceiling panel in accordance with the method of the invention
  • Fig. 2 is a cross section of a panel according to the invention
  • Fig. 3 is a schematic, fragmentary perspective illustration of a ceiling structure assembled from ceiling panels according to the invention.
  • a glasswool mat 2 illustrated in Fig. 1 is manufactured by a method known per se from fibers and bonding agents suspended in a gas flow by collecting the fibers onto a conveying belt, below which a suction box is disposed.
  • the main length of the fibers are forced to rise from their normal, horizontal position to a vertical position so that the fibers will mainly extend in the vertical position in the middle of the mat.
  • the fiber mat is coated on both sides thereof with an underiayer fabric 3, which is attached to the mat by means of the resin contained in the mat.
  • the coated mat 1 is sawn or otherwise separated along its centerline 4 into two layers 2' and the sides of the layers sawn apart from each other which are coated with the underiayer fabric 3 are laminated with a coating fabric 6, whereafter they will be cut into ceiling panels 5 (Fig. 2) of a suitable size.
  • the underiayer fabric 3 is preferably formed of nonwoven fabric made from glasswool, the basis weight of such fabric bei ⁇ g 25-50 g/m 2 .
  • the coating fabric 6 is preferably formed of nonwoven fabric made from glasswool, the basis weight of such fabric being 50-200 g/m 2 .
  • the thickness of the mineral wool layer is preferably 30- 70 mm and the density 30-40 kg/m 3 .
  • Fig. 3 illustrates a ceiling assembly 10 including ceiling panels 5 according to the invention, in which ceiling the panels 5 are bent to form curves to match the curved support moulding 11 and fixed to it, the ceiling itself is suspended by a method known per se with suspension threads 12 extending from the frame construction of the building and the coating fabric 6 forms a smooth suspended ceiling surface which is easy to maintain clean.
  • Example 1 illustrates a ceiling assembly 10 including ceiling panels 5 according to the invention, in which ceiling the panels 5 are bent to form curves to match the curved support moulding 11 and fixed to it, the ceiling itself is suspended by a method known per se with suspension threads 12 extending from the frame construction of the building and the coating fabric 6 forms a smooth suspended ceiling surface which is easy to maintain clean.
  • a mineral wool mat the density of which was about 30 kg/m 3 and thickness 65 mm and which was on both sides thereof coated with glass fabric of 25 g/m 2 , was sawn into two 30 mm thick layers. The surfaces coated with glass fabric of the layers sawn apart from each other were then laminated with another glass fabric, the basis weight of which was 60 g/m 2 . Thereafter, the layers were cut into ceiling panels of 600 mm x 1200 mm. The end product was a flexible panel, the stiffness of which was adequate for installing the panel to rest at its edges on T-moulding.
  • the ceiling panel of the invention provides ceilings which are easy to install. Transport of the panels causes no problems because the panels are flat and not bent intc the shape Of an axe or curve until the installation stage.
  • plastic laminates can be used as the coating fabric of the panel. It will be understood that the panel can be used to other purposes as well.

Abstract

A ceiling panel (5) capable of bending into the shape of an arc, for forming a curved ceiling (10), and a method of manufacturing the ceiling panel. The ceiling panel comprises a mineral wool layer (2') with fibers bonded together, the direction of the fibers being mainly perpendicular to the underlayer fabric (3) which is made from glasswool and attached to one side of the fiber layer, onto the surface of which underlayer fabric a coating fabric (6) made from glasswool is laminated. The panel is manufactured from a mineral wool mat (1) which is coated on both sides thereof and in which, when the panel is viewed in a horizontal position, the fibers of which have been caused to rise from the normal, horizontal position to a vertical position in the manufacturing stage of the mat.

Description

Ceiling panel and method of manufacture
The present invention relates to a ceiling panel capable of bending into the shape of a curve and a method of manufacturing such.
For purposes of noise damping and interior features, glasswool panels installed with the help of support moulding are generally used in ceilings. A flat ceiling is not difficult to make, but construction of a curved ceiling is complicated. Until now, curved ceilings have been made of pressed-to-shape pieces, the manufacture of which calls for expensive moulds and the transport of which is difficult. Furthermore, fitting the pieces together in the assembly stage sets great demands on the dimensional accuracy of the pieces.
An object of the invention is to provide a panel capable of bending into the shape of a curve, by means of which panel the drawbacks described above can be avoided. Another object is to provide a method of manufacturing such panel.
The ceiling panel according to the invention is mainly characterized in that it comprises a mineral wool layer containing fibers bonded together, the direction of extension of the fibers being mainly perpendicular to an underlayer/layer fabric attached to one side of the fiber layer.
The method according to the invention for manufacturing ceiling panels is mainly characterized in that a mineral wool mat which is coated on both sides thereof with an underiayer fabric and the fibers of which mat have been caused to rise from a horizontal position to a mainly vertical position at the manfufacturing stage of the mat, is cut along its centerline into two layers and that the layers cut apart from each other are cut into panels of a suitable size. In the mineral wool panels produced by conventional manufacturing processes, the fiber structure is, for technical reasons, primarily parallel to the surface of the panel, which is why the compression strength of the panel is low in the direction perpendicular to the plane of the panel.
Many methods are known in which a mineral wool mat is divided into lamellas, which are turned 90° and re-combined with each other in order to achieve a vertical fiber structure i.e. perpendicular to the plane of the panel, and consequently, a higher compression strength.
The panel according to the invention is manufactured from a mineral wool sheet, the main portions of the fibers of which axe, in the ■mani'fcic-turing stage -with *the panel regarded lying in a horizontal position, forced to rise fxom the hitherto normal, horizontal disposition to a substantially vertical disposition in such a manner that the fibers proceed steeply wavelike in the base sheet when viewing the profile of the base sheet. This is brought about by decreasing the speed of the mineral wool mat between the top and the bottom wires used in the manufacturing prior to conveying the mat into the heat treatment oven for hardening of the bonding agents.
This "shrink" panel is already coated on both sides thereof in the processing stage with an underiayer fabric (25 - 50 g/m2 glass tissue) which provides an even base for final coating of the panel. The underiayer fabric is attached to the base sheet by means of the resin contained in the base sheet. The base sheet is made twice as thick as that required for the final product plus working allowance.
This base sheet which is coated on both sides thereof with an underiayer fabric and which naturally is stiff in this stage, is sawn along its centerline into two layers. In that way, one surface of both layers is coated with an underiayer fabric, which provides an even base for the final coating. In the middle of the base sheet, the fibers are mainly in the vertical position.
After sawing, the final product has, due to the presence of vertical fibers, sufficient compression strength and solidity so that the panel can be installed to rest freely on mouldings. On the other hand, since the sawing of the base sheet in two is effected mainly perpendicularly to the fibers, the tensile and compression forces are not subjected to the fibers in the direction of the fibers when the sheet is being bent, but perpendicularly to the fibers. Thus, the sheet bends well because of lack of horizontal bonds in the back thereof. The base sheet layers sawn apart are laminated with a final coating fabric on that side -which is coated with an underiayer fabric.
The invention is further described in more detail below, by way of example, with reference to the accompanying drawings, in which
Fig. 1 is a cross-sectional illustration of a stage of manufacture of a ceiling panel in accordance with the method of the invention,
Fig. 2 is a cross section of a panel according to the invention, and Fig. 3 is a schematic, fragmentary perspective illustration of a ceiling structure assembled from ceiling panels according to the invention.
A glasswool mat 2 illustrated in Fig. 1 is manufactured by a method known per se from fibers and bonding agents suspended in a gas flow by collecting the fibers onto a conveying belt, below which a suction box is disposed. By decreasing the speed of the glasswool mat formed thereby between the upper and the lower conveyors in two stages, the main length of the fibers are forced to rise from their normal, horizontal position to a vertical position so that the fibers will mainly extend in the vertical position in the middle of the mat. Thereafter, the fiber mat is coated on both sides thereof with an underiayer fabric 3, which is attached to the mat by means of the resin contained in the mat.
After the heat treatment, the coated mat 1 is sawn or otherwise separated along its centerline 4 into two layers 2' and the sides of the layers sawn apart from each other which are coated with the underiayer fabric 3 are laminated with a coating fabric 6, whereafter they will be cut into ceiling panels 5 (Fig. 2) of a suitable size.
The underiayer fabric 3 is preferably formed of nonwoven fabric made from glasswool, the basis weight of such fabric beiϊg 25-50 g/m2.
The coating fabric 6 is preferably formed of nonwoven fabric made from glasswool, the basis weight of such fabric being 50-200 g/m2.
The thickness of the mineral wool layer is preferably 30- 70 mm and the density 30-40 kg/m3.
Fig. 3 illustrates a ceiling assembly 10 including ceiling panels 5 according to the invention, in which ceiling the panels 5 are bent to form curves to match the curved support moulding 11 and fixed to it, the ceiling itself is suspended by a method known per se with suspension threads 12 extending from the frame construction of the building and the coating fabric 6 forms a smooth suspended ceiling surface which is easy to maintain clean. Example
A mineral wool mat, the density of which was about 30 kg/m3 and thickness 65 mm and which was on both sides thereof coated with glass fabric of 25 g/m2 , was sawn into two 30 mm thick layers. The surfaces coated with glass fabric of the layers sawn apart from each other were then laminated with another glass fabric, the basis weight of which was 60 g/m2. Thereafter, the layers were cut into ceiling panels of 600 mm x 1200 mm. The end product was a flexible panel, the stiffness of which was adequate for installing the panel to rest at its edges on T-moulding.
Besides freedom of design the ceiling panel of the invention provides ceilings which are easy to install. Transport of the panels causes no problems because the panels are flat and not bent intc the shape Of an axe or curve until the installation stage.
The invention is not limited to the embodiment described above, but it can be modified within the scope defined in the accompanying claims. Thus, plastic laminates can be used as the coating fabric of the panel. It will be understood that the panel can be used to other purposes as well.

Claims

Claims
1. A ceiling or other panel capable of bending into the shape of an arc or curve, characterized in that it comprises a mineral wool layer with fibers bonded together, the direction of extension of the fibers being mainly perpendicular to a layer or underiayer of fabric or material attached to one side of the fiber layer.
2. The ceiling panel as claimed in claim 1, characterized in that a coating fabric or material is laminated onto the underiayer or material of fabric.
3. The ceiling panel as claimed in claim 1, characterized in that the underiayer fabric is a glass tissue, the basis weight of which is about 25-50 g/m2.
4. The ceiling panel as claimed in claim 2 or 3, characterized in that the coating fabric is a glass tissue, the basis weight of which is about 50-200 g/m2.
5. A method of manufacturing a ceiling or other panel, characterized in that a mineral wool mat coated on both sides thereof with an underiayer fabric, the fibers of which mineral wool mat have been caused to rise from a horizontal position extending generally in the plane of the panel mainly to a perpendicular position in the manufacturing stage, is cut along its centerline into two layers and that the layers cut apart from each other are cut into panels of a suitable size.
6. The method as claimed in claim 5, characterized in that the underiayer fabrics are attached to the mineral wool mat by means of its own bonding agent in the manufacturing process of the mineral wool mat.
7. The method as claimed in claim 6, characterized in that the sides coated with an underiayer fabric of the layers cut apart from each other are laminated with a coating fabric.
PCT/FI1990/000114 1989-04-26 1990-04-25 Ceiling panel and method of manufacture WO1990012934A1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
NO91914197A NO914197L (en) 1989-04-26 1991-10-25 PROCEDURE FOR MANUFACTURING A ROOF PANEL

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
FI891971 1989-04-26
FI891971A FI83359C (en) 1989-04-26 1989-04-26 Process for making a ceiling board

Publications (1)

Publication Number Publication Date
WO1990012934A1 true WO1990012934A1 (en) 1990-11-01

Family

ID=8528306

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/FI1990/000114 WO1990012934A1 (en) 1989-04-26 1990-04-25 Ceiling panel and method of manufacture

Country Status (6)

Country Link
EP (1) EP0472532B1 (en)
DE (1) DE69002765T2 (en)
DK (1) DK0472532T3 (en)
FI (1) FI83359C (en)
NO (1) NO914197L (en)
WO (1) WO1990012934A1 (en)

Cited By (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO1993012302A1 (en) * 1991-12-16 1993-06-24 Rockwool International A/S Plate ceiling
GB2294236A (en) * 1994-10-21 1996-04-24 Saint Gobain Isover Curvable felt of fibrous materials with random orientation
EP0732460A1 (en) * 1995-03-17 1996-09-18 Daniel Kohler False ceiling for rooms
WO1998009109A1 (en) * 1996-08-30 1998-03-05 Technische Universität Dresden Multilayered sheet insulating material for heat insulation and sound proofing
EP0894909A1 (en) * 1997-07-31 1999-02-03 Thüringer Dämmstoffwerke GmbH Laminated insulating element with selective surface coating and method for producing the same
EP0978602A2 (en) * 1998-08-07 2000-02-09 Armstrong World Industries, Inc. Reinforced ceiling panels
EP1106742A3 (en) * 1999-12-09 2002-11-06 Deutsche Rockwool Mineralwoll GmbH & Co. OHG Insulating element
FR2859492A1 (en) * 2003-09-09 2005-03-11 Frederic Cyrille Pierre Boff Slab for suspended ceiling, has core sandwiched between two laminated plates, where core includes rabbet on its periphery to receive batten to ensure maintenance between slabs
US7051489B1 (en) 1999-08-12 2006-05-30 Hunter Douglas Inc. Ceiling system with replacement panels
US7947615B2 (en) 2005-04-04 2011-05-24 Awi Licensing Company Acoustical canopy system
EP3112546A1 (en) * 2015-07-02 2017-01-04 Saint-Gobain Placo SAS Ceiling and ceiling suspension system

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FI12743Y1 (en) * 2020-06-25 2020-09-15 Honkarakenne Oyj Laminated log and laminated log structure

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
SE390997B (en) * 1971-10-05 1977-01-31 Rockwool Ab INSULATION DISC, MAINLY CONSISTING OF MINERAL WOOL AND KITS FOR THE PRODUCTION OF SUCH A DISC
GB2120704A (en) * 1982-03-29 1983-12-07 Nitto Boseki Co Ltd Curved ceiling
EP0237504A2 (en) * 1986-02-11 1987-09-16 ECOPHON Aktiebolag False ceiling structure including carrying sections and false ceiling slabs carried by them
SE460371B (en) * 1987-09-16 1989-10-02 Ecophon Ab Curved under roof component with stable shape

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
SE390997B (en) * 1971-10-05 1977-01-31 Rockwool Ab INSULATION DISC, MAINLY CONSISTING OF MINERAL WOOL AND KITS FOR THE PRODUCTION OF SUCH A DISC
GB2120704A (en) * 1982-03-29 1983-12-07 Nitto Boseki Co Ltd Curved ceiling
EP0237504A2 (en) * 1986-02-11 1987-09-16 ECOPHON Aktiebolag False ceiling structure including carrying sections and false ceiling slabs carried by them
SE460371B (en) * 1987-09-16 1989-10-02 Ecophon Ab Curved under roof component with stable shape

Cited By (16)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO1993012302A1 (en) * 1991-12-16 1993-06-24 Rockwool International A/S Plate ceiling
GB2294236A (en) * 1994-10-21 1996-04-24 Saint Gobain Isover Curvable felt of fibrous materials with random orientation
BE1008789A3 (en) * 1994-10-21 1996-08-06 Isover B V FELT MATERIAL FIBER GUIDANCE RANDOM bendable.
GB2294236B (en) * 1994-10-21 1997-12-10 Saint Gobain Isover Curvable felt of fibrous material with random orientation
ES2130889A1 (en) * 1994-10-21 1999-07-01 Saint Gobain Isover Curvable felt of fibrous materials with random orientation
EP0732460A1 (en) * 1995-03-17 1996-09-18 Daniel Kohler False ceiling for rooms
WO1998009109A1 (en) * 1996-08-30 1998-03-05 Technische Universität Dresden Multilayered sheet insulating material for heat insulation and sound proofing
EP0894909A1 (en) * 1997-07-31 1999-02-03 Thüringer Dämmstoffwerke GmbH Laminated insulating element with selective surface coating and method for producing the same
EP0978602A2 (en) * 1998-08-07 2000-02-09 Armstrong World Industries, Inc. Reinforced ceiling panels
EP0978602A3 (en) * 1998-08-07 2000-10-18 Armstrong World Industries, Inc. Reinforced ceiling panels
US7051489B1 (en) 1999-08-12 2006-05-30 Hunter Douglas Inc. Ceiling system with replacement panels
EP1106742A3 (en) * 1999-12-09 2002-11-06 Deutsche Rockwool Mineralwoll GmbH & Co. OHG Insulating element
FR2859492A1 (en) * 2003-09-09 2005-03-11 Frederic Cyrille Pierre Boff Slab for suspended ceiling, has core sandwiched between two laminated plates, where core includes rabbet on its periphery to receive batten to ensure maintenance between slabs
US7947615B2 (en) 2005-04-04 2011-05-24 Awi Licensing Company Acoustical canopy system
EP3112546A1 (en) * 2015-07-02 2017-01-04 Saint-Gobain Placo SAS Ceiling and ceiling suspension system
WO2017001137A1 (en) * 2015-07-02 2017-01-05 Saint-Gobain Placo Sas Ceiling and ceiling suspension system

Also Published As

Publication number Publication date
DK0472532T3 (en) 1993-10-18
NO914197D0 (en) 1991-10-25
FI83359B (en) 1991-03-15
EP0472532A1 (en) 1992-03-04
NO914197L (en) 1991-10-25
FI83359C (en) 1991-06-25
EP0472532B1 (en) 1993-08-11
FI891971A (en) 1990-10-27
FI891971A0 (en) 1989-04-26
DE69002765T2 (en) 1993-12-09
DE69002765D1 (en) 1993-09-16

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