EP4015728A1

EP4015728A1 - Sprayable acoustic coating on a modular structure

Info

Publication number: EP4015728A1
Application number: EP20215545.3A
Authority: EP
Inventors: Tuomas HÄNNINEN; Marko MAKKONEN; Juha RYYPPÖ; Tapani TUONONEN
Original assignee: Lumir Oy
Current assignee: Lumir Oy
Priority date: 2020-12-18
Filing date: 2020-12-18
Publication date: 2022-06-22

Abstract

According to an example aspect of the present invention, there is provided an acoustic structure comprising a natural fibrous acoustic coating on a surface of a modular structure.

Description

FIELD

The present invention relates to improved acoustic structures, more precisely sprayable natural fibrous acoustic coatings on modular background structures for providing seamless and easily applicable acoustic solutions.

BACKGROUND

When planning and implementing structures, more and more attention is paid to the acoustics of rooms, offices and other spaces. Naturally, functioning acoustics are a prerequisite, for example, in concert halls, but, the acoustics also have significant impacts on the levels of satisfaction, work efficiency, and even human health, for example, in homes, schools, and workplaces. Since structural solutions cannot be selected on the terms of acoustics alone, different acoustic elements or acoustic surfaces, which are installed in the spaces and on their surfaces after the actual construction stage, are needed.
A primary requirement for the functioning of the acoustic surface or element, naturally, is that it has suitable acoustic properties. Generally, this signifies a sound absorption that is sufficiently strong or has a frequency response of a suitable form. On one hand, since the acoustic elements and surfaces are structures that remain in sight, their architectural image should also be suitable for their environment and the other surfaces of the space. The thickness of the panel or surface should remain within reasonable limits, which, on the other hand, is inconsistent with the high requirement of sound absorption. Naturally, the acoustic elements or surfaces should also fulfil the visual criteria which are set for the surface materials of interiors, and they should also have mechanical and physical properties that are suitable for their environment of use. Similarly, to other structural elements, the requirement of considering environmental aspects, to an increasing extent, also applies to the acoustic surfaces and elements with respect to the manufacture and recyclability of the materials, for example.
The most common commercially available, ready-made acoustic elements include mineral wool-based (fibreglass or rock wool-based) acoustic panels. On the sides of these which remain in sight, the surface of the mineral wool is coated, for example, with paper, plastic, fabric or glass fleece. Being relatively light components, these acoustic elements are simple to install, for example, on the ceiling or walls of the space that is to be provided with sound absorption, either as separate elements or as an unbroken surface. They can also be formed into acoustic planes that are lowered down from the ceiling, for example.
For the coating of walls, ceilings or the like in different interiors, various fibre-based coating compounds are also known, which are sprayed or applied in another way and which provide a mechanical surface structure that is more elastic and durable than glass and rock-based coatings, and which can also contribute to the acoustics of the premises.
For example, the disclosures of FI 95041 and WO 2007/063178 describe natural fibre-based coatings that are sprayed when mixed with water, or applied in a similar manner and hardened through drying. The fibre of the coating compound of FI 95041 comprises fine cellulose fibre. In the solution of WO 2007/063178 , in addition to the fibre material and the binder, the compound includes particle-like, typically mineral-based fillers, by means of which the surface of the coating becomes smooth and which can adjust the acoustic properties of the coating.
US 3,044,919 relates to a surfacing or facing construction particularly adaptable for application on wall and ceiling areas or surfaces and to a method or system of applying the surface of facing to an area, the surfacing or facing construction embodying a thin mat, layer or sheet of mineral material adapted to be adhesively joined to the surface or area to be finished. However, it does not disclose natural fibrous acoustic coatings on modular background structures, nor especially fixing the coating to a desired surface without binders.
US 2018/0251976 relates to acoustic panels, grids for acoustic panels, suspended ceiling systems and a method for producing an acoustic panel. CA 2126059 describes an acoustical ceiling panel, which includes a generally pyramid-form frame having an exterior surface and interior cavity. A fabric covering is positioned on the exterior surface of the frame and a lining of acoustically dampening material is positioned within the interior cavity. US 2020/0002942 on the other hand discloses an acoustic drop ceiling product, a dynamic acoustic drop ceiling system and related methods that include multiple differently shaped drop ceiling products that can be quickly and easily installed into a backer panel and then onto construction drop ceiling hangers to provide an aesthetically pleasing image along with a reduction in unwanted noise or room acoustics. However, these publications do not disclose acoustic solutions, wherein the ceiling structure/system is seamlessly coated with a sprayable natural acoustic fibrous matter without requiring any ground work for preparing the ceiling structure/system for the coating step.
Thus, there is a need for improved acoustic structures and reverberation reducing surfaces utilizing natural fibrous acoustic mass for providing easily applicable seamless acoustic solutions for example to modular and/or structural ceilings.

SUMMARY OF THE INVENTION

The invention is defined by the features of the independent claims. Some specific embodiments are defined in the dependent claims.
According to an aspect of the present invention, there is provided a monolithic acoustic structure made of a modular background structure, which has been seamlessly coated with a sprayable natural fibrous acoustic material.
According to another aspect of the present invention, there is provided an acoustic structure, such as a suspended, drop or modular ceiling comprising panels, coated with a natural fibrous acoustic material, wherein the acoustic coating is attached to the surface of the ceiling structure/system, preferably even without using any binders.
This and other aspects, together with the advantages thereof over known solutions are achieved by the present invention, as hereinafter described and claimed.
The acoustic structure of the present invention is mainly characterized by what is stated in the characterizing part of claim 1.
Considerable advantages are obtained by means of the invention. For example, the natural acoustic coating can be applied by spraying straight on to a surface of a suspended, drop or modular ceiling structure without requiring any ground work, providing a monolithic surface, which essentially improves the visual appearance of the ceiling by hiding the seams and structures beneath. Same applies for wall structures made for example mineral wool-based panels. In addition, the natural fibrous acoustic coating according to the present invention is applicable to the surface of a background structure without using any binders. Furthermore, natural fibrous coatings are not harmful for consumers and they enable moisture vaporization from the below structures. One major advantage is that the acoustic solution of the present invention is able to effectively bind carbon dioxide from the atmosphere due to its natural raw material features. Synthetic acoustic products are not able to do the same. In addition, the present products provide tens of years of service life, whereby carbon dioxide is bound even longer than with typical bio-fibers, such as paper. These features together provide advantageous acoustic solutions and products having very low or negative carbon footprint.
Next, the present technology will be described more closely with reference to certain embodiments.

EMBODIMENTS

The present technology provides sprayable acoustic coatings on modular background structures that improves the acoustic properties of premises and reduces the drawbacks of the known solutions, and provides aesthetically pleasing acoustic solutions. The present technology is particularly suitable for reducing reverberation in inner acoustics of premises.
One purpose of the invention, in particular, is to provide an acoustic structure, which is formed by utilising a natural fibrous coating composition, which is particularly suitable for the purpose and which provides effective sound absorption and acoustic transparency, and from which no significant amounts of dust or other particles come off, even after drying.

FIGURE 1 is a photo of a modular ceiling structure/system from back side.
FIGURE 2 is a drawing of a t-grid profile according to the present invention.
FIGURE 3 is a drawing of a structural ceiling according to the present invention.

The present invention is based on a combination of a modular background material and/or structure and a natural fibrous coating on a surface of the modular background material and/or structure.
One aspect of the present invention is a combination of a modular background structure and an acoustic coating, wherein the acoustic coating is made of natural fibrous matter and is applied by spraying onto a surface of the modular background structure, and wherein the natural fibrous matter seamlessly covers the modular background structure and all its elements.
Herein the term "modular background structure" is intended to comprise all structures and systems made of modules and/or panels. Thus, it may for example be a suspended or drop ceiling structure comprising panels installed into a grid structure or grid system. Also modular structures comprising panels without grid structures/systems belong to the scope of the present invention.
The acoustic structure can thus be for example a ceiling structure, or a wall structure, or any other structure, which requires sound-proofing and is made of modules, which are seamlessly coated with a natural fibrous acoustic coating.
According to one embodiment of the present invention, the natural fibrous matter is plant or plant-based fibre, such as pulp, flax, cotton or hemp fibre, cellulosic man-made fibre, such as viscose, microcellulose or nanocellulose, or animal-based fibre, such as silk or wool-based fibre, or a mixture of such fibres. The acoustic coating comprises the natural fibrous matter 20-100% of the dry-matter mass of the acoustic coating.
In one embodiment of the present invention the acoustic coating has a thickness between 3 to 10 mm, preferably between 6 to 8 mm.
In one embodiment of the present invention, the acoustic coating further comprises 0-80% of mineral filler from its dry matter mass, preferably mineral silicate, mineral sulphate or mineral carbonate, most preferably kaolin.
In a further embodiment of the present invention, the acoustic coating comprises a fire retardant and an anti-rot agent, selected for example from a group of boron-based substances, such as boric acid or borax or a mixture thereof, hydroxides, such as aluminium or magnesium hydroxide or a mixture thereof, or absorbing agents, such as talc or calcium carbonate or a mixture thereof, most preferably boric acid or borax, particularly a mixture thereof, in an amount of 8-25% by weight of the dry matter at the most.
In one particular embodiment of the present invention, the acoustic coating does not contain any binders for binding into the surface of the porous background. This embodiment is achieved by the network of the natural fibrous matter formed on top of the holes in the porous background. Porous acoustic coating can thus be prepared without binders by utilizing particles of different size scales, for example by combining cellulosic fibres with micro-fibrillated or nano-fibrillated cellulose.
One embodiment of the present invention is an acoustic structure comprising a modular ceiling structure having panels attached into a grid structure/system, onto which a natural fibrous acoustic coating is sprayed without any preparatory ground work for providing a seamless ceiling structure. It is preferred that a grid gap between the panels is preferably less than 10 mm, more preferably less than 5 mm. Such grid structure/system may be either rigid or flexible and made from any material, comprises hangers that are preferably adjustable, and may be used to form ceiling structures of any shape. The grid structure/system can be either visible or hidden grip.
According to a further embodiment of the present invention, the natural fibrous acoustic coating seamlessly covers the panels, the grid structure/system and at least partially fills the grid gaps between the panels.
The panels attached, installed or assembled into the grid structure/system can be for example mineral wool-based panels with sanded, fleece or pre-coated surface, perforated gypsum panels comprising holes, non-acoustic panels such as non-perforated gypsum panels for producing partially reflecting fields and solid panels made from any material for installation of various accessories, whereby the panels may have various functionalities such as cooling systems, audio systems and maintenance hatches, which can be seamlessly integrated into the structure. It is also possible to use primers and/or commonly used surface-energy modifying techniques and additives.
According to the present invention, it is preferred that when the structure comprises a grid structure/system, the panels need to be mounted to the grid structure/system with clips, or glue or such for ensuring firm mounting of the panels for withstanding spraying pressure of the natural fibrous acoustic coating. The clips can be made of any material and be of any shape and size.
According to one embodiment of the present invention, the modular background structure consists of mineral wool-based panels, without grid structure/system, glued to a wall. The natural acoustic fibrous matter is sprayed onto the panels similarly as in other embodiments described herein for at least partially filling the gaps between the panels and thus providing a seamless acoustic wall structure.
One aspect of the present invention is that because of the fibre network on top of the surface of the modular background structure, the surface can be made plain and hide the structure beneath it.
Another aspect of the present invention is that the modular background structure does not need to be pre-handled, such as taped, putted and sanded before applying the acoustic coating, which reduces the process steps and costs as well as provides easier yet effective acoustic solutions. The present invention also provides material savings for example in binder and seaming materials.
It has been concluded that the acoustic structures and/or coatings according to the present invention are able to bind about 1,2 kg of CO₂ per m² from the atmosphere.
Reference throughout this specification to one embodiment or an embodiment means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, appearances of the phrases "in one embodiment" or "in an embodiment" in various places throughout this specification are not necessarily all referring to the same embodiment. Where reference is made to a numerical value using a term such as, for example, about or substantially, the exact numerical value is also disclosed.
While the forgoing examples are illustrative of the principles of the present invention in one or more particular applications, it will be apparent to those of ordinary skill in the art that numerous modifications in form, usage and details of implementation can be made without the exercise of inventive faculty, and without departing from the principles and concepts of the invention. Accordingly, it is not intended that the invention be limited, except as by the claims set forth below.
The verbs "to comprise" and "to include" are used in this document as open limitations that neither exclude nor require the existence of also un-recited features. The features recited in depending claims are mutually freely combinable unless otherwise explicitly stated. Furthermore, it is to be understood that the use of "a" or "an", that is, a singular form, throughout this document does not exclude a plurality.

INDUSTRIAL APPLICABILITY

The present invention is applicable to for example ceilings and other kinds of structures comprising modular background structures in for example buildings, providing seamless acoustic solutions mainly to the inner acoustic needs of the space formed by such structures.

EXAMPLE

Attachment points for the hangers are installed to main structural ceiling 600 mm and 1200 mm distances between each other according to figure 2.
Height of the ceiling grid is adjusted with length of the hangers (for example in the Figure 3 down to 180 mm from the structural ceiling).
Grid system is attached to the hangers.
Panels are inserted to the grid. Panels can be fastened to the grid system by clips or by gluing the panels on the grid.
Possible maintenance hatches and other special functionalities are inserted to the grid.
Primer can be applied to enhance the adhesion of the coating, depending on the type of the panels used.
Acoustic coating is sprayed on the ceiling as 1-2 mm layers from alternating directions without drying between the layers until the coating has reached desired thickness.
Coated layer can be leveled using, for example, a trowel. Extra layers can be sprayed to provide different kinds of surface structures.
Coating can contain pigments or colors.
Dried surface can be sanded to change the structure of the surface.

CITATION LIST

Patent literature

Claims

An acoustic structure comprising a combination of a modular background structure and an acoustic coating, characterized in that the acoustic coating is made of natural fibrous matter and applied by spraying on a surface of the modular background structure, wherein the natural fibrous matter seamlessly covers the modular background structure.
The acoustic structure according to claim 1, characterized in that the natural fibrous matter is plant or plant-based fibre, such as pulp, flax, cotton or hemp fibre, cellulosic man-made fibre, such as viscose, microcellulose or nanocellulose, or animal-based fibre, such as silk or wool-based fibre, or a mixture of such fibres.
The acoustic structure according to any of the preceding claims, characterized in that the acoustic coating has a thickness between 3 to 10 mm, preferably between 6 to 8 mm.
The acoustic structure according to any of the preceding claims, characterized in that the acoustic coating further comprising 0-80% of mineral filler from its dry matter mass, preferably mineral silicate, mineral sulphate or mineral carbonate, most preferably kaolin.
The acoustic structure according to any of the preceding claims, characterized in that the acoustic coating further comprises a fire retardant and an anti-rot agent, selected from a group of boron-based substances, such as boric acid or borax or a mixture thereof, hydroxides, such as aluminium or magnesium hydroxide or a mixture thereof, or absorbing agents, such as talc or calcium carbonate or a mixture thereof, most preferably boric acid or borax, particularly a mixture thereof, in an amount of 8-25% by weight of the dry matter at the most.
The acoustic structure according to any of the preceding claims, characterized in that the acoustic coating does not contain any binders.
The acoustic structure according to any of the preceding claims, characterized in that the acoustic coating comprises particles of different size scales, such as a combination of cellulosic fibres with micro-fibrillated or nano-fibrillated cellulose.
The acoustic structure according to any of the preceding claims, characterized in being a modular ceiling structure comprising panels attached into a grid structure.
The acoustic structure according to claim 8, characterized in that a grid gap between the panels is preferably less than 10 mm, more preferably less than 5 mm.
The acoustic structure according to claim 8 or 9, characterized in that the grid structure is rigid or flexible, comprises hangers that are preferably adjustable and forms ceiling structures of any shape.
The acoustic structure according to any of claims 8 to 10, characterized in that the natural fibrous acoustic coating seamlessly covers the panels, the grid structure and at least partially fills the grid gaps between the panels.
The acoustic structure according to any of claims 8 to 11, characterized in that the panels comprise mineral wool-based panels with sanded, fleece or pre-coated surface, perforated gypsum panels comprising holes, non-acoustic panels such as non-perforated gypsum panels and solid panels made from any material.
The acoustic structure according to any of claims 8 to 12, characterized in that the panels are mounted to the grid structure with clips or by gluing for ensuring firm mounting of the panels for withstanding spraying pressure of the natural fibrous acoustic coating.
The acoustic structure according to any of claims 8 to 13, characterized in being a suspended or drop ceiling.
The acoustic structure according to any of claims 1 to 7, characterized in that the modular background structure consists of mineral wool-based panels glued to a wall, wherein the panels are coated and the gaps between the panels are at least partially filled with the natural acoustic fibrous matter thus providing a seamless acoustic wall structure.