PANEL

• US 20190308389A1
• Filed: 07/04/2017
• Published: 10/10/2019
• Est. Priority Date: 07/04/2016
• Status: Active Grant

• Current Assignee: ROCKWOOL BV (Rockwool International A/S)
• Original Assignee: Rockwool International A/S
• Inventors: SKOVGAARD JORGENSEN, Kristian, CHRISTENSEN, Kenn
• Granted Patent: US 11,318,708 B2
• Time in Patent Office: Days
• CPC Class Codes: B32B 13/00 Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material
• CPC Class Codes: B32B 13/02 with fibres or particles being present as additives in the layer
• CPC Class Codes: B32B 13/045 of foam
• CPC Class Codes: B32B 2260/021 Fibrous or filamentary layer
• CPC Class Codes: B32B 2260/044 Water-setting substance, e.g. concrete, plaster
• CPC Class Codes: B32B 2262/067 Wood fibres
• CPC Class Codes: B32B 2262/10 Inorganic fibres
• CPC Class Codes: B32B 2262/101 Glass fibres
• CPC Class Codes: B32B 2262/108 Rockwool fibres
• CPC Class Codes: B32B 2266/0271 Epoxy resin
• CPC Class Codes: B32B 2266/0278 Polyurethane
• CPC Class Codes: B32B 2266/04 Inorganic
• CPC Class Codes: B32B 2266/057 Silicon-containing material, e.g. glass
• CPC Class Codes: B32B 2307/102 Insulating
• CPC Class Codes: B32B 2307/72 Density
• CPC Class Codes: B32B 2307/732 Dimensional properties
• CPC Class Codes: B32B 2419/00 Buildings or parts thereof
• CPC Class Codes: B32B 2419/04 Tiles for floors or walls
• CPC Class Codes: B32B 2607/00 Walls, panels
• CPC Class Codes: B32B 3/02 characterised by features of form at particular places, e.g. in edge regions non-uniform thickness B32B3/263
• CPC Class Codes: B32B 5/022 : Non-woven fabric
• CPC Class Codes: B32B 5/18 : characterised by features of a layer of foamed material
• CPC Class Codes: B32B 5/20 : foamed in situ
• CPC Class Codes: B32B 5/245 : another layer next to it being a foam layer

Abstract

A panel and a method of making a panel are provided. The panel comprises a cured polymeric foam layer that is formed by application of a foam composition to an edge surface of the panel and then shaped and cured. The panel comprises man-made vitreous fibre or wood wool cement.

Claims

1. A method of producing a modified panel, comprising:

providing a panel, which has a first major face that is opposed to a second major face and at least one minor face extending between the major faces;

providing a foam composition;

applying the foam composition to a minor face of the panel; and

curing the applied foam composition, thereby forming a layer of cured polymeric foam,

wherein the panel is selected from the group consisting of a man-made vitreous fibre (MMVF) panel and a wood wool cement panel.

2. The method of claim 1, wherein the panel is a man-made vitreous fibre (MMVF) panel.

3. The method of claim 1, wherein the panel is a panel for a suspended ceiling.

4. The method of claim 1, wherein the minor face is provided with a non-planar profile prior to application of the foam composition.

5. The method of claim 4, wherein during application of the foam composition the panel is positioned such that the major faces are substantially horizontal and the at least one minor face is substantially vertical and a shoulder is milled into the minor face, wherein the shoulder is positioned at the bottom of the minor face and the foam composition is applied to the minor face above the shoulder.

6. The method of claim 1, further comprising shaping the foam composition.

7. The method of claim 1, further comprising shaping the cured polymeric foam.

8. The method of claim 7, wherein the shaping is by milling.

9. The method of claim 7, wherein an edge detail is shaped into the minor face of the panel at the same time as the cured polymeric foam is shaped.

10. The method of claim 1 wherein the MMVF panel comprises a glass fibre facing on the first major face.

11. The method of claim 10 wherein the glass fibre facing overhangs the front major face by a length in the range from 0.5 mm to 5 mm, preferably from 1 mm to 3 mm.

21. Use of a modified panel made according to the method of claim 1 as a ceiling panel.

23. A suspended ceiling formed of an array of modified panels made according to the method of claim 1.

12. A modified panel comprising a man-made vitreous fibre (MMVF) panel or a wood wool cement panel, which has a first major face opposed to a second major face and at least one minor face extending between the major faces;

comprising a layer of milled polymeric foam on a minor face.

13. The modified panel of claim 12 wherein the milled polymeric foam is a polyurethane foam, a silicone foam or an epoxy foam, preferably a polyurethane foam.

14. The modified panel according to claim 12, wherein the milled polymeric foam is a chemically-curing foam.

15. The modified panel of claim 12 wherein the layer of milled polymeric foam covers not more than half the width of the minor face preferably not more than one quarter of the width of the minor face.

16. The modified panel of claim 12 wherein the panel has thickness of 10-100 mm, a width of 300-1200 mm and a length of 600-1200 mm.

17. The modified panel of claim 12, wherein the panel comprises bonded MMVF.

18. The modified panel of claim 17 wherein the panel has a density in the range of 70 to 150 kg/m³, preferably 90 to 120 kg/m³.

19. The modified panel of claim 12 comprising a glass fibre facing on at least one of the two major faces.

20. Use of a modified panel according to claim 12 as a ceiling panel.

22. A suspended ceiling formed of an array of modified panels according to claim 12.