Method for making acoustical panels with a three-dimensional surface
View Patent ↗A method for producing acoustical panels with a three-dimensional surface bonds stacks of design pieces to a flat panel. A layer of adhesive is applied over the assembly, and then a fabric layer is applied over the assembly to bond the fabric over the panel and design pieces.
1. A method for making an acoustical panel with a three-dimensional surface comprising:
providing an acoustical panel having a substantially flat surface;
forming design pieces;
attaching the design pieces to the surface of the panel to create three-dimensional designs;
applying adhesive to the design pieces and surface of the panel;
placing an air-permeable, thin flexible layer over the design pieces and panel;
placing an air-impermeable layer over the thin flexible layer;
drawing air through the panel to suck the thin flexible layer and air-impermeable layer against the design pieces and surface of the panel; and
removing the air-impermeable layer, while leaving the thin flexible layer to bond with the adhesive.
2. The method of claim 1 wherein the thin flexible layer comprises fabric.
3. The method of claim 1 wherein acoustical panel is air-permeable.
4. The method of claim 3 wherein the acoustical panel comprises fiberglass.
5. The method of claim 1 further comprising applying a hardening material to the edges of the acoustical panel prior to bonding the thin flexible layer.
6. The method of claim 1 further comprising attaching reinforcing material to the edges of the acoustical panel prior to bonding the thin flexible layer.
7. The method of claim 1 wherein a plurality of flat design pieces are stacked to create the three-dimensional design.