TECHNICAL FIELD
[0001] The invention relates to an assembly according to claim 1 and a method for producing
an object according to claim 8.
TECHNOLOGICAL BACKGROUND OF THE INVENTION
[0002] Lamps and light fixtures play an important role in a space, for example in a room,
office, commercial space, or multi-use space. Some lamps, light fixtures, and related
objects are disclosed in the following documents.
[0003] DE102012013266 discloses an assembly according to the preamble of claim 1.
[0004] WO2012156060 discloses sound-absorbing lamps comprising a lighting means and a sound-absorbing
casing. An LED panel and/or a plurality of LED spotlights are provided as the lighting
means.
[0005] DE202008008896 discloses a foam hanging arrangement for use in a room as a sound absorber. Also,
a sound absorber based on a foam part attached to a ceiling or a wall is disclosed.
[0006] WO2013190447 discloses an acoustic panel comprising a plurality of parallel- arranged elongated
cavities.
[0007] US5209562 discloses a utility light includes a light source subassembly, removable mounting
means and an elongated flexible gooseneck portion having one end connected to the
mounting means and the opposite end connected to the light source subassembly.
[0008] The shape and the material from which a lamp is made are usually only selected to
perform a decorative function. In most instances in which the shape and/or the material
serve more than a decorative purpose, the choice is usually determined by the effect
that the shape and the material have on the diffusion and dispersion of the light.
For an object that often takes up an appreciable amount of space within an area and
can be somewhat expensive, such a one-sided application appears to represent an inefficient
use of materials and space.
[0009] In addition, lamps and light fixtures are associated with certain limitations: for
example, a ceiling lamp must not weigh too much. In addition, the luminous element
(such as an incandescent bulb or a halogen bulb) of a light fixture frequently also
produces heat, so that the material of a surrounding lamp shade must be placed at
a sufficient distance from the luminous element to avoid the risk of fire. In addition,
the construction of the lamp or of the light fixture is limited by what is technically
and financially feasible, so that unconventional forms can soon become considerably
more expensive.
[0010] Thus there is need for a lamp or light fixture that offers a solution to one or more
of the above-mentioned problems. There is also need for a method of producing such
a lamp or light fixture.
SUMMARY
[0011] The invention and preferred embodiments thereof offer a solution for one or more
of the above-mentioned needs. Embodiments not covered by the claims do not form part
of the invention but represent background art that is useful for understanding the
invention.
[0012] In a first aspect, the invention relates to an assembly according to claim 1.
[0013] The inventors surprisingly discovered that the assembly according to the first aspect
or according to preferred embodiments thereof, leads to objects that perform a dual
function in a space. The objects not only have an illuminating function, but at the
same time improve the acoustics in the space. In addition, the open cell acoustic
foam, preferably melamine foam, is light-weight, fire-resistant and/or flame retardant.
In some embodiments the object can deaden sound by absorption and/or filtering. By
creating a balance between the luminous aspect, safety, aesthetics, and acoustic value
of these objects, a technical solution would be obtained for improving the acoustics
in working and living areas without incurring additional loss of space.
[0014] In a preferred embodiment the object according to the present invention comprises
an internal space, wherein optionally the internal space is connected with the external
environment via one or more openings.
[0015] In a preferred embodiment the object according to the present invention is a milled
object. In some preferred embodiments, the object according to the present invention
is a sanded object.
[0016] In some embodiments, the object according to the present invention is a milled and
sanded object.
[0017] The object according to the present invention is a directly flocked object, preferably
by means of an electrostatic field.
[0018] In a preferred embodiment the object according to the current invention is made of
two or more semifinished articles which are connected together, preferably with adhesive.
[0019] In a preferred embodiment the object according to the present invention is covered
by a membrane or coating, preferably wherein the membrane or the coating comprises
a knitted tube, a flocked cloth, and/or paint. The object is flocked directly. For
fire safety reasons a flocked fabric can provide an additional benefit.
[0020] In a preferred embodiment the open cell acoustic foam, preferably melamine foam,
in the object according to the present invention comprises a pigment, wherein preferably
the object comprises two or more parts of open cell acoustic foam, preferably melamine
foam, of which at least two parts of open cell acoustic foam, preferably melamine
foam, comprise different types of pigment and/or different quantities of pigment.
[0021] In a preferred embodiment the open cell acoustic foam, preferably melamine foam,
in the object according to the present invention comprises a filler material.
[0022] In a second aspect the invention relates to a method for producing an object according
to claim 8.
[0023] The inventors surprisingly found that the method according to the second aspect,
or according to preferred embodiments thereof, permits fabrication in a large selection
of shapes and dimensions in a simple and cost-efficient manner. In some embodiments
the object also has improved resistance to bending forces and impact forces.
[0024] In a preferred embodiment, of the method according to the present invention, step
b) is performed by milling. For this, for example, a robot milling machine or a traditional
cutter milling machine can be used. In a preferred embodiment of the method according
to the present invention, step b) is carried out by means of sanding. In a preferred
embodiment of the method according to the present invention, step b) is carried out
by means of milling and sanding.
[0025] According to the invention, the object is directly flocked, preferably by means of
an electrostatic field.
[0026] In a preferred embodiment the method according to the present invention further comprises:
c) the provision of an internal space in the object; and
d) optionally, the provision of one or more openings in the object, which connect
the internal space with the external environment.
[0027] In a preferred embodiment, the method according to the present invention further
comprises:
e) the addition of electrical wiring and one or more light sockets; and
f) optionally, the addition of one or more light sources.
[0028] In a preferred embodiment, the method according to the present invention comprises
the coupling together of two or more semifinished articles, optionally with adhesive.
DESCRIPTION OF THE FIGURES
[0029]
FIG. 1A is a schematic drawing of a preferred embodiment of the object (100) according to
the invention. FIG. 1B is a cross section of the object (100) in FIG. 1A.
FIG. 2A is a schematic drawing of a preferred embodiment of the object (100) according to
the invention. FIG. 2B is a cross section of the object (100) in FIG. 2A.
FIG. 3A is a front view of a preferred embodiment of the object (100) according to the invention.
FIG. 3B is a schematic drawing of a preferred embodiment of the object (100) according to
the invention. FIG. 3C is a cross section of the object (100) in FIG. 3A and 3B.
FIG. 4 is a schematic drawing of a preferred embodiment of the object (100) according to
the invention.
FIG. 5A is a schematic drawing of a preferred embodiment of the object (100) according to
the invention from two different perspectives. FIG. 5B and 5C are cross sections of the object (100) in FIG. 5A, with indication of some typical dimensions (in mm).
FIG. 6A is a schematic drawing of a preferred embodiment of the object (100) according to
the invention. FIG. 6B shows two cross sections and a front view of the object (100) in FIG. 6A, with indication of some typical dimensions (in mm).
FIG. 7 is a schematic drawing of the electrical configuration of an object (100) according
to a preferred embodiment.
DETAILED DESCRIPTION
[0030] In the remainder of this text, the singular forms used cover both the singular and
the plural unless the context clearly indicates otherwise.
[0031] The terms "comprise, comprises" as used in the following are synonymous with "including,
include" or "contain, contains," and are inclusive or open and do not exclude additional
members, elements or method steps that are not named. The terms "comprise, comprises"
include the term "contain."
[0032] The summation of numerical values using number ranges covers all values and fractions
within these ranges, as well as the cited end points.
[0033] The term "approximately", as is used when referring to a measurable value such as
a parameter, a quantity, a time period, etc., is intended to cover variations of +/-
10% or less, preferably +/- 5 % or less, more preferably +/- 1% or less, and even
more preferably +/- 0.1% or less, from and including the specified value, insofar
as the variations are applicable for use in the invention disclosed. It should be
understood that the value to which the term "approximately" applies is also disclosed
in itself.
[0034] Unless defined otherwise, all terms disclosed in the invention, including technical
and scientific terms, have the meaning that a person skilled in the art would usually
understand. As a further guide, definitions are included for further explanation of
terms used in the description of the invention.
[0035] In a first aspect the invention relates to an assembly according to claim 1. In the
most preferred form, the object (100), preferably a three-dimensional object (100),
is made of melamine foam, preferably obtained from melamine-formaldehyde condensation.
Melamine foam has the advantages of being a flexible, sound-absorbing, duroplastic
polymer foam that is easy to mold. In addition, melamine foam has a very low density,
around 11 kg/m
3, while other foams have a density around 30 kg/m
3. The fire behavior of melamine foam is also an advantage as melamine foam will char
rather than melt.
[0036] In some embodiments the polymer foam comprises felt, polyurethane foam (for example
open-cell polyurethane foam or reticulated polyurethane foam), polypropylene (preferably
injection molded), polyethylene (preferably injection molded), polyester (for example
polyester wool), or a combination thereof. In some embodiments, the polymer foam comprises
felt, polyurethane foam (e.g., open-cell polyurethane foam or reticulated polyurethane
foam), polypropylene (preferably in spray form), polyethylene (preferably in spray
form), polyester (e.g., polyester wool), polyether foam, polyimide foam, or a combination
thereof. Preferably, the polymer foam comprises polyether foam due to a higher degree
of uniformity in the cell distribution.
[0037] In some embodiments the polymer foam comprises melamine foam and one or more components
selected from the list comprising: felt, polyurethane foam (for example open-cell
polyurethane foam or reticulated polyurethane foam), polypropylene (preferably injection
molded), polyethylene (preferably injection molded), and polyester (for example polyester
wool).
[0038] In some embodiments, the polymer foam comprises melamine foam and one or more components
selected from the list comprising: felt, polyurethane foam (e.g., open-cell polyurethane
foam or reticulated polyurethane foam), polypropylene (preferably in spray form),
polyethylene (preferably in spray form), polyester (e.g., polyester wool), polyether
foam, and polyimide foam.
[0039] The term "three-dimensional object" means an object (100) that occupies a substantial
volume in three dimensions or an object (100) that exhibits substantial variation
in at least one dimension. In some embodiments the three-dimensional object (100)
is characterized in that the smallest dimension has a size of at least 5% of the size
of the largest dimension, preferably of at least 10%, preferably of at least 20%,
preferably of at least 30%, for example of at least 40%, for example of at least 50%.
Examples of such three-dimensional objects (100) are shown in
FIG. 1, 2, 4, 5 and
6. In some embodiments the three-dimensional object (100) is characterized in that at
least one dimension has a variation in size of at least 5% of the size, preferably
of at least 10%, preferably of at least 20%, preferably of at least 30%, for example
of at least 40%, for example of at least 50%. An example of such a three-dimensional
object (100) is shown in
FIG. 3. FIG. 3 illustrates a ceiling tile in which a halogen spotlight or LED spotlight is placed.
An example of a two-dimensional object that does not correspond to the above definition
of a "three-dimensional object" is a flat plate or panel: one dimension is much smaller
than the others, and the plate has little or no variation in size in all 3 dimensions.
[0040] In some embodiments the object (100) has a free flowing shape or a free-form structure.
This is intended to give the object (100) an irregular and/or asymmetric shape or
structure, preferably a flowing irregular and/or asymmetric shape or structure. A
free-form structure refers to a three-dimensional geometric object characterized by
a lack of rigid radial measurements, in contrast to regular shapes such as cylinders,
plates and conical shapes. Free-form structures are primarily known in engineering
design disciplines. Free-form structures are often described by "nonuniform rational
B-spline (NURBS)" models, but other methods are also known, such as Gorden or Coons
surfaces. The free form structure can have better acoustic properties.
[0041] In some embodiments the object (100) is not a flat plate. In some embodiments the
object (100) is not cuboidal. In some embodiments the object (100) does not have the
shape of a parallelepiped.
[0042] The term "melamine foam" in this document is used to designate a polymer foam obtained
on the basis of melamine, preferably using melamine-formaldehyde condensation, wherein
melamine functions as a thermosetting molding agent. The melamine foam of the present
invention preferably comprises an open-cell scaffolding structure of foam material.
The scaffolding structure typically comprises a plurality of interconnected three-dimensionally
branched scaffoldings which together form a pore structure.
[0043] The melamine foam can be formed from melamine-formaldehyde precondensate. The precondensate
used for the production of melamine foam suitable for the present invention preferably
has a molar ratio of formaldehyde to melamine in the range of 5:1 to 1.3:1; and more
preferably in the range of 3.5:1 to 1.5:1.
[0044] In some embodiments the precondensate for the melamine foam comprises thermosetting
molding agents other than melamine, for example of 0% to 50 wt-% other thermosetting
molding agents, preferably of 0% to 40 wt-% other thermosetting molding agents, more
preferably of 0% to 30 wt.-% other thermosetting molding agents, and most preferably
from 0% to 20 wt.-% other thermosetting molding agents, with the wt.-% being based
on the total weight of all thermosetting molding agents.
[0045] In some embodiments the precondensate for the melamine foam contains aldehydes other
than formaldehyde, for example from 0% to 50 wt.-% other aldehydes, preferably from
0% to 40 wt.-% other aldehydes, more preferably from 0% to 30 wt.-% other aldehydes,
and most preferably from 0% to 20 wt.-% other aldehydes, with wt.-% being based on
the total weight of all aldehydes.
[0046] In some preferred embodiments the precondensate for the melamine foam contains no
other thermosetting molding agents and no other aldehydes.
[0047] In some embodiments the other thermosetting molding agents are selected from the
list comprising: alkyl and aryl substituted melamine, urea, urethanes, carboxamides,
dicyandiamide, guanidine, sulfurylamide, sulfonamides, aliphatic amines, glycols,
phenol of derivatives thereof, or mixtures thereof.
[0048] In some embodiments the other aldehydes are selected from the list comprising: acetaldehyde,
trimethylolacetaldehyde, acrolein, benzaldehyde, furfural, glyoxal, glutaraldehyde,
phthalaldehyde, terephthalaldehyde or mixtures thereof.
[0049] In some embodiments the precondensate comprises an emulsifier or dispersant. In some
preferred embodiments the precondensate comprises a blowing agent.
[0050] In some embodiments the precondensate comprises added substances, for example selected
from the list comprising: fibers, flame retardants, UV stabilizers, agents for reducing
the toxicity of combustion gases, fragrances or optical brighteners. The open cell
acoustic foam, preferably melamine foam, can, for example, be impregnated with an
ammonium salt or with sodium silicate to improve the fire resistance of the open cell
acoustic foam, preferably melamine foam.
[0051] In some embodiments the precondensate comprises from 0.1% to 20%, preferably 0.1%
to 10 wt.-% (based on the total weight of the precondensate) of these added substances.
These added substances preferably form a homogeneous distribution in the open cell
acoustic foam, preferably melamine foam.
[0052] In some embodiments the polymer foam, preferably open cell acoustic foam, preferably
melamine foam, comprises one or more fillers or pigments. These fillers or pigments
are typically located in the pore structure of the foam.
[0053] In some embodiments the polymer foam, preferably open cell acoustic foam, preferably
melamine foam, comprises one or more fillers. In some embodiments, the polymer foam,
preferably open cell acoustic foam, preferably melamine foam, comprises no fillers.
[0054] The fillers in the polymer foam, preferably open cell acoustic foam, preferably melamine
foam, can be present in different volume fractions and particle sizes. Different materials,
such as ceramics and polymers, can be used as fillers. The filler can be embedded
in the pore structure of the melamine foam.
[0055] In some embodiments the polymer foam comprises a filler material such as glass beads
with, for example, a diameter in the range of 0.1 to 1 mm.
[0056] The particulate fillers are preferably located in the pore structure of the open-cell
foam and thus immobilized. A structure of this type can be produced by subsequent
impregnation of the foamed material with fillers, since in this way the particle size
of the fillers is always selected such that the particle size is smaller than the
pore size of the foam material so that distribution throughout the foam material can
be ensured.
[0057] In some embodiments the open cell acoustic foam, preferably melamine foam, comprises
one or more pigments. Pigments that may be used comprise, for example, the usual organic
pigments. These pigments are preferably mixed with fillers in advance. The exact color
of the polymer foam, for example open cell acoustic foam, preferably melamine foam,
can be difficult to control. Since the resulting color variations are unacceptable
in some uses, pigments may be added to the polymer foam. In particular, different
parts of the
object (100) can be made of polymer foam to which different pigments have been added.
The heterogeneous addition of pigments results in light fixtures with one or more
colors. The pigments can also mask any color variations in the starting material.
[0058] In some preferred embodiments, the invention comprises two or more objects (100).
In some preferred embodiments the object (100) comprises polyethylene or polycarbonate.
The polyethylene or polycarbonate can be used to functionally provide extra light
between two or more objects (100).
[0059] In some embodiments the polymer foam, preferably open cell acoustic foam, preferably
melamine foam, has a density of at least 5 kg/m
3 and at most 20 kg/m
3, preferably of at least 6 kg/m
3 and at most 15 kg/m
3, preferably of at least 7 kg/m
3 and at most 12 kg/m
3, preferably of at least 8 kg/m
3 and at most 11 kg/m
3, as measured according to the EN ISO 845 standard.
[0060] In some embodiments the open cell acoustic foam, preferably melamine foam, has a
compressive strength of at least 5 kPa and at most 10 kPa, as measured according to
the EN ISO 3386-1 standard.
[0061] In some embodiments the polymer foam, preferably open cell acoustic foam, preferably
melamine foam, has a tensile strength of at least 90 kPa, as measured according to
the ISO 1798 standard.
[0062] In some embodiments the polymer foam, preferably open cell acoustic foam, preferably
melamine foam, has an elongation at break of at least 10%, as measured according to
the ISO 1798 standard.
[0063] In some embodiments the open cell acoustic foam, preferably melamine foam, has a
maximum use temperature (as defined in ISO 3386-1) of 220°C, as measured over 1000h
according to the DIN EN ISO 2578 standard. In some embodiments the polymer foam, preferably
open cell acoustic foam, preferably melamine foam, has a maximum use temperature (as
defined in ISO 3386-1) of 200°C, as measured over a period of 5000h according to the
DIN EN ISO 2578 standard. In some embodiments the open cell acoustic foam, preferably
melamine foam, has a maximum use temperature (as defined in ISO 3386-1) of 180°C,
as measured over a period of 20000h according to the DIN EN ISO 2578 standard.
[0064] The open cell acoustic foam, preferably melamine foam, preferably has an open-cell
structure with a content of open cells, measured according to ISO 4590 DIN, of more
than 50% and more preferably of more than 80%.
[0065] The mean pore diameter of the polymer foam, preferably open cell acoustic foam, preferably
melamine foam, preferably falls in the range of 10 to 1000 µm and more particularly
in the range of 50 to 600 µm.
[0066] Sound damping is one of the possible benefits of open cell acoustic foam, preferably
melamine foam. Moreover such materials can have good thermal insulation, fire resistance,
temperature resistance, and plastic memory. Some products based on melamine foam have
a sound absorption of more than 90% (for sound waves with a frequency of 2000 Hz,
with a 50 mm thick panel, according to ISO 10534). This sound-absorbing effect can
be a significant advantage of the use of melamine foam in light fixtures, since it
can improve the acoustics of the space in which the light fixture hangs.
[0067] In addition, the low weight of light fixtures made of open cell acoustic foam, preferably
melamine foam, can be advantageous in various uses, for example for use in light fixtures.
[0068] According to the invention the assembly comprises electrical wiring (140) and one
or more light sockets (142). The one or more light sockets (142) are connected to
the electrical wiring (140), so that the assembly consisting of the object (100),
electrical wiring (140) and one or more light sockets (142) forms a light fixture.
In some embodiments, the electrical wiring (140) is connected to the object (100)
by means of one or more cable mounts (146), as illustrated in
FIG. 4. In some embodiments, the assembly comprises one or more light sources (144), for
example lamps. In some embodiments, the one or more light sources (144) make electrical
contact with the one or more light sockets (142), for example by means of clamps.
In some embodiments, the one or more light sources (144) are selected from the list
comprising: an LED light, a halogen lamp, an incandescent bulb, a neon tube lamp,
a xenon lamp, an energy saving bulb, or an induction lamp. According to a preferred
embodiment of the invention, the one or more light sources (144) are LED lights.
FIG. 7 illustrates an example of an electrical configuration of an object (100) according
to a preferred embodiment.
[0069] In a preferred embodiment one or more internal spaces (110) are hollowed out in the
object (100), for example one or more cavities. These one or more internal spaces
(110) can be connected with the external environment via one or more openings (112),
for example perforations or channels. The above-named one or more light sockets (142)
can be fitted into the one or more internal spaces (110). When one or more internal
spaces are provided in the object, space is created for the light sources (144) as
well as space for the output of the light coming from the light sources (144), so
that the light released by the object (100) is optimally distributed and dispersed
without excessive light loss occurring. In this way the light generated is distributed
optimally and efficiently over the space.
[0070] In a preferred embodiment the three-dimensional object (100) is a hollow ball-shaped
or ellipsoidal shell with a perforation (112) in the shell. Inside the shell, one
or more light sockets (142) and one or more light bulbs (or light sources) (144) may
be located. When the light bulb (144) is on, the light can escape from the shell through
the perforation (112) in the shell. Examples of possible preferred shapes of the object
(100) are shown
FIG. 1-7.
[0071] Preferably the one or more light sources (144) are placed in the one or more light
sockets (142) so that the light source (144) makes electrical contact with the terminals
in the one or more light sockets (142), wherein the one or more light sources (144)
are selected from the list comprising: an LED light, a halogen lamp, an incandescent
bulb, a neon tube lamp, a xenon lamp, an energy-saving bulb, or an induction light
bulb.
[0072] As an alternative for the above-named electrical wiring (140), a battery system can
be used to supply energy for the operation of the light source (144).
[0073] In a preferred embodiment the one or more light sources (144) are dimmable.
[0074] In some embodiments the object (100) is shaped by milling, contour cutting (for example
using a wire saw or a band knife), or stamping. In the most preferred embodiments
the object (100) is shaped by milling. The milled objects can assume any shape and
ensure a uniform, even, high-quality, and/or fine finishing of the object. In some
embodiments, the object (100) according to the present invention is a milled object
(100). In some embodiments, the object (100) according to the present invention is
a sanded object (100). In some embodiments, the object (100) according to the present
invention is a milled and sanded object (100). With sanding, milling lines can be
eliminated. In addition, the sanding can be used in order to reduce the production
cost of milling through the use of coarse milling, and by afterwards eliminating possible
flaws by sanding the object (100).
[0075] In some embodiments, the sanding is performed by mounting the whole on a turntable
/ lathe, rotating the object (100) and sanding the object (100). Preferably, the object
(100) comprises revolution figures. In some embodiments, the object (100) comprises
non-rotation figures.
[0076] In some preferred embodiments, the object (100) is manufactured from one piece of
foam. Preferably, such an object (100) is milled out when the milling machine has
sufficient axes. Preferably, such an object (100) is milled out from a block of foam
with a maximum dimension of 500 mm. An object (100) made of one piece of foam has
the advantage that there is no glue or seam, which is also easier and can be flocked
more cheaply.
[0077] In a preferred embodiment the object (100) can be made from two or more semifinished
articles (101-106); for example 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13,
14, 15 or more semifinished articles that are assembled together. Preferably the semifinished
articles (101-106) are three-dimensional semifinished articles (101-106). By working
with semifinished articles the object can be assembled efficiently. In addition, by
working with semifinished articles (101-106), standard semifinished articles can be
produced which, when they are assembled, form a unique object (100). In a particular
embodiment the two or more semifinished articles (101-106) are complementary to one
another. The fact that the semifinished articles (101-106) to be assembled are complementary
to one another makes the assembly of the object (100) simpler, faster and/or more
efficient.
[0078] For example, the semifinished articles (101-106) can be assembled together by bonding.
In the embodiments of
FIG. 1, 2, and
5 two semifinished articles (101-106) are bonded together. In the embodiments of
FIG. 4 and
6 more than two semifinished articles (101-106) are bonded together. In some embodiments
the adhesive (120) is a fire-retardant adhesive (120).
[0079] In some embodiments at least one of the two or more semifinished articles (101-106)
is a three-dimensional semifinished article, wherein the term three-dimensional is
used as previously described. An example of a three-dimensional semifinished article
(101, 102), wherein the semifinished article has a smallest dimension with a size
at least 5% of the size of the largest dimension, is shown in
FIG. 1, 2 and
4. An example of a three-dimensional semifinished article (101, 102), wherein the semifinished
article has a variation of at least 5% in at least one dimension, is shown in
FIG. 6.
[0080] In a preferred embodiment the one or more internal spaces (110) that are cut out
in the object (100) are formed by recesses in at least two semifinished articles (101,
102), which are mounted relative to one another. In another preferred embodiment one
of the at least two semifinished articles (101, 102) comprises an internal space (110),
wherein the second semifinished article provides for the connection with the external
environment via one or more openings (112).
[0081] In some embodiments, the object (100) comprises 1 piece of open cell acoustic foam,
preferably melamine foam. Preferably, such an object (100) is made by robotic milling.
[0082] In some embodiments, the object (100) has an open structure, for example by means
of perforations, and it is filled with open cell acoustic foam, preferably melamine
foam. Preferably, the object (100) filled up with cutting waste of open cell acoustic
foam, preferably melamine foam. Through the use of cutting waste, the cost of production
can be further reduced in an environmentally friendly way. In addition, an object
filled with cuttings has better acoustic propertiess.
[0083] In a preferred embodiment the open cell acoustic foam, preferably melamine foam,
in the object (100) according to the present invention comprises a pigment. In preferred
forms wherein the object (100) comprises two or more parts of open cell acoustic foam,
preferably melamine foam, it is preferred that at least two parts of open cell acoustic
foam, preferably melamine foam. comprise different types of pigment and/or different
quantities of pigment. The provision of different parts of open cell acoustic foam,
preferably melamine foam, for the object with different types of pigment and/or different
quantities of pigment offers a large number of possible variations for the object
(100) so that each object (100) can be personalized.
[0084] In a preferred embodiment the object (100) can be covered by a membrane or coating.
In this way the object (100) can be personalized. The membrane or the coating can,
for example, be a knitted tube, a flocked cloth, or one or more layers of paint. According
to the invention the object (100) is flocked directly. In some embodiments the membrane
is braided or woven, preferably woven. In some embodiments the membrane comprises
polyester, polyamide, polypropylene, polyimide, or a combination thereof, preferably
in the form of fibers.
[0085] An advantage of a membrane (or pouch) is that the object (100) can be produced with
a hole in it, for example by milling or by the production of the foam. By stretching
a membrane over it, the hole becomes invisible. An additional advantage is that during
milling a coarser / larger milling head may be used, whereby the machine time is shortened.
Because the milling cost is a dominant cost, this again brings with it a price advantage.
[0086] In some embodiments the flocked cloth or direct flocking is applied with adhesive,
preferably fire-retardant adhesive. More preferably, a direct flock is applied with
glue. By attaching a flocked cloth, the object (100) can be given improved resistance
to bending forces and impact forces. With a direct flock, it is preferably first provided
with a layer of adhesive on the object, preferably by spraying a layer of adhesive.
In some embodiments, then an electrostatic field is used to apply the flock. The flock
fibers preferably have a length of 0.5 mm to 3.0 mm, more preferably from 0.7 to 2.0
mm. By placing a layer of adhesive on the foam, it becomes possible to orient fibers
with a fixed length on the surface with the aid of an electrostatic field. This gives
a higher level of control over the positioning of the fibers so that it becomes possible,
for example, to orient the fibers in the same direction, or to orient the fibers straight
(or perpendicular) standing on the layer of adhesive which provides a unique aesthetic
effect. In the case of straight standing fibers this produces a luster / shine.
[0087] Preferably, the adhesive is flexible. This causes less transport damage or damage
by pushing the object (100). In some embodiments, the adhesive comprises a flame retardant.
The adhesive may comprise a one-component adhesive system or a two-component adhesive
system. In some embodiments, the adhesive comprises a pigment, preferably in the same
color as the flock fiber.
[0088] In some embodiments, the thickness of the flock fiber is at least 1.0 dtex and ay
most 80 dtex, for example at least 2.5 dtex and at most 50 dtex, for example at least
8 dtex and at most 20 dtex. For short fibers, for example at most 1 mm, the thickness
is preferably at least 2.5 dtex and at most 8 dtex. For long fibers, for example at
least 2 mm, the thickness is preferably at least 20 dtex and at most 50 dtex. This
ensures that the fiber does not sag too much.
[0089] The material of the fiber is preferably polyamide, which is readily available in
all colors and sizes. In some embodiments, the fiber is a polyamide fiber of at leasts
0.5 and at most 2.0 mm in length. In some embodiments, the fiber is a polyamide fiber
having a thickness of at least 2 dtex and at most 60 dtex. In some embodiments, the
fiber is a polyamide fiber of at least 0.5 and at most 2.0 mm long with a thickness
of at least 2 dtex and at most 60 dtex. In some embodiments, the fiber is a viscose
fiber, a cotton fiber, or a polyester fiber. In some embodiments, the fiber is a modacrylic
fiber, such as a modacrylic fiber of 17 dtex, 2 mm in length. The difference with
polyamide is that this is inherently fire retardant. In some embodiments, the modacrylic
fiber is a fiber of at least 0.5 and at most 2.0 mm in length. In some embodiments,
the fiber is a modacrylic fiber having a thickness of at least 2 dtex and at most
60 dtex. In some embodiments, the modacrylic fiber is a fiber of at least 0.5 and
at most 2.0 mm long with a thickness of at least 2 dtex and at most 60 dtex. In some
embodiments, the fiber is a polyester fiber, preferably a polyester fiber with flame
retardants.
[0090] The adhesive may be applied with a brush, a roller, or preferably by spraying the
adhesive (spray). If some parts of the object (100) may not be flocked, they can be
covered with tape. The thickness of the dried adhesive layer is preferably at least
1 / 10th of the length of the flock fiber. In some embodiments, a primer is first
applied. In some embodiments, instead of a primer, a thicker layer of adhesive is
applied.
[0091] Preferably, the flock fiber is applied directly onto the still wet adhesive. In some
embodiments, the flock fiber is applied by a manual electrostatic flocking apparatus
or an electrostatic flock machine. The flock fibers are preferably charged, preferably
between 50 kV and 100 kV. Preferably, the portion of the object (100) with the adhesive
is grounded. In some embodiments, the adhesive layer itself is grounded.
[0092] For example, the adhesive is dried at room temperature. Excess flock fibers are then
preferably removed, for example by blowing, vacuuming, brushing, or washing.
[0093] In some embodiments, flock fibers are used with different colors on one and the same
object in order to obtain color effects. Thus, one can make a basic color seem darker
or lighter.
[0094] Preferably, this effect is achieved by the use of a flocked cloth, in that it has
a smooth surface, all fibers are at the same height and provide a sleek additional
color and gloss effect. Without the use of a cloth, the surface will be rougher by
the occurrence of pores, whereby a part of the fibers will be oriented in different
directions.
[0095] In addition, there exists a possibility of combining fibers of different color types
on one and the same object in order to obtain color effects. This creates a possibility
to make a basic color darker or lighter without the use of specific fibers of the
desired color. This creates an opportunity to create a new color or color gradation
from commercially available colors.
[0096] One of the advantages of a flocked cloth compared with direct flocking is that a
flocked cloth is less expensive. In addition, the flocked fibers of the flocked cloth
may be shorter, for example around 0.7 mm. In some embodiments the flocked fibers
have a length of at least 0.2 and at most 1.5 mm, for example at least 0.4 and at
most 1.0 mm, for example at least 0.6 and at most 0.8 mm. In direct flocking, longer
fibers are usually used, for example around 2.0 mm, to hide defects in the polymer
foam. This also results in a greater fire load (twice as much adhesive + longer flock).
For shorter flockfibres fibers will be more upright, resulting in a better luster
/ shine.
[0097] In a preferred embodiment the object (100) can be connected to one or more hanging
mechanisms (150). The one or more hanging mechanisms (150) can for example comprise
one or more cords and/or one or more hooks. Preferably the object (100) is hung on
a ceiling. A possible hanging mechanism is illustrated in
FIG. 7. In some embodiments the hanging mechanism (150) comprises electrical wiring (140).
[0098] In some embodiments, the object (100) is reinforced, for example by aluminum foil
or strips of wood. In this way the object (100) can be hung from a ceiling in a more
rigid manner.
[0099] In a preferred embodiment the object (100) contains a motion sensor. In a preferred
embodiment the motion sensor can be used to turn on the lighting.
[0100] In a second aspect the invention relates to a method for producing an object according
to claim 8.
[0101] The preparation of melamine foam in step a) can be performed as described below.
The melamine-formaldehyde precondensate and, optionally, solvent, can preferably be
foamed with an acid, a dispersant, a blowing agent, and optionally inorganic fillers
at temperatures above the boiling point of the blowing agent, then dried.
[0102] In some embodiments a precondensate, comprising melamine and formaldehyde, and optionally
other substances as described above, is foamed. This can be done by heating the suspension
of melamine-formaldehyde precondensate, optionally in the presence of a blowing agent,
preferably to a temperature above the boiling point of the blowing agent and preferably
in a closed mold.
[0103] A preferred embodiment of the method for producing the foam of the present invention
comprises the steps of:
- (1) producing a suspension comprising a melamine-formaldehyde precondensate, and possibly
other added constituents such as a blowing agent;
- (2) foaming the precondensate by heating the suspension from step (1) to a temperature
above the boiling point of the blowing agent; and
- (3) drying the foam obtained from step (2).
[0104] The melamine-formaldehyde precondensate can be prepared in the presence of alcohols,
for example methanol, ethanol or butanol, so that partially or completely etherified
condensates can be obtained. The formation of the ether groups influences the solubility
of the melamine-formaldehyde precondensate and the mechanical properties of the cured
material.
[0105] Anionic, cationic and nonionic surface-active substances and also mixtures thereof
can be used as dispersants and/or emulsifiers in the precondensate.
[0106] Usable anionic surface-active substances comprise, for example, diphenylene oxide
sulfonates, alkane and alkylbenzene sulfonates, alkylnaphthalene sulfonates, olefin
sulfonates, alkyl ether sulfonates, fatty alcohol sulfates, ether sulfates, [alpha]
sulfo-fatty acid esters, acylaminoalkane sulfonates, acyl isethionates, alkyl ether
carboxylates, N acyl sarcosinates, alkyl and alkyl ether phosphates.
[0107] Usable ionic surface-active substances are alkylphenol polyglycol ethers, fatty alcohol
polyglycol ethers, fatty acid polyglycol ethers, fatty acid alkanolamides, ethylene
oxide-propylene oxide block copolymers, amine oxides, glycerol fatty acid esters,
sorbitan esters and alkylpolyglycosides.
[0108] Usable cationic emulsifiers are, for example, alkyltriammonium salts, alkyl benzyl
dimethyl ammonium chloride salts and alkylpyridinium salts.
[0109] In some embodiments the dispersants/emulsifiers are added in a range of 0.2% to 5
wt.-%, with wt.-% based on the total weight of the melamine-formaldehyde precondensate.
[0110] In principle both physical and chemical blowing agents can be used in the method
according to the present invention. Depending on the choice of melamine-formaldehyde
precondensate, the mixture contains a blowing agent. The quantity of blowing agent
in the mixture generally depends on the desired density of the foam. Preferred "physical"
blowing agents comprise, for example, hydrocarbons, such as pentane, hexane, halogenated,
particularly chlorinated and/or fluorinated, hydrocarbons, such as methylene chloride,
chloroform, trichloroethane, chlorofluorocarbons, chlorofluorohydrocarbons (CFHCs),
alcohols, for example methanol, ethanol, n-propanol or isopropanol, ethers, ketones
and esters, such as methyl formate, ethyl formate, methyl acetate or ethyl acetate,
in liquid form, or air, nitrogen or carbon dioxide as gases. Preferred "chemical"
blowing agents comprise for example isocyanates mixed with water, which release carbon
dioxide as an active foaming agent.
[0111] In a preferred embodiment of the invention the precondensate contains at least one
blowing agent. The blowing agent is preferably present in the mixture in a quantity
of 0.5% to 60% by weight, preferably 1% to 40 wt.-% and more preferably 1.5% to 30
wt.-%, with wt.-% being based on the total weight of the melamine-formaldehyde precondensate.
[0112] In some embodiments acid compounds are used to catalyze the further condensation
of the melamine resin. These acid compounds are preferably added in a range of 0.01%
to 20% by weight and more preferably in a range of 0.05% to 5 wt.-%, with wt.-% based
on the total weight of the melamine-formaldehyde precondensate.
[0113] Usable acid compounds can be selected from the list comprising: organic and inorganic
acids, for example chosen from the group consisting of hydrochloric acid, sulfuric
acid, phosphoric acid, nitric acid, formic acid, acetic acid, oxalic acid, toluenesulfonic
acid, sulfamic acid, acid anhydrides, and mixtures thereof.
[0114] Heating can be performed with electromagnetic radiation, for example via high-frequency
radiation of 5 to 400 kW, preferably of 5 to 200 kW and more preferably of 9 to 120
kW per kg of the mixture, in a frequency range of 0.2 to 100 GHz, preferably of 0.5
to 10 GHz. Magnetrons are a useful source of electromagnetic radiation.
[0115] The foamed material is preferably dried, wherein residual water and foaming agent
are removed from the foam. After-treatment may be used to make the foam hydrophobic.
This after-treatment preferably provides a hydrophobic coating with a high thermal
stability and low flammability, for example a coating comprising silicones, siliconates
or fluorinated compounds.
[0116] The method described typically results in blocks or plates of foam material, which
can be cut to size.
[0117] The foam (in blocks or plates) can possibly be treated by thermocompression in a
subsequent process step. Thermocompression often provides for better fixation of the
particulate filler materials in the open-cell structure of the foam.
[0118] In a preferred embodiment step b) is performed by milling. In a preferred embodiment
of the method according to the present invention, step b) is carried out by means
of sanding. In a preferred embodiment of the method according to the present invention,
step b) is carried out by means of milling and sanding.
[0119] In an embodiment, a complete block of polymer foam, preferably open cell acoustic
foam, preferably melamine foam, is placed on a milling table. A milling head, preferably
rotatable around multiple axes, then processes the block into the desired shape. The
milling head is preferably specially selected for milling foams, for example by choosing
a milling head with a fine structure. An exhaust system and dust masks are recommended
when milling open cell acoustic foam, preferably melamine foam.
[0120] In some embodiments a membrane or coating is applied.
[0121] In some embodiments the membrane or the coating is applied before milling. In some
embodiments the membrane or the coating is applied after milling. In some embodiments
the membrane or the coating is applied to parts of the object before milling. In some
embodiments the membrane or the coating is applied to parts of the object after milling.
[0122] In some embodiments the flocked cloth or direct flocking is applied before milling.
In some embodiments the flocked cloth or direct flocking is applied after milling.
In some embodiments the flocked cloth or direct flocking is applied to parts of the
object before milling. In some embodiments the flocked cloth or direct flocking is
applied to parts of the object after milling.
[0123] According to the method according to the present invention, the object (100) is directly
flocked, preferably by means of an electrostatic field.
[0124] In some embodiments step b) is performed by contour cutting and/or stamping.
[0125] In some embodiments step b) is performed partly by milling and partly by contour
cutting and/or stamping.
[0126] In a preferred embodiment one or more internal spaces (110) are provided in the object
(100) and, optionally, the one or more internal spaces (110) are connected with the
external environment through one or more openings (112).
[0127] In a preferred embodiment electrical wiring (140) and one or more light sockets (142)
are added. In some embodiments the electrical wiring (140) also functions as a mechanism
for hanging (150).
[0128] In a preferred embodiment the method comprises the coupling together of two or more
semifinished articles (101-106), preferably by bonding the two or more semifinished
articles (101-106), for example using adhesive (120) or screws, preferably by means
of adhesive (120).
[0129] In some embodiments the two or more semifinished articles (101-106) are connected
reversibly to one another. In some embodiments the two or more semifinished articles
(101-106) are connected irreversibly to one another. In some embodiments a metal plate
(130) provides additional rigidity and/or provides for the fastening of a light bulb
socket (142).
[0130] In some embodiments the object (100) is packaged.