Transparent sound absorbing panels

Abstract

A sound absorbing panel and method therefor comprising providing a first sheet of photosensitive material, applying a first mask having a first plurality of features to the first sheet of photosensitive material, exposing the masked material to ultraviolet light, heating the first sheet of photosensitive material to form crystals in exposed portions of the first sheet, and etching the crystals to form a second plurality of features in the first sheet of photosensitive material.

What is claimed is: 
     
         1 . A method of making a sound absorbing panel comprising the steps of:
 a) applying a first mask having a first plurality of features to a first sheet of photosensitive material to form a masked material;   b) exposing the masked material to ultraviolet light;   c) heating the first sheet of photosensitive material to form crystals in exposed portions of the first sheet; and   d) etching the crystals to form a second plurality of features in the first sheet of photosensitive material.   
     
     
         2 . The method of  claim 1  further comprising the step of repeating steps a) through d) for a second sheet of photosensitive material. 
     
     
         3 . The method of  claim 2  further comprising the step of providing a resilient surface spaced apart from and substantially in the same shape of the first or second sheet of photosensitive material wherein the first and second sheets of photosensitive material are between the resilient surface and environment. 
     
     
         4 . The method of  claim 1  further comprising the steps of:
 a) applying a second mask having a third plurality of features to the etched first sheet of photosensitive material; 
 b) exposing the masked material to ultraviolet light; 
 c) heating the first sheet of photosensitive material to form crystals in exposed portions of the first sheet; and 
 d) etching the crystals to form a fourth plurality of features in the first sheet of photosensitive material. 
 
     
     
         5 . The method of  claim 1 , wherein the first sheet of material is three dimensional. 
     
     
         6 . The method of  claim 1  further comprising either one or both the step of tinting, coloring or decorating the first sheet of photosensitive material and the step of strengthening the first sheet photosensitive material. 
     
     
         7 . The method of  claim 1 , wherein the second plurality of features have a diameter or depth of up to about 20 μm, up to about 40 μm, up to about 60 μm, up to about 100 μm, up to about 0.1 mm, up to about 0.3 mm, up to about 0.5 mm, up to about 1.0 mm, up to about 1.5 mm, or up to about 2.0 mm. 
     
     
         8 . A sound absorbing panel comprising:
 a first sheet of photosensitive material; and   a resilient surface spaced apart from the first sheet of photosensitive material by a predetermined distance,   wherein the sheet of photosensitive material includes a first plurality of features.   
     
     
         9 . The sound absorbing panel of  claim 8 , wherein the first plurality of features comprise etched features. 
     
     
         10 . The sound absorbing panel of  claim 8 , wherein the first sheet of material is three dimensional. 
     
     
         11 . The sound absorbing panel of  claim 8 , wherein the photosensitive material is a glass or glass ceramic material. 
     
     
         12 . The sound absorbing panel of  claim 8 , wherein the photosensitive material comprises:
 about 75-85 wt % SiO 2 ,   about 2-6 wt % Al 2 O 3 ,   about 7-11 wt % Li 2 O,   about 3-6 wt % K 2 O,   about 0.5-2.5 wt % Na 2 O,   about 0.01-0.5 wt % Ag,   about 0.01-0.5 wt % Sb 2 O 3 ,   about 0.01-0.04 wt % CeO 2 ,   about 0-0.01 wt % Au, and   about 0-0.01 wt % SnO 2 .   
     
     
         13 . The sound absorbing panel of  claim 8 , wherein the first sheet has a thickness of up to about 20 μm, up to about 40 μm, up to about 60 μm, up to about 100 μm, up to about 0.1 mm, up to about 0.3 mm, up to about 0.5 mm, up to about 1.0 mm, up to about 1.5 mm, or up to about 2.0 mm. 
     
     
         14 . The sound absorbing panel of  claim 8 , wherein the photosensitive material is translucent, transparent, tinted, colored, or decorated. 
     
     
         15 . The sound absorbing panel of  claim 8 , wherein the photosensitive material is strengthened. 
     
     
         16 . The sound absorbing panel of  claim 8 , wherein the features have a diameter or depth of up to about 20 μm, up to about 40 μm, up to about 60 μm, up to about 100 μm, up to about 0.1 mm, up to about 0.3 mm, up to about 0.5 mm, up to about 1.0 mm, up to about 1.5 mm, or up to about 2.0 mm 
     
     
         17 . The sound absorbing panel of  claim 8  further comprising a second sheet of photosensitive material having a second plurality of features etched therein, the second sheet intermediate the first sheet and the resilient surface. 
     
     
         18 . A sound absorbing panel comprising:
 a first sheet of photosensitive material; and   a resilient surface spaced apart from the first sheet of photosensitive material by a predetermined distance,   wherein the first sheet of photosensitive material includes a plurality of features formed therein without mechanical etching.   
     
     
         19 . The sound absorbing panel of  claim 18  wherein the plurality of features are formed by chemical etching. 
     
     
         20 . The sound absorbing panel of  claim 18 , wherein the first sheet of material is three dimensional.