Sound-absorbing panel with modifiable size and/or shape and associated manufacturing method

Abstract

A sound-absorbing panel comprising a padding layer with a first face, a second face and an edge, a fabric and fastening members for fixing the fabric to the padding layer, is described, wherein the padding layer comprises a layer of heat-bonded synthetic fibers, wherein the density of the fibers in the proximity of the first face and in the proximity of the second face is greater than the density of the fibers in the central zone of the padding layer, wherein the fabric is arranged so as to adhere to the first face and to the edge of the padding layer and form fabric flaps along the second face, wherein the fastening members are removable fastening members and are configured to fix at least one of the fabric flaps to the padding layer along the second face.

1 . A sound-absorbing panel comprising a padding layer with a first face, a second face and an edge, a fabric and fastening members for fixing the fabric to the padding layer,
 wherein the padding layer comprises a layer of heat-bonded synthetic fibers, wherein the density of the fibers in the proximity of the first face and in the proximity of the second face is greater than the density of the fibers in the central area of the padding layer, wherein the fabric is arranged so as to adhere substantially to the first face and to the edge of the padding layer and to form fabric flaps along the second face, wherein the fastening members are removable fastening members and are configured to fix at least one of the fabric flaps to the padding layer along the second face, wherein the fastening members comprise at least one screw.   
     
     
         2 . The sound-absorbing panel of  claim 1 , wherein the edge is a sharp-cut edge. 
     
     
         3 . The sound-absorbing panel of  claim 1 , wherein the fastening members do not comprise glue or adhesive. 
     
     
         4 . The sound-absorbing panel of  claim 1 , wherein the fastening members are discrete fastening members. 
     
     
         5 . The sound-absorbing panel of  claim 1 , wherein the fastening members comprise one or more of the following: nails, metal staples, staples made of non-metallic material, snap-fasteners, buttons and eyelets or rubber bands. 
     
     
         6 . The sound-absorbing panel according to  claim 1 , wherein at least one fabric flap is fixed with at least one first screw in the proximity of a first end thereof and a second screw in the proximity of its second end. 
     
     
         7 . The sound-absorbing panel of  claim 6 , wherein the at least one fabric flap is also fixed with one or more staples. 
     
     
         8 . The sound-absorbing panel according to  claim 1 , wherein the fabric is shaped as an open box and comprises a bottom, edges and flaps. 
     
     
         9 . The sound-absorbing panel according to  claim 1 , wherein the fabric is made by interweaving an elastic texturized yarn and comprises polyester. 
     
     
         10 . A method of modifying the shape and/or size of a sound-absorbing panel, comprising:
 providing a sound-absorbing panel according to  claim 1 , wherein the sound-absorbing panel comprises a first shape and a first size;   removing one or more of the fastening members and temporarily uncovering a part of the edge of the padding layer;   cutting a portion of the padding layer;   covering again the uncovered part of the edge with the fabric; and   fixing again the fabric by means of one or more fastening members, thus obtaining a sound-absorbing panel with a second shape and/or a second size.   
     
     
         11 . The method of  claim 10 , wherein the step of fixing again the fabric is carried out using, at least in part, the fastening members with which the fabric was originally fixed to the padding layer. 
     
     
         12 . The method of  claim 10 , wherein the step of cutting a portion of the padding layer comprises the step of cutting the padding layer with a straight-blade cutting member, for example a cutter knife. 
     
     
         13 . The method of  claim 10 , further comprising the step of cutting off the excess fabric. 
     
     
         14 . A method for manufacturing a sound-absorbing panel according to  claim 1 , comprising:
 providing a padding layer with a first face, a second face and an edge, wherein the padding layer comprises a layer of heat-bonded synthetic fibers, wherein the density of the fibers in the proximity of the first face and in the proximity of the second face is greater than the density of the fibers in the central area of the padding layer;   providing a fabric shaped so as to form a bottom of shape and size substantially corresponding to the first face, and edges of shape and size substantially corresponding to the edges, and flaps which extend from said edges;   coupling the padding layer to the fabric; and   applying fastening members so as to fix the fabric to the padding layer along the second face, wherein said fastening members comprise at least one screw screwed into the thickness of the padding layer from the second face.   
     
     
         15 . The method of  claim 14 , wherein the step of applying fastening members comprises applying at least one staple and/or other removable fastening members.