Abstract:
Room dividers with a layer of porous fibrous tackable/acoustic sheet material which is sufficiently durable to serve the same function as a non-tackable/acoustic layer, yet which is sufficiently porous that it can be used as a tackable/acoustic surface. This layer can be provided over a panel core, or can be provided in the form of tiles used to cover a panel core.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
       [0001]    The present application claims the benefit of U.S. Provisional Patent Application No. 61/798,896, entitled TACKABLE WALL PANEL SYSTEM, filed on Mar. 15, 2013. 
     
    
     FIELD AND BACKGROUND OF THE INVENTION 
       [0002]    The present invention relates to room divider panels. Such panels are used in the office furniture industry to delineate worked spaces and created cubicles. Such panels are sometimes provided with tackable surfaces over a portion of the panel area, usually the area just above the workspace, because of their limited durability. Add on tackable surface forming tiles for room divider panel systems are sometimes provided. 
       SUMMARY OF THE INVENTION 
       [0003]    In the present invention, room divider panels are provided with a layer of porous fibrous tackable and acoustic sheet material which is sufficiently durable to serve as a non-tackable layer, yet which is sufficiently porous that it can be used as a tackable and acoustic absorption surface. This layer can be provided over a panel core, or can be provided in the form of tiles used to cover a panel core. 
         [0004]    The tackable/acoustic surfaces provided by the present invention are more durable than prior art non-woven fibrous tackable surfaces. Thus they can be used over the entire surface area of the panel, since they are able to withstand limited impact, as for example from the feet of workers. Further, said tackable/acoustic surfaces are receptive to multiple penetrations by the same tack in the same hole, giving said surfaces a longer useful life. The tackable/acoustic surface provided is sufficiently durable that it can be machined to any shape and size desired. 
         [0005]    These and other objects, features and advantages of the invention will be more fully understood and appreciated by reference to the description of the preferred embodiments and the appended drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS  
         [0006]      FIG. 1  is a perspective view of an office cubicle system; 
           [0007]      FIG. 2  is a cut-away view of the panel embodiment of the present invention; 
           [0008]      FIG. 3  is a cross-sectional view of one panel embodiment of the present invention; 
           [0009]      FIG. 4  is a cross-sectional view of one panel embodiment of the present invention; 
           [0010]      FIG. 5  is an exploded view of a panel covered with tiles made in accordance with a preferred embodiment of the invention; and 
           [0011]      FIG. 6  is a cross-sectional view of the tile embodiment. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0012]    The panels  10  of the preferred embodiment can be arranged to form a variety of configurations, such as that shown in  FIG. 1 . Panels  10  comprise a series of layers which make said panels tackable, stiff, and acoustically dampened. 
         [0013]    In embodiment shown in  FIGS. 2 and 3 , the innermost panel core  12 , is comprised of a honeycomb configuration of kraft cardboard or like material. The outer dimensions of the panel are defined by a particle board frame  11 . Attached to each side of the frame  11  is a tackable/acoustic layer comprised of sheet of porous fibrous material  13 . Attachment is preferable made on the outside edge of frame  11 . Porous fibrous material  13  is optionally laminated to a scrim layer  14 . The entire surface of the panel is covered with upholstery or other decorative material  15 .  FIG. 4  shows an alternative panel  10   a , which differs from panel  10  in that it employs a particle board core  12   a.    
         [0014]    There core  12  or  12   a  is 0.25 to 3 inches thick, preferably 0.5 to 2.5 inches thick, and most preferably between 1 and 2 inches thick. The tackable/acoustic porous fibrous layer  13  is between 1 and 4 mm thick, most preferably between 2 and 3 mm. 
         [0015]    The porous fibrous sheets  13  preferably comprise a non-woven, consolidated fibrous material containing at least two types of fibers, most preferably polypropylene and natural or glass fibers. Their porosity gives them an irregular non-smooth surface. One of the fibers must have a melting point greater than the other, such that the application of heat and pressure will melt one fiber and not the other, consolidating a non-woven batt into a sheet. Said porous fibrous sheets preferably have a consolidated density between 200 and 400 kg/m 3 , most preferably between 250 and 350 kg/m 3 . Said porous fibrous sheet preferably have a basis weight of between 500 and 1,500 g/m 2 , most preferably between 600 and 1,000 g/m 2 . A thin, e.g. 0.5 mil (0.127 mm), non-porous vinyl or polymeric film scrim  14  may be, in certain applications, adhered to one side of each porous fibrous sheet  13 . The porous fibrous sheet  13  is preferably free of formaldehyde. 
         [0016]    The non-woven fibrous sheet  13 , with or without optional scrim  14 , can be easily handled during panel manufacture, as for example by using a vacumm table. It provides a tackable/acoustic surface in which holes formed by tacks tend to re-seal, such that they hold subsequently inserted tacks even when they are inserted into previously occupied tack holes. Finally its porosity and resulting surface roughness provides an acoustic dampening surface. The fact that it is secured to frame  11 , rather than being laminated to panel core  12  or  12   a,  also contributes to its sound deadening acoustic properties. A preferable way of securing porous fibrous sheet to frame  11  is to staple it to the outside edge of frame  11 . 
         [0017]    Alternative embodiment panel  10   b  ( FIG. 5 ) comprises a frame  11  to which a plurality of tackable/acoustic tiles  20  are attached. Each tile  20  comprises a front tackable/acoustic laminate layer  21  and back tackable/acoustic laminate layer  22  which are adhered to an inner tackable/acoustic core of stiffening material, most preferably corrugated cardboard or other stiffening materials,  23 . Each tackable/acoustic layer comprises porous fibrous sheet  13  as described above. The laminated thus formed is stiff, durable and can be machined. It can easily be cut into the desired size and shape for making tiles  20 . 
         [0018]    The outward facing surface of each tile  20  is covered with upholstery  24 . Attachment members  25 , are attached to the inward facing surface. The attachment members allow the tiles to be secured to a frame  21 , such that both faces of the finished divider have upholstered, tackable/acoustic surfaces. The core layer  23  has a thickness between 0.25 and 1.5 inches, most preferably between 0.50 and 1.25 inches. 
         [0019]    Although the present invention has been described in detail with regard to the exemplary embodiments thereof and accompanying drawings, it should be apparent to those skilled in the art that various modifications of the present invention may be accomplished with departing from the spirit and the scope of the invention. Accordingly, the invention is not limited to the precise embodiments shown in the drawings and described above. Rather, it is intended that all such variations not departing from the spirit of the invention be considered as within the scope thereof.