WO2016041023A1

WO2016041023A1 - Light fixture made of open cell acoustic foam

Info

Publication number: WO2016041023A1
Application number: PCT/BE2015/000043
Authority: WO
Inventors: Thierry Vereecke
Original assignee: Isomo N.V.
Priority date: 2014-09-15
Filing date: 2015-09-15
Publication date: 2016-03-24
Also published as: WO2016041023A4; EP3194847A1; BE1021608B1; EP3194847B1

Abstract

The invention relates to a lamp or light fixture made of melamine foam. The invention also relates to a method for producing a lamp or light fixture made of melamine foam. The invention also relates to the use of melamine foam for producing a lamp or light fixture.

Description

LIGHT FIXTURE MADE OF OPEN CELL ACOUSTIC FOAM TECHNICAL FIELD

The invention relates to a lamp or light fixture made of open cell acoustic foam, preferably melamine foam. The invention also relates to a method for producing a lamp or light fixture made of open cell acoustic foam, preferably melamine foam. The invention also relates to the use of open cell acoustic foam, preferably melamine foam for producing a lamp or light fixture.

TECHNOLOGICAL BACKGROUND OF THE INVENTION Lamps and light fixtures play an important role in a space, for example in a room, office, commercial space, or multi-use space. 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.

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. 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

The invention and preferred embodiments thereof offer a solution for one or more of the above- mentioned needs.

In a first aspect, the invention comprises an object that is suitable for housing one or more light sources. More specifically, the object or a part thereof comprises open cell acoustic foam, preferably melamine foam.

The inventors surprisingly discovered that the objects according to the first aspect or according to preferred embodiments thereof, lead 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. In a preferred embodiment, the object according to the present invention also comprises electrical wiring and one or more light bulb sockets, wherein the one or more light bulb sockets are connected with the electrical wiring.

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.

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. In some embodiments, the object according to the present invention is a milled and sanded object. In a preferred embodiment, the object according to the present invention is a directly flocked object, preferably by means of an electrostatic field.

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. 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. In some preferred embodiments, the object is flocked directly. For fire safety reasons a flocked fabric can provide an additional benefit. 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. In a preferred embodiment the open cell acoustic foam, preferably melamine foam, in the object according to the present invention comprises a filler material.

In a second aspect the invention comprises a method for producing an object according to the first aspect of the invention. The method for producing an object suitable for housing a light source comprises the following steps: a) the production of an open cell acoustic foam, preferably melamine foam; and b) the processing of the open cell acoustic foam, preferably melamine foam, into an object that is suitable for housing a light source.

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.

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.

In a preferred embodiment of the method according to the present invention, the object is directly flocked, preferably by means of an electrostatic field. 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. In a preferred embodiment, the method according to the present invention further comprises: e) the addition of electrical wiring and one or more light bulb sockets; and f) optionally, the addition of one or more light sources.

In a preferred embodiment, the method according to the present invention comprises the coupling together of two or more semifinished articles, optionally with adhesive. In a preferred embodiment, the method according to the present invention provides for the production of an object according to the present invention.

In a third aspect the invention comprises the use of open cell acoustic foam, preferably melamine foam, for producing an object according to the first aspect of the invention. The invention also comprises the use of open cell acoustic foam, preferably melamine foam, for producing a housing for a light source.

The inventors surprisingly discovered that open cell acoustic foam, preferably melamine foam, is excellently suited for producing objects of this type.

DESCRIPTION OF THE FIGURES FIG. 1 A is a schematic drawing of a preferred embodiment of the object (100) according to the invention. FIG. 1 B 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

In the remainder of this text, the singular forms used cover both the singular and the plural unless the context clearly indicates otherwise. 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."

The summation of numerical values using number ranges covers all values and fractions within these ranges, as well as the cited end points.

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.

All documents cited in the current specification are incorporated by reference in their entirety. 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. In a first aspect the invention comprises an object (100), preferably a three-dimensional object (100), that is suitable for housing one or more light sources (144). The object (100) is made of polymer foam. The object (100) is preferably suitable for housing one or more light sources (144), wherein the object (100) or a part thereof comprises open cell acoustic foam, preferably melamine foam. In the most preferred form, the 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/m³, while other foams have a density around 30 kg/m³. The fire behavior of melamine foam is also an advantage as melamine foam will char rather than melt. 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.

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). 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. 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. 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.

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.

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. 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. 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.

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.

In some preferred embodiments the precondensate for the melamine foam contains no other thermosetting molding agents and no other aldehydes.

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.

In some embodiments the other aldehydes are selected from the list comprising: acetaldehyde, trimethylolacetaldehyde, acrolein, benzaldehyde, furfural, glyoxal, glutaraldehyde,

phthalaldehyde, terephthalaldehyde or mixtures thereof. In some embodiments the precondensate comprises an emulsifier or dispersant. In some preferred embodiments the precondensate comprises a blowing agent.

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.

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.

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. 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.

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.

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.

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.

In some embodiments the polymer foam, preferably 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.

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).

In some embodiments the polymer foam, preferably open cell acoustic foam, preferably melamine foam, has a density of at least 5 kg/m° and at most 20 kg/m , preferably of at least 6 kg/m and at most 15 kg/m , preferably of at least 7 kg/m and at most 12 kg/m , preferably of at least 8 kg/nrr and at most 11 kg/m , as measured according to the EN ISO 845 standard.

In some embodiments the polymer foam, preferably 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. 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.

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.

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 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 polymer foam, preferably 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. The polymer foam, preferably 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%.

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 μιη and more particularly in the range of 50 to 600 pm.

Sound damping is one of the possible benefits of polymer foams such as 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.

In addition, the low weight of light fixtures made of polymer foam, for example open cell acoustic foam, preferably melamine foam, can be advantageous in various uses, for example for use in light fixtures.

In a preferred embodiment the object (100) according to the present invention comprises electrical wiring (140) and one or more light bulb sockets (142). The one or more light bulb sockets (142) are preferably connected to the electrical wiring (140), so that the assembly consisting of the object (100), electrical wiring (140) and one or more light bulb sockets (142) can serve as a light fixture. In some embodiments, the object (100) is 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 object (100) 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 bulb 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. Preferably, 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. In a preferred embodiment one or more internal spaces (1 10) are hollowed out in the object (100), for example one or more cavities. These one or more internal spaces (1 10) 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 bulb 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. 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 bulb 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. Preferably the one or more light sources (144) are placed in the one or more light bulb sockets (142) so that the light source (144) makes electrical contact with the terminals in the one or more light bulb 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. 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).

In a preferred embodiment the one or more light sources (144) are dimmable.

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).

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.

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.

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.

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).

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.

In a preferred embodiment the one or more internal spaces (1 10) 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 (1 10), wherein the second semifinished article provides for the connection with the external environment via one or more openings (1 12).

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. 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.

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.

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. In some embodiments 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. 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. 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.

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.

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.

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.

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.

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.

For example, the adhesive is dried at room temperature. Excess flock fibers are then preferably removed, for example by blowing, vacuuming, brushing, or washing.

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.

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.

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. 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.

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).

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.

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.

In a second aspect the invention comprises a method for producing an object (100), preferably a three-dimensional object (100), that is suitable for housing a light source (144). In a preferred embodiment the method comprises the following steps: a) the preparation of a polymer foam, preferably open cell acoustic foam, preferably melamine foam; and b) the processing of the polymer foam, preferably open cell acoustic foam, preferably melamine foam, into an object (100) that is suitable for housing a light source (144).

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.

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.

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). 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.

Anionic, cationic and nonionic surface-active substances and also mixtures thereof can be used as dispersants and/or emulsifiers in the precondensate.

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.

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. Usable cationic emulsifiers are, for example, alkyltriammonium salts, alkyl benzyl dimethyl ammonium chloride salts and alkylpyridinium salts.

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. 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.

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.

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. 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.

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.

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.

The method described typically results in blocks or plates of foam material, which can be cut to size.

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.

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.

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.

In some embodiments a membrane or coating is applied.

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.

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.

In a preferred embodiment of the method according to the present invention, the object (100) directly flocked, preferably by means of an electrostatic field.

In some embodiments step b) is performed by contour cutting and/or stamping. In some embodiments step b) is performed partly by milling and partly by contour cutting and/or stamping.

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).

In a preferred embodiment electrical wiring (140) and one or more light bulb sockets (142) are added. In some embodiments the electrical wiring (140) also functions as a mechanism for hanging (150).

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). 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).

In some embodiments the object (100) is packaged.

In a third aspect, the invention comprises the use of open cell acoustic foam, preferably melamine foam for producing a housing of a light source (144).

In a fourth aspect the invention comprises the use of an object (100) according to the first aspect of the invention as a housing for one or more light sources (144). Preferably the object (100) is used in a space selected from the list comprising: a residential space, a professional space, a commercial space, a utility space, an office, a sound studio, an athletic facility, a school building or auditorium, an athletic facility, a meeting room, a catering business, or a hotel.

Claims

1. An object (100) suitable for housing one or more light sources (144), wherein the object (100) or a part thereof comprises open cell acoustic foam, preferably melamine foam.

2. The object (100) as claimed in claim 1 , wherein the object (100) is directly flocked.

3. The object (100) as claimed in any one of claims 1 or 2, wherein the object (100) is a milled object (100), preferably wherein the milled object (100) is a milled and sanded object (100).

4. The object (100) as claimed in one of claims 1 to 3, which also comprises electrical wiring (140) and one or more light bulb sockets (142), wherein the one or more light bulb sockets (142) are connected with the electrical wiring (140).

5. The object (100) as claimed in one of claims 1 to 4, which comprises an internal space (110), wherein that optionally the internal space (110) is connected with the external environment via one or more openings (112).

6. The object (100) as claimed in one of claims 1 to 5, wherein the object (100) is made of two or more semifinished articles (101-106) which are connected together, preferably with adhesive (120).

7. The object (100) as claimed in one of claims 1 to 6, wherein the object (100) is covered by a membrane or coating, preferably wherein the membrane or the coating comprises a knitted tube, a flocked cloth, and/or paint.

8. A method for producing an object (100) is suitable for housing one or more light sources (144); the method comprising the following steps:

a) the production of an open cell acoustic foam, preferably melamine foam; and b) the processing of the open cell acoustic foam, preferably melamine foam, into an object (100) that is suitable for housing one or more light sources (144).

9. The method as claimed in claim 8, wherein step b) is performed by milling, preferably by milling and sanding.

10. The method as claimed in claim 8 or 9, wherein the object (100) is directly flocked, preferably by means of an electrostatic field.

11. The method as claimed in one of claims 8 to 10, further comprising:

c) the provision of an internal space (110) in the object (100); and

d) optionally, the provision of one or more openings (112) in the object (100), which connect the internal space (110) with the external environment.

12. The method as claimed in one of claims 8 to 11 , further comprising:

e) the addition of electrical wiring (140) and one or more light bulb sockets (142); and f) optionally, the addition of one or more light sources (144).

13. The method as claimed in one of claims 8 to 12, comprising the coupling together of two or more semifinished articles (101-106), optionally with adhesive (120).

14. The method as claimed in one of claims 8 to 13 for producing an object (100) as claimed in one of claims 1 to 7.

15. The use of open cell acoustic foam, preferably melamine foam for producing a housing for one or more light sources (144).