US20230091295A1

US20230091295A1 - Acoustic insulated ceiling system

Info

Publication number: US20230091295A1
Application number: US17/798,001
Authority: US
Inventors: Derek DE VILLENFAGNE
Original assignee: Spantech International
Current assignee: Spantech International
Priority date: 2020-02-06
Filing date: 2021-02-05
Publication date: 2023-03-23
Also published as: WO2021156452A1; BE1028016A1; EP4100588A1; BE1028016B1; EP3862500A1

Abstract

An acoustic insulated ceiling system is disclosed. The system comprises a first profile and a second profile. The system comprises a carrier layer connected to the first profile and the second profile. As such the carrier layer is suspended between the first profile and the second profile. The system comprises a bottom layer in a high density material. The bottom layer supports on the carrier layer. The bottom layer extends from the first profile to the second profile. The system comprises an intermediate layer in a low density insulation material. The intermediate layer supports on the bottom layer. The system comprises a top layer in a high density material. The top layer supports on the intermediate layer. The top layer extends from the first profile to the second profile.

Description

CROSS-REFERENCE TO RELATED APPLICATION(S)

This present application is a national stage application of International Patent Application No. PCT/EP2021/052833, filed Feb. 5, 2021, which claims priority to European Patent Application No. 20155915.0, filed Feb. 6, 2020, the disclosures of which are hereby incorporated by reference in their entireties.

TECHNICAL FIELD

The present invention relates to an acoustic insulated ceiling system, a set for assembling the acoustic insulated ceiling, a method for assembling the acoustic insulated ceiling system, and a method for disassembling the acoustic insulated ceiling system.

BACKGROUND ART

Acoustic insulated ceiling system known from the prior art are mostly composed of acoustic insulated ceiling elements which all have to be individually connected to profiles of the ceiling and to each other by means of screws or other connection elements, in order to cover the entire surface area of the ceiling. This makes the assembly of such acoustic insulated ceiling systems difficult and time consuming.

DISCLOSURE OF THE INVENTION

It is an aim of the present invention to provide an acoustic insulated ceiling system which is easy to assemble and disassemble.
This aim is achieved according to the invention with an acoustic insulated ceiling system showing the technical characteristics of the first independent claim.
Therefore, the present invention provides an acoustic insulated ceiling system. The system comprises a first profile and a second profile. The system comprises a carrier layer connected to the first profile and the second profile. As such the carrier layer is suspended between the first profile and the second profile. Preferably, the carrier layer is a fabric liner. Preferably, the carrier layer is a weldable PVC coated fabric liner. The system comprises a bottom layer in a high density material. Preferably, the bottom layer is a plate, i.e. a bottom plate. The bottom layer supports on the carrier layer. The bottom layer extends from the first profile to the second profile. The system comprises an intermediate layer in a low density insulation material. The intermediate layer supports on the bottom layer. The system comprises a top layer in a high density material. Preferably, the top layer is a plate, i.e. a top plate. The top layer is arranged above the intermediate layer. Preferably, the top layer supports on the intermediate layer. The top layer extends from the first profile to the second profile.
The acoustic insulated ceiling system according to the present invention offers the advantage that for assembling the acoustic insulated ceiling system only the carrier layer needs to be connected to the first profile and the second profile. The further layers of the acoustic insulated ceiling system, such as the bottom layer, the intermediate layer and the top layer, can just be arranged on top of each other supporting on the carrier layer. Thereby, those further layers of the acoustic insulated ceiling system, such as the bottom layer, the intermediate layer and the top layer, do not necessarily have to be connected to the first profile and the second profile. This enables to the acoustic ceiling system to be assembled quickly and easily, and also to be disassembled quickly and easily.
In an embodiment of the acoustic insulated ceiling system according to the present invention edges of at least one layer of the bottom layer and the top layer are configured for pressing against the first profile and the second profile.
The edges of the at least one layer pressing against the first profile and the second profile provides a good contact between the at least one layer on the one hand and the first profile and the second profile on the other hand, such that the at least one layer can easily be connected to and clamped in between the first profile and the second profile. As such, the at least one layer can maintain its position between the first profile and the second profile. The good contact between the at least one layer on the one hand and the first profile and the second profile on the other hand also offers the advantage of preventing noise leakage at the connection between the at least one layer on the one hand and the first profile and the second profile on the other hand.
In an embodiment of the acoustic insulated ceiling system according to the present invention the edges of at least one layer of the bottom layer and the top layer are bended upwards and slightly outwards for pressing against the first profile and the second profile. Preferably, the edges are bended outwards for optimally following the curvature of the acoustic insulated ceiling system determined by the carrier layer.
The inventors have found that by means of the upwards and slightly outwards bending of the edges of the at least one panel, the edges of the at least one panel can be configured in a simple manner for pressing against the first profile and the second profile.
Alternatively, the edges of the at least one layer could also be bended downwards and slightly outwards for pressing against the first profile and the second profile, but the upwards bended configuration is more beneficial for allowing the at least one layer to follow the curvature of the carrier layer suspended between the first profile and the second profile, and as such support on the carrier layer, either directly in case of the bottom layer or indirectly via het intermediate layer and the bottom layer in case of the top layer.
In an embodiment of the acoustic insulated ceiling system according to the present invention the edges are bended outwards for at least 0.5°, preferably for at least 1.0° and more preferably for at least 1.5°. In an embodiment of the acoustic insulated ceiling system according to the present invention the edges are bended outwards for at most 4.0°, preferably for at most 3.5°, and more preferably for at most 3.0°.
The edges of the at least one layer being bended outwards in this range is beneficial for allowing the at least one layer to optimally follow the curvature of the carrier layer suspended between the first profile and the second profile, and as such support on the carrier layer, either directly in case of the bottom layer or indirectly via het intermediate layer and the bottom layer in case of the top layer.
In an embodiment of the acoustic insulated ceiling system according to the present invention the bended edges have a length of at least 2 cm, preferably at least 3 cm, more preferably at least 4 cm. In an embodiment of the acoustic insulated ceiling system according to the present invention the bended edges have a length of at most 8 cm, preferably at most 7 cm, more preferably at most 6 cm. In an embodiment of the acoustic insulated ceiling system according to the present invention the bended edges have a length of 5 cm.
The bended edges having a length in the this range provide a good contact surface for the edges to press sufficiently against the first profile and the second profile to clamp the at least one layer between the first profile and the second profile, but without making it too difficult to take the at least one layer back out from between the first profile and the second profile for disassembling the acoustic insulated ceiling system.
The bended edges having a length in the this range provide a good contact surface for preventing noise leakage at the connection between the at least one layer on the one hand and the first profile and the second profile on the other hand.
In an embodiment of the acoustic insulated ceiling system according to the present invention the intermediate layer is substantially thicker than the bottom layer and the top layer.
The intermediate layer being substantially thicker than the bottom layer and the top layer is beneficial for limiting the overall weight of the acoustic insulated ceiling system, and as such limit the load on the carrier layer, while still maintaining good acoustical insulation properties.
In an embodiment of the acoustic insulated ceiling system according to the present invention at least one layer of the bottom layer and the top layer has a thickness of at least 0.5 mm, preferably at least 0.6 mm, more preferably at least 0.7 mm, and even more preferably at least 0.8 mm. In an embodiment of the acoustic insulated ceiling system according to the present invention at least one layer of the bottom layer and the top layer has a thickness of at most 1.5 mm, preferably at most 1.4 mm, more preferably at most 1.3 mm, and even more preferably at most 1.2 mm. This thickness is beneficial for the acoustic insulation properties of the at least one layer, and thus of the acoustic insulated ceiling system of the present invention.
In an embodiment of the acoustic insulated ceiling system according to the present invention the intermediate layer has a thickness of at least 15 cm, preferably at least 17 cm, more preferably at least 19 cm, even more preferably at least 21 cm, and yet even more preferably at least 23 cm. In an embodiment of the acoustic insulated ceiling system according to the present invention the intermediate layer has a thickness of at most 35 cm, preferably at most 33 cm, more preferably at most 31 cm, even more preferably at most 29 cm, and yet even more preferably at most 27 cm. In an embodiment of the acoustic insulated ceiling system according to the present invention the intermediate layer has a thickness of 25 cm. This thickness is beneficial for the acoustic insulation properties of the intermediate layer, and thus of the acoustic insulated ceiling system of the present invention.
In an embodiment of the acoustic insulated ceiling system according to the present invention at least one layer of the bottom layer and the top layer is a steel plate.
In an embodiment of the acoustic insulated ceiling system according to the present invention the intermediate layer is composed of particles of a foam insulation material.
The use of particles of a foam insulation material offers the advantage that said particles can be spread on top of the bottom layer, if surrounded by a closure, to quickly and easily form the intermediate layer on the bottom layer. The use of particles of a foam insulation material also offers the advantage that said particles can be injected or blown in between the top layer and the bottom layer, if surrounded by a closured, to quickly and easily form the intermediate layer between the bottom layer, the top layer and the closure.
In an embodiment of the acoustic insulated ceiling system according to the present invention at least one profile of the first profile and the second profile is provided with connection means for connecting to the carrier layer. The at least one profile of the first profile and the second profile extends upwards from the connection means for contacting the bottom layer and the top layer.
In an embodiment of the acoustic insulated ceiling system according to the present invention at least one profile of the first profile and the second profile is a keder profile. The carrier layer is provided with a keder. A keder bead of said keder is arranged in a keder guide track of the at least one profile for connecting the carrier layer to the at least one profile.
The at least one profile being a keder profile and the carrier layer being provided with a keder offers the advantage that the carrier layer can be connected quickly and easily to the at least one profile by sliding the keder bead of the keder into the keder guide track of the at least one profile. This further enhances the quick and easy assembly and disassembly of the acoustic insulated ceiling system according to the present invention.
The present invention further provides a set for assembling the acoustic insulated ceiling system of the present invention. The set comprises the first profile. The set comprises the second profile. The set comprises the carrier layer. The set comprises the bottom layer. The set comprises the top layer. The set comprises the intermediate layer, or a low density insulation material for forming the intermediate layer.
The present invention further provides a method for assembling the acoustic insulated ceiling system according to the present invention, preferably by means of the set according to the present invention. The method comprises the step of positioning the first profile and the second profile at predetermined positions. The method comprises the step of connecting the carrier layer to the first profile and the second profile. Thereby, the carrier layer is suspended between the first profile and the second profile. The method comprises the step of arranging the bottom layer between the first profile and the second profile. Thereby, the bottom layer is supported on the carrier layer. Preferably, the bottom layer is thereby clamped in between the first profile and the second profile by means of edges of the bottom layer pressing against the first profile and the second profile. Preferably, the bottom layer is clamped in between the first profile and the second profile by means of upwards and slightly outwards bended edges of the bottom layer pressing against the first profile and the second profile. The method comprises the step of arranging the intermediate layer on the bottom layer. The method comprises the step of arranging the top layer between the first profile and the second profile at a predetermined distance above the bottom layer. Preferably, the top layer is thereby clamped in between the first profile and the second profile by means of edges of the top layer pressing against the first profile and the second profile. Preferably, the top layer is clamped in between the first profile and the second profile by means of upwards and slightly outwards bended edges of the top layer pressing against the first profile and the second profile. The top layer may be arranged between the first profile and the second profile before or after the intermediate layer is arranged on the bottom layer. Preferably, the top layer is arranged between the first profile and the second profile after the intermediate layer has been arranged on the bottom layer, in which case the top layer is supported on the intermediate layer. As such, the predetermined distance of the top layer above the bottom layer is determined by a predetermined thickness of the intermediate layer. If, alternatively, the top layer is arranged between the first profile and the second profile before the intermediate layer has been arranged on the bottom layer, the intermediate layer or a low density insulation material for forming the intermediate layer is afterwards inserted or injected, e.g. by blowing, between the bottom layer and the top layer. In case of injecting, there is preferably provided a closure around the bottom layer and the top layer. In this case, the predetermined distance of the top layer above the bottom layer is also determined by a predetermined thickness for the intermediate layer.
The present invention further provides a method for disassembling the acoustic ceiling system according to the present invention. The method comprises the step of removing the top layer from the intermediate layer. The method comprises the step of removing the intermediate layer from the bottom layer. The method comprises the step of removing the bottom layer from the carrier layer. The method comprises the step of disconnecting the carrier layer from the first profile and the second profile to remove the carrier layer. The method comprises optionally the step of removing the first profile and the second profile. As such, the acoustic ceiling system according to the present invention can be disassembled to the set according the present invention for being reused for assembling a further acoustic ceiling system according to the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will be further elucidated by means of the following description and the appended figures.

FIG. 1 shows an acoustic insulated ceiling system according to an embodiment of the present invention.

FIG. 2 shows an acoustic insulated ceiling system according to an embodiment of the present invention.

FIG. 3 shows a detailed view of the acoustic insulated ceiling system of FIG. 2 .

MODES FOR CARRYING OUT THE INVENTION

The present invention will be described with respect to particular embodiments and with reference to certain drawings but the invention is not limited thereto but only by the claims. The drawings described are only schematic and are non-limiting. In the drawings, the size of some of the elements may be exaggerated and not drawn on scale for illustrative purposes. The dimensions and the relative dimensions do not necessarily correspond to actual reductions to practice of the invention.
Furthermore, the terms first, second, third and the like in the description and in the claims, are used for distinguishing between similar elements and not necessarily for describing a sequential or chronological order. The terms are interchangeable under appropriate circumstances and the embodiments of the invention can operate in other sequences than described or illustrated herein.
Moreover, the terms top, bottom, over, under and the like in the description and the claims are used for descriptive purposes and not necessarily for describing relative positions. The terms so used are interchangeable under appropriate circumstances and the embodiments of the invention described herein can operate in other orientations than described or illustrated herein.
The term “comprising”, used in the claims, should not be interpreted as being restricted to the means listed thereafter; it does not exclude other elements or steps. It needs to be interpreted as specifying the presence of the stated features, integers, steps or components as referred to, but does not preclude the presence or addition of one or more other features, integers, steps or components, or groups thereof. Thus, the scope of the expression “a device comprising means A and B” should not be limited to devices consisting only of components A and B. It means that with respect to the present invention, the only relevant components of the device are A and B.
FIG. 1 and FIG. 2 shows a roof 200 of a tent with an acoustic insulated ceiling system 100 according to an embodiment of the present invention in two different configurations. More detail of the acoustic insulated ceiling system 100 of FIG. 2 is shown in FIG. 3 , but this figure is also representative for the acoustic insulated ceiling system 100 of FIG. 1 . Although, the figures show the use of an insulated ceiling system 100 according to the present invention in the roof 200 of a tent, it should be remarked that the use thereof is not limited to tents, but that it can also be used in other types of buildings or constructions.
The roof 200 is composed of truss legs 201, low roof beams 202, high roof beams 203, purlins 204, roof cables 205 and scissor cables 206. In FIG. 1 the acoustic insulated ceiling system 100 is arranged between two of the high roof beams 203, and in FIG. 2 the acoustic insulated ceiling system 100 is arranged between two of the low roof beams 202.
The acoustic insulated ceiling system 100 comprises a first profile 110, a second profile 120, and a carrier layer 130 suspended between the first profile 110 and the second profile 120. In the embodiments shown, the first profile 110 and the second profile 120 are provided together on a single roof beam 202, 203, albeit for use in separate acoustic insulated ceiling systems 100 arranged on opposing sides of the roof beam 202, 203. It should however be clear that in other embodiments the first profile 110 and the second profile 120 can also be provided separate from each other, and that the first profile 110. In other embodiments a single profile can also be used, for example in a circular or a U-shaped configuration, as long as a carrier layer 130 can be suspended by the profile. In this case, opposing sides of the single profile can be considered as the first profile 110 and the second profile 120.
The carrier layer 130 is used for carrying or supporting the further elements 140, 150, 160 of the acoustic insulated ceiling system 100, which will be arranged on top of the carrier layer 130. The carrier layer 130 may for example be a fabric liner 130, but it should be clear that any other type of carrier layer 130 can be used suitable for carrying or supporting the further elements 140, 150, 160 of the acoustic insulated ceiling system 100.
As can be seen in FIG. 3 , the carrier layer 130 is provider with a keder 131. The carrier layer 130 is connected to the first profile 110 and the second profile 120 by means of a keder bead 132 which is slid in a corresponding keder guide track 111, 121 of the first profile 110 and the second profile 120. It should however be clear that in other embodiments of the acoustic insulated ceiling system 100 other types of connection means can be provided on the first profile 110, the second profile 120 and/or the carrier layer 130 for connecting the carrier layer 130 to the first profile 110 and the second profile 120.
On top of the carrier layer 130, there is arranged a bottom layer 140 in a high density material. In the embodiment shown, the bottom layer 140 is a steel plate, but it should be clear that other types of suitable high density materials for acoustic insulation and for carrying the weight of further elements 150, 160 of the acoustic insulated ceiling system 100 arranged on top of the bottom layer 140, can also be used.
The bottom layer 140 has a thickness of 1.2 mm for optimal acoustic insulation properties of the bottom layer 140 and thus the acoustic insulated ceiling system 100. Additionally, this gives the bottom layer 140 sufficient strength to support further elements 150, 160 of the acoustic insulated ceiling system 100 arranged on top of the bottom layer 140, sufficient flexibility to follow the curvature of the carrier layer 130 suspended between the first profile 110 and the second profile 120 such that bottom layer 140 is well supported by the carrier layer 130, and a sufficient low weight to be carried by the carrier layer 130. It should however be clear that the bottom layer 140 can also be provided in other thicknesses, taking into account these requirements.
The bottom layer 140 extends from the first profile 110 to the second profile 120, and is clamped between the first profile 110 and the second profile 120 by means of the edges 141, 142 of the bottom layer 140 pressing against the first profile 110 and the second profile 120. For this purpose, the edges 141, 142 of the bottom layer 140 are bended upwards and slightly outwards, such that the overall length of the bottom layer 140 is slightly larger than the distance between the first profile 110 and the second profile 120. In this way, when the bottom layer 140 is arranged between the first profile 110 and the second profile 120 a press-fit connection is formed between the bottom layer 140 on the one hand and the first profile 110 and the second profile 120 on the other hand. Preferably, the edges are bent outwards 1.5° to 3.0° from the height direction to provide a strong contact with the first profile 110 and the second profile 120, which may nonetheless be undone relatively easy for disassembling the acoustic insulated ceiling system 100. The press-fit connection is also beneficial for preventing noise leakage between the bottom layer 140 on the one hand and the first profile 110 and the second profile 120 on the other hand.
On top of the bottom layer 140, there is arranged an intermediate layer 160 in a low density insulation material. The low density insulation material may for example be mineral wool, cellulose foam, fibres, particles of a foam insulation material, etc.
The intermediate layer 160 has a thickness of approximately 25 cm, which is sufficiently thicker than the bottom layer 140 and the top layer 150 discussed below. This thickness of the intermediate layer 160 gives good acoustic insulation properties to the intermediate layer 160 and thus to the acoustic insulated ceiling system 100. It should however be clear that intermediate layer 160 may also be provided in other thicknesses, taking into account the acoustic insulation requirements.
On top of the intermediate layer 160, there is arranged a top layer 150 in a high density material. In the embodiment shown, the top layer 150 is a steel plate, but it should be clear that other types of suitable high density materials for acoustic insulation can also be used.
The top layer 150 has a thickness of 0.8 mm for optimal acoustic insulation properties of the top layer 150 and thus the acoustic insulated ceiling system 100. Additionally, this gives the top layer 150 sufficient flexibility to follow the curvature of the intermediate layer 160 such that the top layer 150 is well supported by the intermediate layer 160, and a sufficient low weight to be carried by the carrier layer 130. It should however be clear that the top layer 150 can also be provided in other thicknesses, taking into account these requirements. The top layer 150 can be provided with a smaller thickness than the bottom layer 140, since no further elements need to be arranged on the top layer 150, such that the strength requirement is of lesser importance. Nonetheless, the bottom layer 150 should be sufficiently strong for being handled and transported without damage.
The top layer 150 extends from the first profile 110 to the second profile 120, and is clamped between the first profile 110 and the second profile 120 by means of the edges 151, 152 of the top layer 150 pressing against the first profile 110 and the second profile 120. For this purpose, the edges 151, 152 of the top layer 150 are bended upwards and slightly outwards, such that the overall length of the top layer 150 is slightly larger than the distance between the first profile 110 and the second profile 120. In this way, when the top layer 150 is arranged between the first profile 110 and the second profile 120 a press-fit connection is formed between the top layer 150 on the one hand and the first profile 110 and the second profile 120 on the other hand. Preferably, the edges are bent outwards 1.5° to 3.0° from the height direction to provide a strong contact with the first profile 110 and the second profile 120, which may nonetheless be undone relatively easy for disassembling the acoustic insulated ceiling system 100. The press-fit connection is also beneficial for preventing noise leakage between the top layer 150 on the one hand and the first profile 110 and the second profile 120 on the other hand.
When assembling the acoustic insulated ceiling system 100, the intermediate layer 130 may have been pre-fabricated and arranged on the bottom layer 140 after the bottom layer 140 has been arranged on the carrier layer 130, or a low density material for forming the intermediate layer 160, such as for example particles of a foam insulation material, may be arranged on the bottom layer 140. Alternatively, a low density insulation material may be injected or blown between the bottom layer 140 and the top layer 150 for forming the intermediate layer 160, provided that a closure is provided around the bottom layer 140 and the top layer 150 to keep the low density insulation material between the bottom layer 140 and the top layer 150. In this case the top layer 150 needs to be arranged beforehand between the first profile 110 and the second profile 120 at a predetermined distance from the bottom layer 140 to leave sufficient space to form the intermediate layer 130 with the desired thickness. Alternatively, a pre-fabricated intermediate layer 130 can also by inserted between the bottom layer 140 and the top layer 150, which have been arranged between the first profile 110 and the second profile 120 beforehand.

REFERENCES


100	system	132	keder bead
110	first profile	140	bottom layer
111	guide track	141, 142	bended edge
120	second profile	150	top layer
121	guide track	151, 152	bended edge
130	carrier layer	160	intermediate layer
131	keder	200	roof
201	truss legs	204	purlin
202	low roof beam	205	roof cables
203	high roof beam	206	scissor cables

Claims

1. An acoustic insulated ceiling system, the system comprising:

a first profile and a second profile;

a carrier layer connected to the first profile and the second profile, and as such suspended between the first profile and the second profile;

a bottom layer in a high density material supporting on the carrier layer and extending from the first profile to the second profile;

an intermediate layers in a low density insulation material supporting on the bottom layer; and

a top layer in a high density material arranged above the intermediate layer and extending from the first profile to the second profile.

2. The system according to claim 1, wherein edges of at least one layer of the bottom layer and the top layer are configured for pressing against the first profile and the second profile.

3. The system according to claim 2, wherein the edges of the at least one layer are bended upwards and slightly outwards for pressing against the first profile and the second profile.

4. The system according to claim 3, wherein the edges are bended outwards for at least 0.5 and for at most 4,0.

5. The system according to claim 3, wherein the bended edges have a length of at least 2 cm and of at most 8 cm.

6. The system according to claim 1, wherein the intermediate layer is substantially thicker than the bottom layer and the top layer.

7. The system according to claim 1, wherein at least one layer of the bottom layer and the top layer has a thickness of at least 0.5 mm and of at most 1.5 mm.

8. The system according to claim 1, wherein the intermediate layer has a thickness of at least 15 cm and of at most 35 cm.

9. The system according to claim 1, wherein at least one layer of the bottom layer and the top layer is a steel plate.

10. The system according to claim 1, wherein the intermediate layer is composed of particles of a foam insulation material.

11. The system according to any claims, wherein at least one profile of the first profile and the second profile is provided with connection means for connecting to the carrier layer, and wherein the at least one profile extends upwards from the connection means for contacting the bottom layer and the top layer.

12. The system according to claim 1, wherein at least one profile of the first profile and the second profile is a keder profile, and wherein the carrier layer is provided with a keder of which a keder bead (132) is arranged in a keder guide track of the at least one profile for connecting the carrier layer to the at least one profile.

13. A set for assembling the acoustic insulated ceiling system according to claim 1, wherein the set comprises the first profile, the second profile, the carrier layer, the bottom layer, the top layer, and one of the intermediate layer and a low density insulation material for forming the intermediate layer.

14. A method for assembling the acoustic insulated ceiling system according to claim 1, wherein the method comprises the steps of:

positioning the first profile and the second profile at predetermined positions;

connecting the carrier layer to the first profile and the second profile, thereby suspending the carrier layer between the first profile and the second profile;

arranging the bottom layer between the first profile and the second profile, thereby supporting on the carrier layer;

arranging the intermediate layer on the bottom layer; and

arranging the top layer between the first profile and the second profile at a predetermined distance above the bottom layer.

15. A method for disassembling the acoustic ceiling system according to claim 1, wherein the method comprises the steps of:

removing the top layer from the intermediate layer;

removing the intermediate layer from the bottom layer;

removing the bottom layer from the carrier layer;

disconnecting the carrier layer from the first profile and the second profile to remove the carrier layer; and

optionally removing the first profile and the second profile.