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Molding a lightweight cast acoustical product

a technology of lightweight cast and acoustic panels, which is applied in the field of casting sound absorption products, can solve the problems of increasing the product density, not all surfactants or foaming agents are useful in the preparation of lightweight acoustic panels,

Active Publication Date: 2011-10-13
USG INTERIORS INC
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

The method produces a lightweight acoustical product with a density of at least 16 pounds per cubic foot and hardness of at least 80 pounds force, avoiding the formation of wool knots and improving sound absorption as product density decreases, with the Noise Reduction Coefficient being inversely proportional to product density.

Problems solved by technology

It has also been discovered that, contrary to the expectation of an artisan, not all surfactants or foaming agents are useful in the preparation of lightweight acoustical panels.
A number of foaming agents were found that actually result in an increase in the product density.

Method used

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  • Molding a lightweight cast acoustical product
  • Molding a lightweight cast acoustical product
  • Molding a lightweight cast acoustical product

Examples

Experimental program
Comparison scheme
Effect test

example 1

Preparation of Test Boards

[0046]A base formula for a pulp for acoustical panels is shown in Table I. Starch, boric acid and stucco were weighed out into separate cups. 350 Grams of cold water was measured and placed into a small metal beaker. The dry ingredients were added to the cold water while stirring, first adding the starch, then the boric acid and finally the stucco. 2571 Grams of boiling water was added to the mixture. The mixture was stirred to achieve a homogeneous gel. Mineral wool was measured to 871 grams and placed in a HOBART® mixer. The gel was added to the mixer and mixed for 45 seconds at speed 1, forming a pulp. Unblended ingredients on the side of the mixing bowl were pushed down into the pulp and the pulp was mixed for an additional three minutes at speed 2.

TABLE IPULP BASE FORMULAWeight,Weight PercentPercent TotalComponentgramsSolidsWeightCold Water3500.0%8.5%Hot Water25710.0%62.5%Starch17514.7%4.2%Boric Acid7.50.6%0.2%Stucco14111.8%3.4%Mineral Wool87172.9%21.2...

example 2

Test Board Properties

[0049]Physical properties of each of the test boards made in Example 1 were measured. Results are shown in Table III.

TABLE IIITEST BOARD PROPERTIESSampleThicknessDensityMORCMORMOEHardness1C0.85522.01228.8228.633570291.310.76921.53235.8246.437226298.820.76920.97175.1192.725485235.930.75521.45226.3238.134952312.640.73821.45180.7190.228415226.050.78120.40184.3214.131388256.060.75121.46189.2199.031985263.170.78020.85224.2249.635751309.880.76221.48201.7211.628249254.190.80121.16197.5233.036063258.8100.79520.65188.4213.631305268.6110.75321.54236.8247.023397304.6120.74421.97186.9187.410111266.9130.83319.99199.0241.028310226.1140.71721.36177.1206.812840212.2150.79720.54192.3220.715892247.5160.77421.18188.0202.810161253.0170.79221.33193.6226.819685250.1180.76621.34192.0203.713406286.2190.81619.55203.0257.019022231.2200.82818.19128.2187.55691134.1210.82319.11182.3241.515270216.1220.81416.58123.2217.15597151.2230.81519.07160.8214.110423204.5240.81515.31119.7246.95350105.12...

example 3

Preparation of Test Samples

[0052]The most promising foaming agents identified in the screening tests of Examples 1 and 2 were selected for additional testing. Samples of the pulp base formula were prepared according to Example 1 with foaming agents, if present, added according to Table IV.

TABLE IVCOMPOSITION OF TEST BOARDS% FoamingBoardFoaming AgentAgentThickness1CNoneNone0.8551Linear Sodium Alkylbenzene0.10%0.807Sulfonate2Linear Sodium Alkylbenzene0.20%0.825Sulfonate3Linear Sodium Alkylbenzene0.30%0.817Sulfonate4Linear Sodium Alkylbenzene0.40%0.843Sulfonate5Linear Sodium Alkylbenzene0.50%0.823Sulfonate6Cocamidopropyl Betaine0.10%0.7987Cocamidopropyl Betaine0.20%0.8098Cocamidopropyl Betaine0.30%0.8259Cocamidopropyl Betaine0.40%0.77010Cocamidopropyl Betaine0.50%0.82311Cocamidopropyl Hydroxysultaine0.10%0.80712Cocamidopropyl Hydroxysultaine0.20%0.85613Cocamidopropyl Hydroxysultaine0.30%0.79014Cocamidopropyl Hydroxysultaine0.40%0.80615Cocamidopropyl Hydroxysultaine0.50%0.80016Disodium ...

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Abstract

A lightweight cast article that is made by the method of the present invention. A foamed acoustical product is prepared by blending a starch with cold water, then heating the starch / water blend to form a starch gel. Mineral wool is added to the starch gel to form a pulp and the pulp is wet-mixed until wool nodules are formed. The pulp is then combined with a surfactant and an amount of foam water. The foaming agent is selected from the group consisting of a linear sodium dodecylbenzene sulfonate, a cocamidopropyl betaine, a cocamidopropyl hydroxysultaine, their salts and mixtures thereof. Mixing of the foaming agent and pulp continues to form a foamed pulp. The foamed pulp is cast into a mold and allowing the foamed pulp to dry forming a foamed product. The foamed product is removed from the mold.

Description

FIELD OF THE INVENTION[0001]This invention relates to a method of making a cast sound-absorbing product. More specifically it relates to a method of making a foamed acoustical panel that produces a light weight product.BACKGROUND OF THE INVENTION[0002]Acoustic panels are widely used in the building construction industry. Acoustical panels are used on ceilings, on walls, in theatres or concert halls to control sound. These products absorb sound by allowing the sound to penetrate to the interior of the product, where the sound energy is absorbed. Access to the interior of the product is provided in many ways. Openings in the surface of the product allow sound to enter the product interior. The composition of the product can be designed to be at least partially transparent to sound, allowing it to pass through the product surface. Other means of admitting sound energy to the product interior can be used as are known to an artisan of acoustical products. Once inside the product interior...

Claims

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Application Information

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Patent Type & Authority Applications(United States)
IPC IPC(8): E04B1/84B29C44/40B29C59/00B29C39/36
CPCC04B26/285C04B28/14C04B2111/52E04B1/86C04B14/365C04B14/46C04B20/0076C04B22/0013C04B22/16C04B24/123C04B24/124C04B24/20C04B40/0028C04B40/005C04B40/0082C04B40/0263C04B38/106C04B38/10C04B24/383C04B26/28C04B24/38
Inventor ENGLERT, MARK
Owner USG INTERIORS INC