Ceiling Tile Base Mat Using Expanded Glass Beads
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Solution Overview
Problem
Existing ceiling tile materials face challenges in achieving sound absorption, low density, fire-resistance, and sag-resistance while being environmentally sustainable and cost-effective, with limited availability of recycled materials that meet these criteria and are compatible with existing manufacturing processes.
Innovation Solution
A high recycled content formulation using expanded glass beads as a filler in a wet felted ceiling tile base mat, combined with mineral wool, cellulose fiber, and a binder, which enhances sound absorption, mechanical properties, and energy efficiency, and is compatible with industry-standard materials and processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If recycled materials are used to increase environmental sustainability, then environmental performance is improved, but mechanical properties and processing compatibility deteriorate
Solution Approach 1:
The patent uses a composite formulation combining expanded glass beads (recycled content) with mineral wool fibers and binders to create a base mat that achieves both environmental sustainability and acceptable mechanical properties. The glass beads provide bulk and sound absorption while the mineral wool matrix provides structural integrity.
Solution Approach 2:
The patent optimizes the density parameter of the base mat to approximately 15 lbs/cubic ft, which balances the use of recycled glass bead filler with the need for adequate mechanical strength and sag resistance in ceiling tile applications.
2Ease of manufacture
If recycled materials are used to reduce material costs, then procurement cost is improved, but material availability and processing compatibility worsen
Solution Approach 1:
The patent maintains the base mat density at approximately 15 lbs/cubic ft, which ensures compatibility with existing water-based felting manufacturing processes while incorporating cost-effective recycled glass beads as the primary filler material.
3Use of energy by moving object
If low density is achieved to reduce material usage, then energy efficiency is improved, but mechanical strength and sag resistance deteriorate
Solution Approach 1:
The patent creates a composite structure where expanded glass beads provide low density and sound absorption, while mineral wool fibers and binders form a reinforcing matrix that provides sag resistance and mechanical strength at the target density of 15 lbs/cubic ft.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The formulation achieves satisfactory sound absorption and mechanical properties with low density, reduces water usage and energy consumption in the manufacturing process, and simplifies supply chain and processing issues, while maintaining compatibility with existing equipment and processes.
Implementation Method 1
achieves satisfactory sound absorption as well as suitable mechanical properties
Implementation Method 2
conveyed to a dryer where remaining water is evaporated out of the mat and a binder in the mat formulation is caused to set or cure
Implementation Method 3
a binder in the mat formulation is caused to set or cure
Data Source
AI summary
A water felted base mat for a suspended ceiling tile comprising on a weight basis about 1/2 mineral wool, starch binder, limited to about 1/8, newsprint, limited to about 1/8, and about 1/4 expanded glass beads.