Recycled Ceiling Panel Pelletization for Acoustic Performance
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing building panels made from recycled materials face challenges in achieving desired performance properties such as acoustical performance and structural rigidity without reducing the fraction of recycled material.
Innovation Solution
A method involving forming a mixture of recycled material and water, processing it into a uniform web using an extruder, forming pellets from the web, and then creating an acoustical building panel from these pellets, which includes a combination of fibrous material, binder, and recycled material pellets.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If recycled material is used in building panels, then cost and environmental performance improve, but performance properties such as acoustical performance and structural rigidity deteriorate
Solution Approach 1:
The invention segments the building panel into distinct layers: a first layer comprising fibrous material and binder, and a second layer comprising pellets of recycled material. This segmentation allows each layer to perform its specific function optimally while maintaining overall panel performance.
Solution Approach 2:
The invention uses composite materials by combining fibrous material with binder in the first layer, and using processed recycled material pellets in the second layer. This composite approach enables the panel to achieve desired performance properties while incorporating significant amounts of recycled material.
2Reliability
If less recycled material is used to maintain performance properties, then acoustical performance and structural rigidity improve, but environmental benefits and cost advantages deteriorate
Solution Approach 1:
The invention changes the physical parameters of recycled material by processing it through extrusion to form uniform pellets with controlled size and shape. This parameter change enables higher recycled material content (up to 95 wt%) while maintaining performance properties.
Solution Approach 2:
The invention performs preliminary processing of recycled material by forming it into uniform pellets before incorporating it into the building panel. This preliminary action ensures consistent performance and enables higher recycled material content without compromising quality.
3Reliability
If additional expensive material is included to offset performance degradation, then performance properties improve, but cost advantages deteriorate
Solution Approach 1:
The invention enables recycled material to serve itself by processing it into a form (uniform pellets) that inherently provides the necessary structural and acoustical performance. This eliminates the need for additional expensive materials to compensate for performance degradation.
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
This approach allows for the production of acoustical building panels that maintain high levels of recycled material content while achieving superior acoustical performance and structural integrity.
Implementation Method 1
feeding the mixture to an extruder at an entry point, whereby the mixture is processed into uniform web that exits the extruder at an exit point
Data Source
AI summary
Described herein is an acoustical building panel that comprises a body formed from a first component comprising a fibrous material, and a binder; and a second component comprising pellets of a recycled material, wherein the second component is present in an amount ranging from about 25 wt. % to about 45 wt. % based on the total weight of the body.