Single-Layer Wool Basemat for Lightweight Acoustic Ceiling Panels
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Solution Overview
Problem
Existing fibrous panels, such as ceiling tiles, are thick, heavy, difficult to install, and costly due to dual-layer construction, with high energy consumption and carbon footprint, and suffer from quality issues during installation.
Innovation Solution
A basemat comprising wool fibers with a combination of fine (less than 3 microns) and large (greater than 6 microns) diameters, achieving a single-layer structure with enhanced acoustical performance and reduced density, allowing for a high NRC and CAC rating while minimizing weight and production time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If dual-layer construction is used to achieve high NRC and CAC ratings, then acoustical performance is improved, but weight and thickness increase making installation difficult
Solution Approach 1:
The patent merges the functions of front and back panels into a single basemat layer by incorporating a distributed air gap structure within the same panel. This eliminates the need for separate front and back panels while maintaining both sound absorption (NRC) and sound blocking (CAC) performance, thereby reducing overall weight and simplifying installation.
Solution Approach 2:
The patent introduces a third dimension by creating an internal air gap structure within the basemat rather than using separate layers. This internal cavity structure provides sound blocking functionality without increasing the panel's external thickness or weight, as the air gap is contained within the single panel structure.
2Reliability
If dual-layer construction is used to achieve high NRC and CAC ratings, then acoustical performance is improved, but thickness increases making installation difficult
Solution Approach 1:
The patent combines multiple acoustic functions (sound absorption and sound blocking) into a single basemat structure with internal air gaps, eliminating the need for separate front and back panels. This integration maintains high NRC and CAC ratings while reducing the overall panel thickness compared to dual-layer construction.
Solution Approach 2:
The patent utilizes an internal air gap dimension within the single panel to provide sound blocking functionality. This internal cavity structure achieves the acoustic performance of thick dual-layer panels without increasing the external thickness, as the air gap is contained within the panel's internal structure rather than adding to its overall dimension.
3Productivity
If conventional drying methods are used for basemats, then production is achieved, but energy consumption is high and production time is long
Solution Approach 1:
The basemat incorporates a porous structure with distributed air gaps that facilitates rapid moisture evaporation and removal during drying. This porous architecture increases the surface area for evaporation and improves moisture transport pathways, enabling faster drying times and reduced energy consumption compared to dense conventional basemats.
Solution Approach 2:
The patent modifies the physical structure of the basemat by incorporating air gaps and porous features, which changes the drying parameters. These structural modifications enable more efficient moisture removal through enhanced evaporation and reduced thermal mass, thereby decreasing both drying time and energy consumption while maintaining production output.
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 basemat achieves high noise reduction coefficient (NRC) and ceiling attenuation class (CAC) ratings with reduced density and weight, facilitating easier installation and lower production costs, and energy consumption.
Implementation Method 1
The acoustical performance of fibrous panels is a particularly important factor in use. Fibrous panels are designed to absorb sound/noise, as reflected by a NRC (noise reduction coefficient) rating
Implementation Method 2
block sound from entering into adjacent plenum space, as reflected by a CAC (ceiling attenuation class) rating
Data Source
AI summary
A low density basemat provided as a single layer having a thickness of greater than about 1.1 inches (2.80 cm) and comprising at least about 90 weight percent wool fibers, based on the weight of the basemat, wherein the wool fibers include wool fibers having a diameter of less than about 3 microns and wool fibers having a diameter of greater than about 6 microns, wherein from 5% to 40% of the wool fibers have a diameter of less than about 3 microns, wherein at least 30% of the wool fibers have a diameter of greater than about 6 microns, wherein less than 15 wt. % of the wool fibers have a diameter greater than about 12 μm, and wherein the wool fibers have a mean diameter of at least about 5 microns, and a low density fibrous panel comprising the basemat and a porous scrim.