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US 2026/0233496 A1Published application
Acoustic insulating panel using recycled material
AssigneeCSR Industries Inc.
InventorPaul Charles DOWNEY
Life of this patent
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Abstract
In an aspect a method of manufacturing an acoustic floor panel is described. The method may include: combining a binding agent with plastic flakes; passing the plastic flakes and the binding agent to a lamination machine; applying a force to the binding agent and the plastic flakes using the lamination machine to create a plastic sheet; cutting the plastic sheet; and adding an acoustic insulator to at least a first side of the plastic sheet.
Claims20
A method of manufacturing an acoustic floor panel, the method comprising:
- combining a thermally activated adhesive with a plurality of recycled plastic flakes, the recycled plastic flakes including category seven (7) plastic flakes comprising at least one of polycarbonate plastic flakes and plastic flakes containing bisphenol A (BPA);
- applying heat to activate the thermally activated adhesive at a temperature below a melting point of the recycled plastic flakes;
- applying pressure while the thermally activated adhesive is activated to bond the recycled plastic flakes together without melting the recycled plastic flakes, thereby forming a consolidated plastic substrate in which the recycled plastic flakes remain unmelted and retain discrete flake morphology;
- and
- coupling an acoustic insulating layer to at least one side of the consolidated plastic substrate.
2 more elements
An acoustic floor panel comprising:
- a consolidated plastic substrate comprising a plurality of recycled plastic flakes bonded together by a thermally activated adhesive, the recycled plastic flakes including category seven (7) plastic flakes comprising at least one of polycarbonate plastic flakes and plastic flakes containing bisphenol A (BPA),
- wherein the thermally activated adhesive bonds the recycled plastic flakes together without melting the recycled plastic flakes such that the recycled plastic flakes remain unmelted and retain discrete flake morphology within the consolidated plastic substrate;
- and
- an acoustic insulating layer coupled to at least one side of the consolidated plastic substrate.
1 more element
Dependencies are inferred from the claim text.