Durable porous article of manufacture and a process to create same
AssigneeAWI Licensing LLC
InventorsDean L. Putt, Marsha Stalker Bischel, Anthony L. Wiker, Andrea M. Moser
Life of this patent
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Abstract
An acoustically absorbent porous panel formed from a cured aqueous foamed cementitious material comprising on a wet basis of about 53% to about 68% by weight cement, about 17% to about 48% by weight water, about 0.05% to about 5% by weight fiber, and about 0.01% to about 10% by weight surfactant. The panel also has pores distributed within the cured material comprising about 75% to about 95% by volume of the material. The cement-based, foamed panel provides good acoustical performance with enhanced durability and moisture resistance.
Claims60
An acoustically absorbent porous panel comprising:
- a cured aqueous foamed cementitious material comprising on a wet basis about 53% to about 68% by weight cement, about 17% to about 48% by weight water, about 0.05% to about 5% by weight fiber, and about 0.01% to about 10% by weight surfactant;
- and
- pores distributed within the cured material comprising about 75% to about 95% by volume of the material.
A process for producing an acoustically absorbent porous panel comprising:
- aerating a foam slurry comprised of between about 53% to about 68% by weight cement, between about 17% to about 48% by weight water, between about 0.05% to about 5% by weight fibers and between about 0.01% to about 10% by weight surfactant;
- and
- drying the aerated foam slurry.
An acoustically absorbent porous panel comprising cementitious material, the cementitious material comprising cement, fibers and surfactant, the cementitious material having a density between about 10 lb/ft3 and about 40 lb/ft3, a scratch resistance test result of at least 12, an indent of less than 0.12 inches, a Noise Reduction Coefficient of at least 0.5, and a sag test result of less than 0.15 inches at 90% RH.
An acoustically absorbent porous panel comprising at least 90% by weight of a gypsum cement and having a Noise Reduction Coefficient of at least 0.5.
An acoustically absorbent porous panel comprising at least 90% by weight of a gypsum cement and having a density between about 10 lb/ft3 and about 40 lb/ft3.
An acoustically absorbent porous panel comprising a substantially compositionally homogenous cementitious material, the compositionally homogenous material comprising a cement, fiber and surfactant, the panel having two opposed surfaces, a surface portion adjacent one of the opposed surfaces having a first density, a center portion at the center of the panel between the two opposed surfaces having a second density, the first density being substantially greater than the second density.
Dependencies are inferred from the claim text.