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US 7,364,015 B2Granted
Acoustical panel comprising interlocking matrix of set gypsum and method for making same
AssigneeUnited States Gypsum Company
InventorsMark H. Englert, Richard B. Stevens, Steven W. Sucech, Therese A. Fults, Michael J. Porter, Bruce L. Petersen, Russell A. Dombeck
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Abstract
An acoustical panel comprising a continuous phase of an interlocking set gypsum matrix and a method of preparing an acoustical panel are disclosed.
Claims118
A continuous method for preparing acoustical panel comprising:
- forming a mixture comprising water and calcined gypsum;
- adding foaming agent to the aqueous calcined gypsum mixture;
- casting the mixture in a continuous ribbon;
- maintaining the ribbon under conditions sufficient for the calcined gypsum to form an interlocking matrix of set gypsum;
- cutting the ribbon to form wet acoustical panel precursor;
- and
- drying the wet panel precursor to form acoustical panel, wherein acoustical panel has a Normal Incident Sound Absorption of at least about 0.32, according to a modified ASTM E 1050-98.
4 more elements
A continuous method for preparing acoustical panel comprising:
- providing a backing sheet;
- forming a first mixture comprising (a) water, (b) calcined gypsum, and (c) foaming agent, and optionally one or more of the following:
- (d) cellulosic fiber, (e) lightweight
- aggregate, (f) binder, (g) accelerator, (h) water reducing agent, and (i) enhancing material selected from the group consisting of an ammonium polyphosphate having 500-3000 repeating phosphate units, a trimetaphosphate compound, a tetrametaphosphate compound, a hexametaphosphate compound, and combinations thereof;
- forming a second mixture comprising (a) water, and (b) calcined gypsum, and optionally one or more of the following ingredients:
- (c) cellulosic fiber, (d) lightweight
- aggregate, (e) binder, (f) accelerator, (g) water reducing agent, and (h) an enhancing material selected from the group consisting of an ammonium polyphosphate having 500-3000 repeating phosphate units, a trimetaphosphate compound, a tetrametaphosphate compound, a hexametaphosphate compound, and combinations thereof;
- casting the second mixture onto the backing sheet to form a densified layer precursor;
- casting the first mixture as an acoustical layer precursor onto the densified layer precursor to form a continuous ribbon;
- maintaining the ribbon under conditions sufficient for the calcined gypsum in each of the densified layer precursor and the acoustical layer precursor to form an interlocking matrix of set gypsum;
- cutting the ribbon to form wet acoustical panel precursor;
- and
- drying the wet panel precursor to form the acoustical panel, wherein the acoustical panel has a Normal Incident Sound Absorption of at least about 0.32, according to a modified ASTM E 1050-98.
10 more elements
A continuous method for preparing acoustical panel comprising:
- (i) forming a mixture comprising
- (a) water,
- (b) calcined gypsum, and
- (c) cellulosic fiber;
- (ii) adding foaming agent in the form of a pregenerated foam to the aqueous calcined gypsum mixture;
- (iii) casting the mixture in a continuous ribbon;
- (iv) maintaining the ribbon under conditions sufficient for the calcined gypsum to form an interlocking matrix of set gypsum;
- (v) cutting the ribbon to form wet acoustical panel precursor;
- and
- (vi) drying the wet panel precursor to form acoustical panel;
- wherein acoustical panel has a density of from about 10 lb/ft3 to about 25 lb/ft3 and an open cell structure sufficient to give rise to a Normal Incident Sound Absorption of at least about 0.32 according to a modified ASTM E 1050-98.
8 more elements
A continuous method for preparing acoustical panel comprising:
- (i) forming a mixture comprising
- (a) water,
- (b) calcined gypsum, and
- (c) about 1% to about 12% by weight of the solids content in the mixture cellulosic fiber having an average fiber length of less than about 2 mm;
- (ii) adding foaming agent to the aqueous calcined gypsum mixture;
- (iii) casting the mixture in a continuous ribbon;
- (iv) maintaining the ribbon under conditions sufficient for the calcined gypsum to form an interlocking matrix of set gypsum;
- (v) cutting the ribbon to form wet acoustical panel precursor;
- and
- (vi) drying the wet panel precursor to form acoustical panel;
- wherein acoustical panel has a Normal Incident Sound Absorption of at least about 0.32 according to a modified ASTM E 1050-98.
8 more elements
A continuous method for preparing acoustical panel comprising:
- (i) forming a mixture comprising
- (a) water,
- (b) calcined gypsum, and
- (c) about 1% to about 12% by weight of the solids content in the mixture cellulosic fiber;
- (ii) adding foaming agent in the form of a pregenerated foam to the aqueous calcined gypsum mixture;
- (iii) casting the mixture in a continuous ribbon;
- (iv) maintaining the ribbon under conditions sufficient for the calcined gypsum to form an interlocking matrix of set gypsum;
- (v) cutting the ribbon to form wet acoustical panel precursor;
- and
- (vi) drying the wet panel precursor to form acoustical panel;
- wherein acoustical panel has a density of from about 10 lb/ft3 to about 25 lb/ft3 and an open cell structure sufficient to give rise to a Normal Incident Sound Absorption of at least about 0.32 according to a modified ASTM E 1050-98.
8 more elements
Dependencies are inferred from the claim text.