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.
Claims45
An acoustical panel comprising:
- acoustical layer comprising an interlocking matrix of set gypsum and an additive selected from the group consisting of cellulosic fiber and lightweight aggregate, and combinations thereof, wherein the panel has a Normal Incident Sound Absorption of at least about 0.32, according to a modified ASTM E 1050-98.
An acoustical panel comprising:
- acoustical layer comprising (a) an interlocking matrix of set gypsum, and (b) 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, wherein the panel has voids therein, and wherein the panel has a Noise Reduction Coefficient of at least about 0.5, according to ASTM C 423-02.
An acoustical panel comprising (a) acoustical layer comprising (i) an interlocking matrix of set gypsum (ii) cellulosic fiber, and (iii) lightweight aggregate, and optionally one or more of the following ingredients:
- (iv) binder, (v) foaming agent, (vi) accelerator, (vii) water reducing agent, and (viii) 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;
- (b) a backing sheet for supporting the acoustical layer;
- and (c) a densified layer disposed between the backing sheet and the acoustical layer wherein the panel has a Normal Incident Sound Absorption of at least about 0.32, according to a modified ASTM E 1050-98.
A panel comprising acoustical layer comprising (a) an interlocking matrix of set gypsum, (b) cellulosic fiber, and (c) lightweight aggregate, and optionally one or more of the following ingredients:
- (d) binder, (e) foaming agent, (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, wherein the panel has voids therein, wherein the voids in the panel have an average maximum diameter of about 2 mm or less.
Dependencies are inferred from the claim text.