Acoustical gypsum board panel and method of making it
AssigneeUnited States Gypsum Company
InventorsW. David Song, Mark H. Englert, Qiang Yu, Martin W. Brown, Richard B. Stevens
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Abstract
The acoustical product of the present invention comprises an acoustical product including a matrix of calcium sulfate dihydrate crystals and expanded perlite distributed throughout the matrix. The expanded perlite has a particle size distribution with at least 10% of the perlite having a particle diameter of 700 microns or more, and the amount of expanded perlite to calcium sulfate dihydrate is about 35% to about 75% by weight, based upon the dry weight of the calcium sulfate dihydrate. A dispersing agent and glass fibers having a particle length of about ¼ inch to about 1 inch are dispersed throughout the gypsum matrix.
Claims14
An acoustical product comprising:
- a matrix of calcium sulfate dihydrate crystals;
- a lightweight aggregate distributed throughout the matrix, said lightweight aggregate having a bimodal particle size distribution curve having a first maximum in the range of 500 to 2000 microns and a second maximum in the range of 10 to 100 microns, and wherein the ratio of lightweight aggregate to calcium sulfate dihydrate ranges from about 35% to about 75% by weight, based upon the dry weight of the calcium sulfate dihydrate;
- a foaming agent comprising at least one of alkyl ether sulfates and sodium laureth sulfates;
- a dispersing agent;
- and
- long reinforcing fibers distributed throughout said calcium sulfate dihydrate matrix.
Dependencies are inferred from the claim text.