Molding a lightweight cast acoustical product

Details Molding a lightweight cast acoustical product Molding a lightweight cast acoustical product

2010-04-13

2011-10-04

Phillips, Forrest M (Department: 2832)

Acoustics

Sound-modifying means

Sound absorbing panels

C181S290000, C181S284000

Reexamination Certificate

active

08028803

ABSTRACT:
A lightweight cast article that is made by the method of the present invention. A foamed acoustical product is prepared by blending a starch with cold water, then heating the starch/water blend to form a starch gel. Mineral wool is added to the starch gel to form a pulp and the pulp is wet-mixed until wool nodules are formed. The pulp is then combined with a surfactant and an amount of foam water. The foaming agent is selected from the group consisting of a linear sodium dodecylbenzene sulfonate, a cocamidopropyl betaine, a cocamidopropyl hydroxysultaine, their salts and mixtures thereof. Mixing of the foaming agent and pulp continues to form a foamed pulp. The foamed pulp is cast into a mold and allowing the foamed pulp to dry forming a foamed product. The foamed product is removed from the mold.

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