Variable density board having improved thermal and acoustical pr

Details Variable density board having improved thermal and acoustical pr Variable density board having improved thermal and acoustical pr

1983-05-09

1985-09-03

Cannon, James C.

Stock material or miscellaneous articles

Structurally defined web or sheet

Including components having same physical characteristic in...

181198, 181200, 181204, 181294, 428284, 428285, 428288, 428290, 4283105, 428920, C04B 4302, E04B 176, E04B 182, E04B 188

Patent

active

045392528

ABSTRACT:
A board having improved thermal and/or acoustical properties is disclosed, together with a method and apparatus for producing same. The board is of finite thickness and has a graduated density, the two opposing major surfaces have the greatest density and the intermediate portion has the least density with the board density gradually decreasing in the region between the major surfaces toward the intermediate portion thereof. The board is produced by a molding process, wherein blankets of loosely gathered fibers and containing a suitable binder, are utilized to form the board. The blankets are preferably high compressible and have interposed therebetween an initially relatively highly incompressible air filled member. These laminates are pressed together between a pair of heated mold halves. As the temperature of the laminate increases, the interposed member softens and is rapidly reduced in thickness due to the escape of air as it softens and melts. The resilient blankets which have previously undergone compression expand into the void created by the contracting interposed member at a time prior to the setting of the inner portions of said resilient blankets, wherein the resulting product provides improved thermal and/or acoustic properties by virtue of the density profile of the finished product which has maximum density at the major surfaces thereof and which gradually decreases in density toward the intermediate portion thereof. The interposed member in one preferred embodiment, is comprised of pockets of air encapsulated in a plastic material which softens and melts at a temperature well below that at which the binder in said blankets is cured. The interposed media may be a filler of a low density, preferably thermoplastic material which is significantly less yieldable than said blankets and which is adapted to contract significantly as it softens and melts.

REFERENCES:
patent: 3652377 (1972-03-01), Helmick
patent: 3936555 (1976-02-01), Smith
patent: 3952124 (1976-04-01), Mesek
patent: 4175148 (1979-11-01), Luck et al.
patent: 4195110 (1980-03-01), Dierks et al.
patent: 4283450 (1981-08-01), Luck et al.
patent: 4310585 (1982-01-01), Shannon

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