Process for manufacturing an acoustic element and an acoustic element thereof

Abstract

The present invention relates to a manufacturing method of acoustic elements and elements thereof, which are based on perforated gypsum plasterboards coated with an acoustic mass. The combination of the present invention, i.e. gypsum plasterboard with a high perforation rate together with an acoustic mass layer, which fills the holes of said gypsum plasterboard, provides a light-weighted and rigid element with excellent acoustic properties in a wide frequency level range.

1 . A process of manufacturing a plate-like acoustic element, comprising the steps of
 producing a perforated gypsum plasterboard having holes of pre-determined size,   spreading an acoustic mass onto the gypsum plasterboard,   forming an acoustic mass layer at least on one surface of the gypsum plasterboard, and   at least partially filling said holes with said acoustic mass.   
     
     
         2 . The process according to  claim 1 , further comprising spreading a wet cellulose-based acoustic mass onto a surface of the gypsum plasterboard, wherein said mass incorporates one or more binders for binding the acoustic mass together and into the gypsum plasterboard. 
     
     
         3 . The process according to  claim 1 , further comprising spreading the acoustic mass onto the gypsum plasterboard mechanically or by spraying, followed by drying the element. 
     
     
         4 . The process according to  claim 1 , further comprising subjecting the acoustic mass layer of the element to pressure to adjust the density and thus forming the acoustic characteristics of the final element structure. 
     
     
         5 . The process according to  claim 1 , further comprising compressing the acoustic mass layer of the gypsum plasterboard to a thickness in a range of 1 mm to 30 mm. 
     
     
         6 . The process according to  claim 1 , further comprising adjusting the relative proportion of the holes on the gypsum plasterboard to a value in a range of 25% to 50% per surface area of the gypsum plasterboard. 
     
     
         7 . A plate-like acoustic element comprising a gypsum plasterboard and an acoustic mass layer at least on one surface of the gypsum plasterboard having holes of a pre-determined size filled with the acoustic mass. 
     
     
         8 . The plate-like acoustic element according to  claim 7 , wherein the thickness of the acoustic mass layer is in a range of 1 mm to 30 mm. 
     
     
         9 . The plate-like acoustic element according to  claim 7 , wherein the element has an absorption value α of at least 0.60 at a frequency level from 500 to 2000 Hz. 
     
     
         10 . The plate-like acoustic element according to  claim 7 , wherein the thickness of the gypsum plasterboard is in a range of 6 mm to 12.5 mm. 
     
     
         11 . The plate-like acoustic element according to  claim 7 , wherein surface area of a single hole of the gypsum plasterboard is in a range of 0.25 cm 2  to 4 cm 2 . 
     
     
         12 . The plate-like acoustic element according  claim 7 , wherein the total surface area of the holes is in a range of 30% to 40% per surface area of the gypsum plasterboard. 
     
     
         13 . The plate-like acoustic element according to  claim 7 , wherein the acoustic mass is organic or inorganic material. 
     
     
         14 . The plate-like acoustic element according to  claim 7 , wherein the acoustic mass further comprises one or more binders selected from a group of carboxy-methyl cellulose, hydroxypropyl cellulose, methyl cellulose, ethylene vinyl acetate, polyvinyl alcohol, polyvinyl acetate, polyvinyl chloride, polyolefins, and starch, as well as mixtures thereof. 
     
     
         15 . The plate-like acoustic element according to  claim 7 , wherein it further comprises a fire retardant and an anti-rot agent, selected from a group of magnesite, boron-based substances, hydroxides, or absorbing agents, in an amount of 1 to 20% by weight of the acoustic mass. 
     
     
         16 . (canceled)