The disclosure provides a method of forming an acoustical panel base mat, including providing a green board including an alkyl ether sulfate surfactant, wherein the green board includes from about 10 to about 40 wt. % solids, and dewatering the green board slurry to form a dewatered green board, whe
The disclosure provides a method of forming an acoustical panel base mat, including providing a green board including an alkyl ether sulfate surfactant, wherein the green board includes from about 10 to about 40 wt. % solids, and dewatering the green board slurry to form a dewatered green board, wherein the dewatering comprises supplying hot air and applying a vacuum to the green board.
대표청구항▼
1. A method of forming an acoustical panel base mat, comprising: providing a green board comprising an alkyl ether sulfate surfactant, wherein the green board comprises from about 10 to about 40 wt % solids; anddewatering the green board to form a dewatered green board, wherein the dewatering compri
1. A method of forming an acoustical panel base mat, comprising: providing a green board comprising an alkyl ether sulfate surfactant, wherein the green board comprises from about 10 to about 40 wt % solids; anddewatering the green board to form a dewatered green board, wherein the dewatering comprises supplying hot air and applying a vacuum to the green board. 2. The method of claim 1, wherein the hot air is supplied and the vacuum is applied to the green board concurrently. 3. The method of claim 1, wherein the surfactant is provided in an amount in a range of about 0.10 wt % to about 3.0 wt %, based on the total weight of the solids. 4. The method of claim 1, wherein the surfactant is provided in an amount in a range of about 0.10 wt % to about 0.5 wt %, based on the total weight of the solids. 5. The method of claim 1, wherein the green board further comprises a mineral wool, a cellulose, a mineral aggregate, and a starch. 6. The method of claim 5, wherein the mineral aggregate is selected from the group consisting of perlite, vermiculite, clay, and combinations thereof. 7. The method of claim 5, wherein the cellulose is provided by newspaper. 8. The method of claim 1, wherein dewatering further comprises a pressing step. 9. The method of claim 8, wherein the green board comprises about 22 wt % to about 28 wt % solids after pressing. 10. The method of claim 1, wherein applying a vacuum to the green board comprises a first step of applying a vacuum and a second step of applying a vacuum. 11. The method of claim 10, wherein hot air is supplied concurrently with applying the vacuum in both steps of applying a vacuum. 12. The method of claim 10, wherein hot air is supplied concurrently with at least the second step of applying a vacuum. 13. The method of claim 1, wherein the hot air has a temperature in a range of about 250° F. (about 120° C.) to about 500° F. (about 260° C.). 14. The method of claim 1, wherein the hot air has a temperature in a range of about 350° F. (about 177° C.) to about 400° F. (about 204° C.). 15. The method of claim 1, further comprising a drying step after dewatering to provide a dried base mat. 16. The method of claim 15, wherein the dewatered green board is dried at a temperature of about 300° F. (about 150° C.) to about 600° F. (about 316° C.). 17. The method of claim 1, wherein dewatering achieves a reduction in water of at least about 5% compared to an equivalent base mat formed by dewatering a green board under ambient conditions with no surfactant included. 18. The method of claim 15, wherein the dried base mat demonstrates a reduction in modulus of rupture (MOR) value of no greater than 10% compared to an equivalent base mat with no surfactant included.
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