Basalt Fiber Acoustic Panel
Patent Number: US 11769477 Grant Date: 2023-09-26 Filing Date: 2022-11-09
Overview
Filed on November 9, 2022 and granted on September 26, 2023, this patent protects an acoustical panel design that replaces traditional fiberglass structural mats and framing with a woven basalt textile cover wrapped around a mineral wool absorbent core. Drafting emphasized both material engineering and practical manufacture: the basalt cloth provides mechanical support and edge stability so panels can be produced and installed without separate structural boards or frames, while the Rockwool-and-resin core retains targeted sound‑absorbing performance. The prosecution highlights measurable manufacturing and safety advantages—basalt filament diameters of about 10–20 μm sit well above fine particulate respiratory thresholds, and the basalt cover contributes to substantially improved fire and smoke performance compared with fiberglass-faced alternatives. The application was filed for inventors based in Amarillo, TX and assigned to JayVic LLC (Amarillo, TX); the claims carefully capture dimensional and compositional ranges to preserve both functional and regulatory benefits.
Key Features
- Woven basalt cover that wraps and adheres to an absorbent mineral wool core, providing structural support and eliminating separate structural mats
- Mineral wool (Rockwool) core ranges: density ~2.5–4.5 lb/ft3, thickness ~35–45 mm, core binder ~1.75–2.75%
- Basalt filament diameter ~10–20 μm for handling safety and improved fire resistance
- Demonstrated improvement in fire/smoke ratings and reduced manufacturing hazards
This patented solution advances safer, lower‑complexity acoustic treatments for ceilings and interiors, with clear relevance to building construction, venue acoustics, and fire‑sensitive environments.
Invention Details
Abstract: A sound absorbing panel assembly comprising the woven basalt material. The sound absorbing panel assembly comprises a height, a width, a length, a cover and an absorbent panel. The cover comprises a woven basalt material. The absorbent panel comprises a sound absorbent acoustic panel. The absorbent panel is covered by the cover.
Summary of the Invention: A sound absorbing panel assembly comprising a woven basalt material. Said sound absorbing panel assembly comprises a height, a width, a length, a cover and an absorbent panel. Said cover comprises said woven basalt material. Said absorbent panel comprises a sound absorbent acoustic panel. Said absorbent panel is covered by said cover.
Said sound absorbing panel assembly comprising said woven basalt material. Said sound absorbing panel assembly comprises said height, said width, said length, said cover and said absorbent panel. Said cover comprises said woven basalt material. Said absorbent panel comprises a sound absorbent acoustic panel. Said absorbent panel is covered by said cover. Said woven basalt material comprises basalt fibers woven into a cloth. Said woven basalt material wraps around and adheres to said absorbent panel. Said woven basalt material provides a structural support to said sound absorbing panel assembly thereby eliminating the need for a structural mats. Said absorbent panel comprises Rockwool and resin. A rockwool mat comprising materials characterized by a core density and a core binder percentage. said core density is between 2½-4½ pounds/cubic-foot. said core binder percentage is between 1¾-2¾ percent. Said rockwool mat weighs between ¼-½ oz. Said rockwool mat comprises a thickness between 35-45 mm.
Patent Document
Related: Mechanical Engineering | Acoustics | Construction | Materials | Safety Systems | Amarillo, Texas | Shannon Warren, Patent Attorney