Proposal:
A new client asked us if we could manufacture a 2'x8' and 3'x8' cloud but 2" deep. We had coincidentally just developed our new wall box panel, but we hadn't done a hanging version yet.
Over the next week we developed the new product in-house, we manufactured a prototype, and tested it for strength and rigidity.
Challenges:
- We were worried there would be excessive sag and bowing in a large 3'x8' cloud.
- We were also concerned that a short 2" lip would be difficult to assemble.
- We were not sure if the cloud would stay together, or if the installer would need to reinforce the contact points with construction adhesive, such as PL.
Solution:
- We made 2 to 3 full size prototypes.
- The backing support covered the entire backside of the acoustic cloud, but we had made quite a few holes in the backing, to allow for the installers to grip it, and pull the edges up into the backing. But these holes took away from the rigidity.
- The next prototype we used the full felt sheet for the backing, with just a couple of 2 small slots. This made the box cloud completely rigid. The sag / bowing over 8' was less than 1/16". This is acceptable for a ceiling cloud.
- We also found that we didn't need to use any adhesive, although we still recommended it.
- We also recommended using a 3" depth.
Note:
If the end user wanted to reach NRC values in the 1.10 and above range, all they would have to do is insert Roxul / Roodwool into the cavity of the cloud (ideally wrapped in 1 mil vapor barrier).