US2002096278A1PendingUtilityA1

Durable acoustical panel and method of making the same

Assignee: ARMSTRONG WORLD IND INCPriority: May 24, 2000Filed: May 18, 2001Published: Jul 25, 2002

Est. expiryMay 24, 2020(expired)· nominal 20-yr term from priority

Inventors:Robert E. Foster Larry R. Parks James Lokey John Janczura Robert G. Ganse Barry Buhay Walter Chamberlain John Felegi, Jr.

C04B 26/02D21F 9/00Y10T428/12236C04B 2111/52C04B 26/28E04B 9/0464E04B 9/0457B44C 5/0461Y10T428/249928E04B 9/001D21J 1/08B44C 5/0469C04B 2111/00612D21J 1/16Y10T428/249925D21H 27/38E04B 9/045B44C 5/04Y02W30/91

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Claims

Abstract

An acoustical panel has a fiberboard which includes a fibrous filler and a base binder, and a nodulated overlay disposed on the fiberboard, wherein the overlay includes nodulated wool and an overlay binder and has a substantially smooth surface. In one embodiment of the present invention, the fibrous filler is mineral wool and the base binder is granular starch. In an another embodiment of the present invention, the nodulated wool is nodulated mineral wool and the overlay binder is cooked pearl cornstarch. A method of making the durable acoustical panel in accordance with the present invention is disclosed. Initially, an aqueous slurry comprising a fibrous filler, a base binder, and water is formed. The aqueous slurry is deposited onto a moving foraminous support wire to form an aqueous felt, thereby creating a continuous process. Thereafter, the aqueous felt is de-watered to form a wet felt. The wet felt is coated with an aqueous overlay comprising nodulated wool, overlay binder, and water and has a substantially smooth surface. Finally, the wet felt and aqueous overlay are dried to form the ceiling panel.

Claims

exact text as granted — not AI-modified

What is claimed is:

1 . A durable acoustical panel comprising:
a fiberboard comprising a fibrous filler and a base binder, and a nodulated overlay disposed on the fiberboard, wherein the overlay comprises nodulated wool and an overlay binder and has a substantially smooth surface.

2 . The panel as claimed in claim 1 , wherein the fiberboard comprises about 30 to about 90 dry wt. % fibrous filler and about 3 to about 10 dry wt. % base binder.

3 . The panel as claimed in claim 1 , wherein the fibrous filler is selected from mineral wool, polyester fibers, polypropylene fibers, NYLON fibers, carbon fibers, cellulosic fibers from hard pulped wood, cellulosic fibers from soft pulped wood, wollastonite, fiberglass, rock wool, and combinations thereof.

4 . The panel as claimed in claim 1 , wherein the fibrous filler is mineral wool.

5 . The panel as claimed in claim 1 , wherein the base binder is granular starch.

6 . The panel as claimed in claim 1 , wherein the base binder is selected from pearl cornstarch, wheat starch, potato starch, polystyrene, polyvinyl acetate, polystyrene acrylic, styrene butadiene, and combinations thereof.

7 . The panel as claimed in claim 1 , wherein the fiberboard further comprises up to about 15 dry wt. % of cellulose fibers derived from primary paper fibers, secondary paper fibers, or cotton linters.

8 . The panel as claimed in claim 1 , wherein the fiberboard further comprises about 0.02 to about 0.2 dry wt. % of a retention agent.

9 . The panel as claimed in claim 1 , wherein the fiberboard further comprises:

non-fibrous filler
0 to about 20 dry wt. %

expanded perlite
0 to about 30 dry wt. %

boric acid
0 to about 1 dry wt. %

dry broke
0 to about 40 dry wt. %

additives
0 to about 0.5 dry wt. %,

wherein the additives are selected from dispersants, defoaming agents, fungicides, and combinations thereof and wherein at least one of non-fibrous filler, expanded perlite, boric acid, dry broke, and additive is present.

10 . The panel as claimed in claim 9 , wherein the fiberboard further comprises cellulose fibers derived from primary paper fibers, secondary paper fibers, or cotton linters.

11 . The panel as claimed in claim 9 , wherein the filler is selected from kaolin clay, calcium carbonate, silica, vermiculite, ball clay, talc, mica, gypsum, and combinations thereof.

12 . The panel as claimed in claim 1 , wherein the overlay binder is a starch or a foaming agent.

13 . The panel as claimed in claim 12 , wherein the starch is selected from pearl cornstarch, wheat starch, potato starch, and combinations thereof.

14 . The panel as claimed in claim 1 , wherein the overlay binder is a cooked starch.

15 . The panel as claimed in claim 14 , wherein the cooked starch is cooked pearl cornstarch.

16 . The panel as claimed in claim 12 , wherein the foaming agent is selected from bis(2-hydroxyethyl)tallowalkylamine, sodium laureth (1) sulfate, ammonium deceth (3) sulfate, ammonium C 6-10 alcohol ethoxysulfate, sodium dodecylbenzene sulfonate, and combinations thereof.

17 . The panel as claimed in claim 12 , wherein the foaming agent is bis(2-hydroxyethyl) tallowalkylamine.

18 . The panel as claimed in claim 12 , wherein the overlay further comprises about 2 to about 8 dry wt. % of a granular binder when the overlay binder includes a foaming agent.

19 . The panel as claimed in claim 17 , wherein the overlay further comprises about 2 to about 8 dry wt. % of a granular binder.

20 . The panel as claimed in claim 18 , wherein the granular binder is selected from pearl cornstarch, wheat starch, potato starch, polystyrene, polyvinyl acetate, polystyrene acrylics, styrene butadiene, and combinations thereof.

21 . The panel as claimed in claim 19 , wherein the granular binder is selected from pearl cornstarch, wheat starch, potato starch, polystyrene, polyvinyl acetate, polystyrene acrylics, styrene butadiene, and combinations thereof.

22 . The panel as claimed in claim 1 , wherein the overlay further comprises up to about 10 dry wt. % of cellulose fibers.

23 . The panel as claimed in claim 22 , wherein the cellulose fibers are derived from primary paper fibers, secondary paper fibers, or cotton linters.

24 . The panel as claimed in claim 1 , wherein the overlay further comprises:

non-fibrous filler
0 to about 15 dry wt. %

expanded perlite
0 to about 20 dry wt. %

boric acid
0 to about 1 dry wt. %

dry broke
0 to about 35 dry wt. %

slipping agent
0 to about 1 dry wt. %

additives
0 to about 1 dry wt. %,

wherein the additives are selected from dispersants, defoaming agents, fungicides, and combinations thereof, and wherein at least one of non-fibrous filler, expanded perlite, boric acid, dry broke, and additives is present.

25 . The panel as claimed in claim 24 , wherein the non-fibrous filler is selected from kaolin clay, calcium carbonate, silica, vermiculite, ball clay, talc, mica, gypsum, and combinations thereof.

26 . The panel as claimed in claim 24 , wherein the slipping agent is selected from isostearamidopropyl ethyl dimonium ethosulfate and polyethylene oxide.

27 . The panel as claimed in claim 1 , wherein the nodulated wool is selected from nodulated mineral wool, nodulated metal slag wool, nodulated fiberglass, nodulated rock wool, and combinations thereof.

28 . The panel as claimed in claim 1 , wherein the nodulated wool is nodulated mineral wool.

29 . A method of making a durable acoustical panel comprising:
(a) forming an aqueous slurry comprising a fibrous filler, a base binder, and water; (b) depositing the aqueous slurry onto a moving foraminous support wire to form an aqueous felt; (c) de-watering the aqueous felt to form a wet felt; (d) coating the wet felt with an aqueous overlay comprising nodulated wool, overlay binder, and water, wherein the aqueous overlay has a substantially smooth surface; and (e) drying the wet felt and aqueous overlay to form the panel.

30 . The method of claim 29 , wherein the substantially smooth surface has a surface texture of about less than 100 ml/sq. ft.

31 . The method of claim 29 , wherein in step (c) the aqueous felt is de-watered by pressing.

32 . The method of claim 29 , wherein in step (c) the aqueous felt is de-watered by operably engaging a vacuum with the aqueous felt.

33 . The method of claim 29 , wherein in step (c) the aqueous felt is de-watered by pressing and then a vacuum is operably employed to withdraw water from the aqueous felt.

34 . The method of claim 29 , further comprising between steps (d) and (e):
partially de-watering the wet felt and aqueous overlay.

35 . The method of claim 34 , wherein the wet felt and aqueous overlay are partially de-watered by operably engaging a vacuum with the wet felt.

36 . The method of claim 35 , further comprising pressing the partially de-watered wet felt and aqueous overlay.

37 . The method of claim 29 , further comprising between steps (c) and (d) partially perforating the wet felt.

38 . The method of claim 29 , further comprising between steps (d) and (e) screeding the aqueous overlay to a substantially uniform thickness across the wet felt.

39 . The method of claim 34 , wherein the aqueous overlay is screeded to a substantially uniform thickness across the wet felt prior to partially de-watering the wet felt and aqueous overlay.

40 . The method of claim 29 , wherein in step (e) the wet felt and aqueous overlay are dried at a temperature from about 400° F. to about 750° F.

41 . The method of claim 29 , wherein in step (a) the aqueous slurry is formed by substantially uniformly mixing the fibrous filler, the base binder, and water.

42 . The method of claim 29 , wherein the aqueous slurry of step (a) is a substantially uniform aqueous mixture having between about 2 to about 13 wt. % solids and comprises:

fibrous filler
about 30 to about 90 dry wt. %

base binder
about 3 to about 10 dry wt. %

cellulose fibers
0 to about 15 dry wt. %

retention aid
about 0.02 to 0.2 dry wt. %

non-fibrous filler
0 to about 20 dry wt. %

expanded perlite
0 to about 30 dry wt. %

boric acid
0 to about 1 dry wt. %

dry broke
0 to about 40 dry wt. %

additives
0 to about 0.5 dry wt. %,

wherein the additives are selected from dispersants, defoaming agents, fungicides, and combinations thereof.

43 . The method of claim 42 , wherein the fibrous filler is selected from mineral wool, polyester fibers, polypropylene fibers, NYLON fibers, carbon fibers, cellulosic fibers from hard pulped wood, cellulosic fibers from soft pulped wood, wollastonite, fiberglass, rock wool, and combinations thereof.

44 . The method of claim 42 , wherein the fibrous filler is mineral wool.

45 . The method of claim 42 , wherein the base binder is granular starch.

46 . The method of claim 45 , wherein the base binder is selected from pearl cornstarch, wheat starch, potato starch, polystyrene, polyvinyl acetate, polystyrene acrylics, styrene butadiene, and combinations thereof.

47 . The method of claim 42 , wherein the cellulose fibers are derived from primary paper fibers, secondary paper fibers, or cotton linters.

48 . The method of claim 42 , wherein the non-fibrous filler is selected from kaolin clay, calcium carbonate, silica, vermiculite, ball clay, talc, mica, gypsum, and combinations thereof.

49 . The method of claim 29 , wherein the aqueous overlay of step (d) is formed by the steps comprising:
forming a mixture comprising an overlay binder, wool fibers, and water; and agitating the mixture for a sufficient amount of time to substantially uniformly distribute and nodulate the wool fibers.

50 . The method of claim 29 , wherein the aqueous overlay is a substantially uniform aqueous mixture having between about 15 to about 35 wt. % solids and the overlay binder is selected from a cooked starch and a foaming agent.

51 . The method of claim 50 , wherein the aqueous overlay comprises:

nodulated wool
about 50 to about 85 dry wt. %

cellulose fibers
0 to about 10 dry wt. %

non-fibrous filler
0 to about 15 dry wt. %

expanded perlite
0 to about 20 dry wt. %

boric acid
0 to about 1 dry wt. %

dry broke
0 to about 35 dry wt. %

slipping agent
0 to about 1 dry wt. %

additives
0 to about 1 dry wt. %,

wherein the additives are selected from dispersants, defoaming agents, fungicides, and combinations thereof.

52 . The method of claim 51 , wherein the overlay binder is cooked starch comprising about 5 to about 12 dry wt. % of the aqueous overlay and is selected from pearl cornstarch, wheat starch, potato starch, and combinations thereof.

53 . The method of claim 51 , wherein the overlay binder is a foaming agent comprising about 0.1 to about 1 dry wt. % of the aqueous overlay and is selected from bis(2-hydroxyethyl) tallowalkylamine, sodium laureth (1) sulfate, ammonium deceth (3) sulfate, ammonium C 6-10 alcohol ethoxysulfate, sodium dodecylbenzene sulfonate, and combinations thereof.

54 . The method of claim 53 , wherein the overlay further comprises about 2 to about 8 wt. % of a granular binder and 0 to about 1 dry wt. % aluminum sulfate.

55 . The method of claim 54 , wherein the granular binder is selected from pearl cornstarch, wheat starch, potato starch, polystyrene, polyvinyl acetate, polystyrene acrylics, styrene butadiene, and combinations thereof.

56 . The method of claim 51 , wherein the cellulose fibers are derived from primary paper fibers, secondary paper fibers, or cotton linters.

57 . The method of claim 52 , wherein the filler is selected from kaolin clay, calcium carbonate, silica, vermiculite, ball clay, talc, mica, gypsum, and combinations thereof.

58 . The method of claim 52 , wherein the slipping agent is selected from isostearamidopropyl ethyl dimonium ethosulfate and polyethylene oxide.

59 . The method of claim 52 , wherein the additives are selected from dispersants, defoaming agents, fungicides, and combinations thereof, with the proviso that defoaming agents are absent in the overlay when a foaming agent is present therein.

60 . The method of claim 52 , wherein the nodulated wool is selected from nodulated mineral wool, nodulated metal slag wool, nodulated chopped glass, nodulated rock wool, and combinations thereof.

61 . A durable acoustical panel comprising:
a fiberboard comprising a fibrous filler and a base binder, and a nodulated overlay disposed on the fiberboard, wherein the overlay comprises nodulated wool and an overlay binder and has a surface texture of about less than 100 ml/sq. ft.

62 . The panel as claimed in claim 61 , wherein the fiberboard comprises about 30 to about 90 dry wt. % fibrous filler and about 3 to about 10 dry wt. % base binder.

63 . The panel as claimed in claim 61 , wherein the fibrous filler is mineral wool.

64 . The panel as claimed in claim 61 , wherein the base binder is granular starch.

65 . The panel as claimed in claim 61 , wherein the fiberboard further comprises about 0.02 to about 0.2 dry wt. % of a retention agent.

66 . The panel as claimed in claim 61 , wherein the fiberboard further comprises:

non-fibrous filler
0 to about 20 dry wt. %

expanded perlite
0 to about 30 dry wt. %

boric acid
0 to about 1 dry wt. %

dry broke
0 to about 40 dry wt. %

additives
0 to about 0.5 dry wt. %,

67 . The panel as claimed in claim 61 , wherein the overlay further comprises:

non-fibrous filler
0 to about 15 dry wt. %

expanded perlite
0 to about 20 dry wt. %

boric acid
0 to about 1 dry wt. %

dry broke
0 to about 35 dry wt. %

slipping agent
0 to about 1 dry wt. %

additives
0 to about 1 dry wt. %,

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