Thermo formable acoustical panel

Abstract

Disclosed is both a method and composition for forming a thermo-formable acoustical panel. The panel may be formed from multi-component polymer fibers or mono-filament polymer fibers dispersed in a mineral fiber batt. The polymer fibers are bound to the mineral fibers by the application of heat to form the acoustical panel. The panel exhibits both enhanced flame resistance and thermal insulation.

What is claimed is:  
     
         1 . An acoustical panel comprising: 
 multi-component polymer fibers, each of the polymer fibers having a sheath layer substantially surrounding an inner core, the sheath layer comprising a first polymer having a melting point lower than a melting point of a second polymer comprising the inner core; and    mineral wool.    
     
     
         2 . The acoustical panel of  claim 1 , wherein the first polymer comprising the sheath layer has a melting point of between about 100° C. to about 200° C.  
     
     
         3 . The acoustical panel of  claim 1 , wherein the second polymer comprising the inner core has a melting point of at least about 160° C.  
     
     
         4 . The acoustical panel of  claim 1 , wherein the first polymer comprising the sheath layer is selected from the group consisting of a polyester, a polyethylene, a polyolefin and combinations thereof.  
     
     
         5 . The acoustical panel of  claim 1 , wherein the second polymer comprising the inner core formed from a polymeric material selected from the group consisting of a polyester, polypropylene, and combinations thereof.  
     
     
         6 . The acoustical panel of  claim 5 , wherein the polyester is polyethylene terepthalate.  
     
     
         7 . The acoustical panel of  claim 1 , wherein the mineral wool forms a fiber complex having the multi-component polymer fibers interdispersed within the fiber complex.  
     
     
         8 . The acoustical panel of  claim 1 , wherein the outer layer is bound to the mineral wool.  
     
     
         9 . The acoustical panel of  claim 1 , wherein the panel has an NRC value of at least about 0.65.  
     
     
         10 . The acoustical panel of  claim 1 , further comprising a cellulosic material.  
     
     
         11 . The acoustical panel of  claim 10 , wherein the cellulosic material is selected from the group consisting essentially of newsprint, pulped sisal, hemp abaca and combinations thereof.  
     
     
         12 . The acoustical panel of  claim 10 , wherein the cellulosic material comprises up to about 40% by weight of the panel.  
     
     
         13 . The acoustical panel of  claim 1 , further including a reinforcement fiber having a length between about 0.2 inches to about 2 inches.  
     
     
         14 . The acoustical panel of  claim 1 , wherein the multi-component fibers comprise from about 2% to about 40% by weight of the panel.  
     
     
         15 . The acoustical panel of  claim 1 , wherein the mineral wool comprises from about 60% to 98% by weight of the panel.  
     
     
         16 . The acoustical panel of  claim 1 , further having a density of between about 5 lb./ft 3  to about 40 lb./ft 3 .  
     
     
         17 . The acoustical panel of  claim 16 , wherein the density of the panel is between about 5 lb./ft 3  to about 10 lb./ft 3 .  
     
     
         18 . The acoustical panel of  claim 1 , further including an embossed surface.  
     
     
         19 . The acoustical panel of  claim 1 , further exhibiting a humidity sag test deflection at 90% of less than 0.125 inches.  
     
     
         20 . The acoustical panel of  claim 1 , wherein the panel has a thermal K value of between about 0.22 to about 0.3 BTU-in/hr-ft 2 -° F.  
     
     
         21 . The acoustical panel of  claim 1 , wherein the panel has fire resistance of between about 40 minutes to about 120 minutes according to ASTM E-119.  
     
     
         22 . A method of forming an acoustical panel comprising the steps of: 
 providing multi-component polymer fibers having a sheath layer surrounding an inner core with the sheath layer being comprised of a first polymer having a melting point lower than a melting point of a second polymer comprising the inner core;    dispersing and mixing the polymer fibers with mineral wool fibers to form a fibrous batt;    heating the fibrous batt; and    melting the sheath polymer layer to form the acoustical panel.    
     
     
         23 . The method of  claim 22 , wherein the polymer fibers and mineral fibers are mixed and dispersed in a high velocity air stream.  
     
     
         24 . The method of  claim 22 , further comprising mixing and dispersing the polymer fibers and mineral fibers in water to form a wet mixture.  
     
     
         25 . The method of  claim 22 , further including de-watering the wet mixture to form the fibrous batt.  
     
     
         26 . The method of  claim 22 , wherein the fibrous batt is heated to a temperature above the melting temperature of the first polymer and below the melting temperature of the second polymer.  
     
     
         27 . The method of  claim 22 , further comprising consolidating the formed acoustical panel.  
     
     
         28 . The method of  claim 27 , wherein the formed acoustical panel is consolidated by sequential heating and cooling.  
     
     
         29 . The method of  claim 28 , further comprising pressing the formed acoustical panel.  
     
     
         30 . The method of  claim 22 , wherein the formed acoustical panel is form cured.  
     
     
         31 . The method of  claim 22 , wherein the panel has a thermal K value of between about 0.22 to about 0.3 BTU-in/hr-ft 2 -° F.  
     
     
         32 . The method of  claim 22 , wherein the panel has a fire resistance of between about 40 minutes to about 120 minutes according to ASTM E-119.  
     
     
         33 . A method of forming an acoustical panel comprising the steps of: 
 providing mono-filament polymer fibers;    dispersing and mixing the polymer fibers with mineral wool fibers in an aqueous mix to form a wet fibrous batt;    dewatering the wet fibrous batt to form a dewatered batt;    heating the dewatered batt; and    melting the polymer fibers within the dewatered batt to form the acoustical panel.    
     
     
         34 . The method of  claim 33 , wherein the mono-filament polymer fibers are selected from fibers consisting of polypropylene, polyethylene terepthalate, polyethylene and combinations thereof.  
     
     
         35 . The method of  claim 33 , wherein the panel has a thermal K value of between about 0.22 to about 0.3 BTU-in/hr-ft 2 -° F.  
     
     
         36 . The method of  claim 33 , wherein the panel has a fire resistance of between about 40 minutes to about 120 minutes according to ASTM E-119.  
     
     
         37 . A method of forming an acoustical panel comprising the steps of: 
 providing dispersible polymer particulate binders;    dispersing and mixing the particulate binders with mineral wool fibers in a high velocity air stream to form a fibrous batt;    heating the fibrous batt; and    melting the particulate binders within the fibrous batt to form the acoustical panel.    
     
     
         38 . The method of  claim 37 , wherein the particulate binders are selected from the group consisting of polypropylene, polyesters, cross linkable thermoplastics and combinations thereof.  
     
     
         39 . The method of  claim 37 , further comprising consolidating the formed acoustical panel.  
     
     
         40 . The method of  claim 37 , wherein the formed acoustical panel is consolidated by sequential heating and cooling.  
     
     
         41 . The method of  claim 37 , further comprising pressing the formed acoustical panel.  
     
     
         42 . The method of  claim 37 , further including surface scrimming the formed acoustical panel.  
     
     
         43 . The method of  claim 37 , wherein the panel has a thermal K value of between about 0.22 to about 0.3 BTU-in/hr-ft 2 -° F.  
     
     
         44 . The method of  claim 37 , wherein the panel has a fire resistance of between about 40 minutes to about 120 minutes according to ASTM E-119.  
     
     
         45 . A method of forming an acoustical panel comprising the steps of: 
 providing dispersible polymer particulate binders having a glass transition temperature of between about −50° C. to about 75° C.;    dispersing and mixing the particulate binders with mineral wool fibers in an aqueous mix to form a wet fibrous batt;    dewatering the wet fibrous batt to form a dewatered batt;    heating the dewatered batt;    melting the particulate binders within the dewatered batt to form the acoustical panel; and    thermo-forming the acoustical panel.    
     
     
         46 . The method of  claim 45 , further including applying a scrim coat to the thermo-formed acoustical panel.  
     
     
         47 . The method of  claim 45 , further including applying an organic coating to the thermo-formed acoustical panel.  
     
     
         48 . An acoustical panel comprising: 
 a first layer including multi-component polymer fibers, the polymer fibers having a sheath layer substantially surrounding an inner core, the sheath layer comprising a first polymer having a melting point lower than a melting point of a second polymer comprising the inner core and mineral wool; and    a second layer in contact with the first layer and the second layer including a binder and filler.    
     
     
         49 . The acoustical panel of  claim 48 , wherein the binder is selected from the group consisting of multi-component polymer fibers, monocomponent polymer fibers, thermoplastic particulate, latexes, resins, thermosetting particulates and combinations thereof.  
     
     
         50 . The acoustical panel of  claim 48 , wherein the filler is selected from the group consisting of glass, polymeric materials, cellulose and combinations thereof.  
     
     
         51 . The acoustical panel of  claim 48 , wherein the acoustical panel comprises between about 0.2% to about 20% by weight binder and about 80% to about 99.8% by weight filler.  
     
     
         52 . The acoustical panel of  claim 48 , wherein the panel has a thermal K value of between about 0.22 to about 0.3 BTU-in/hr-ft 2 -° F.  
     
     
         53 . The acoustical panel of  claim 48 , wherein the panel has a fire resistance of between about 40 minutes to about 120 minutes according to ASTM E-119.  
     
     
         54 . A method of forming an acoustical panel comprising the steps of: 
 providing a first mono-filament polymer fiber and a second mono-filament polymer fiber, wherein the melting point of the first polymer fiber is lower than the melting point of the second polymer fiber;    dispersing and mixing the first and second polymer fibers with mineral wool fibers in an aqueous mix to form a wet fibrous batt;    dewatering the wet fibrous batt to form a dewatered batt;    heating the dewatered batt; and    substantially melting the first polymer fiber within the dewatered batt to form the acoustical panel.    
     
     
         55 . The method of  claim 54 , wherein first polymer fiber has a melting point of between about 100° C. to about 200° C.  
     
     
         56 . The method of  claim 54 , wherein the second polymer fiber has a melting point of at least about 160° C.  
     
     
         57 . The method of  claim 54 , wherein the first polymer fiber comprises a material selected from the group consisting of a polyester, a polyethylene, a polyolefin and combinations thereof.  
     
     
         58 . The method of  claim 54 , wherein the second polymer fiber comprises a material selected from the group consisting of a polyester, polypropylene, and combinations thereof.  
     
     
         59 . The method of  claim 54 , wherein the panel has a thermal K value of between about 0.22 to about 0.3 BTU-in/hr-ft 2 -° F.  
     
     
         60 . The method of  claim 54 , wherein the panel has fire resistance of between about 40 minutes to about 120 minutes according to ASTM E-119.  
     
     
         61 . A method of forming an acoustical panel comprising the steps of: 
 providing dispersible polymer particulate binders and polymer fibers;    dispersing and mixing the particulate binders and polymer fibers with mineral wool to form a fibrous mix;    combining the fibrous mix to form a fibrous batt;    heating the fibrous batt; and    substantially melting the particulate binders within the fibrous batt to form the acoustical panel.    
     
     
         62 . The method of  claim 61 , wherein the particulate binders, polymer fibers and mineral wool fibers are mixed in a high velocity air stream.  
     
     
         63 . The method of  claim 61 , further including adding water to the fibrous mix.  
     
     
         64 . The method of  claim 61 , wherein the panel has a thermal K value of between about 0.22 to about 0.3 BTU-in/hr-ft 2 -° F.  
     
     
         65 . The method of  claim 61 , wherein the panel has fire resistance of between about 40 minutes to about 120 minutes according to ASTM E-119.