Acoustic ceiling board with improved aesthetics

Abstract

Described herein are acoustical panels, comprising: a substrate; a non-woven veil having an airflow resistance of greater than 45 mks rayls, comprising: from about 20 wt. % to about 60 wt. % glass fibers; from about 40 wt. % to about 80 wt. % of a filler; and from about 110 dry g/m2 to about 135 dry g/m2 of a coating. Methods of making and using the panels are also described.

1 . An acoustical structure comprising:
 a dry coating comprising non-fibrous filler and fibrous filler;   a first layer having a first major surface opposite a second major surface, the first layer comprising fibrous material different from the fibrous filler;   wherein the dry coating is present atop the first major surface of the first layer in an amount ranging from about 110 g/m 2  to about 135 g/m 2  and the acoustical panel has an airflow resistance of about 300 mks rayls or less.   
     
     
         2 . The acoustical structure of  claim 1 , wherein the non-fibrous filler comprises a material selected from calcium carbonate, dolomite, titanium dioxide, barium sulfate, clay, mica, limestone, silica, talc, perlite, gypsum, wollastonite, calcite, aluminum trihydrate, zinc, a polymer, a pigment and a combination of two or more thereof. 
     
     
         3 . The method according to  claim 2 , wherein the non-fibrous filler comprises aluminum trihydrate. 
     
     
         4 . The acoustical structure of  claim 1 , wherein the non-fibrous filler has a d 50  of from about 50 microns to about 300 microns. 
     
     
         5 . The acoustical structure of  claim 1 , wherein the first layer is a non-woven veil. 
     
     
         6 . The acoustical structure according to  claim 1 , wherein the dry coating further comprises polymer binder. 
     
     
         7 . The acoustical structure according to  claim 1 , wherein the first layer is substantially free of punch holes, wheel abrasions, embossing or erosion. 
     
     
         8 . An acoustical structure comprising:
 a dry coating comprising non-fibrous filler and fibrous filler;   a first having a first major surface opposite a second major surface, the layer comprising fibrous material different from the fibrous filler;   a second layer having an upper surface opposite a lower surface;   wherein the dry coating is present atop the first major surface of the first layer in an amount ranging from about 110 g/m 2  to about 135 g/m 2  and the acoustical panel has an airflow resistance of about 300 mks rayls or less; and   wherein the second major surface of the first layer is adjacent to the lower surface of the second layer.   
     
     
         9 . The acoustical structure of  claim 8 , wherein the non-fibrous filler comprises a material selected from calcium carbonate, dolomite, titanium dioxide, barium sulfate, clay, mica, limestone, silica, talc, perlite, gypsum, wollastonite, calcite, aluminum trihydrate, zinc, a polymer, a pigment and a combination of two or more thereof. 
     
     
         10 . The method according to  claim 9 , wherein the non-fibrous filler comprises aluminum trihydrate. 
     
     
         11 . The acoustical structure of  claim 8 , wherein the non-fibrous filler has a d 50  of from about 50 microns to about 300 microns. 
     
     
         12 . The acoustical structure of  claim 8 , wherein the substrate is a non-woven veil. 
     
     
         13 . The acoustical structure according to  claim 8 , wherein the dry coating further comprises polymer binder. 
     
     
         14 . The acoustical structure according to  claim 8 , wherein the first layer is affixed to the second layer by an adhesive 
     
     
         15 . The method according to  claim 8 , wherein the first layer is substantially free of punch holes, wheel abrasions, embossing or erosion. 
     
     
         16 . The method according to  claim 8 , wherein the second layer is substantially free of punch holes, wheel abrasions, embossing or erosion. 
     
     
         17 . An acoustical structure comprising:
 a dry coating comprising non-fibrous filler and fibrous filler;   a non-woven veil having a first major surface opposite a second major surface, the non-woven veil comprising fibrous material different from the fibrous filler;   a fibrous body having an upper surface opposite a lower surface;   wherein the dry coating is present atop the first major surface of the first layer in an amount ranging from about 110 g/m 2  to about 135 g/m 2  and the acoustical panel has an airflow resistance of about 300 mks rayls or less; and   wherein the second major surface of the non-woven veil and the lower surface of the fibrous body are bonded together by an adhesive.   
     
     
         18 . The acoustical structure of  claim 17 , wherein the non-fibrous filler comprises a material selected from calcium carbonate, dolomite, titanium dioxide, barium sulfate, clay, mica, limestone, silica, talc, perlite, gypsum, wollastonite, calcite, aluminum trihydrate, zinc, a polymer, a pigment and a combination of two or more thereof. 
     
     
         19 . The method according to  claim 17 , wherein the non-fibrous filler comprises aluminum trihydrate. 
     
     
         20 . The acoustical structure of  claim 17 , wherein the non-fibrous filler has a d 50  of from about 50 microns to about 300 microns.