Acoustical tile

Abstract

The present invention relates to an acoustical tile that includes a core and a surface treatment. The surface treatment comprises a formaldehyde-free latex binder, the binder including at least one formaldehyde-free biocide. The present invention also provides a process of manufacturing an acoustical tile.

The invention claimed is: 
     
       1. An acoustical tile comprising a core and a surface treatment, wherein the surface treatment comprises a surface treatment composition that is applied to the core, and wherein the surface treatment composition prior to drying comprises:
 from about 30 to about 50 weight % solvent; 
 from about 40 to about 60 weight % filler; 
 from about 2 to about 15 weight % TiO 2 ; 
 from about 2 to about 20 weight % formaldehyde-free and non-formaldehyde-emitting latex; 
 from about 0.25 to about 1.00 weight % dispersant; 
 from about 0.01 to about 1.00 weight % formaldehyde-free and non-formaldehyde-emitting thickener, wherein the formaldehyde-free and non-formaldehyde-emitting thickener is a material selected from the group consisting of methyl cellulose, methylhydroxycellulose methylhydroxyethylcellulose, methylhydroxypropylcellulose, hydroxypropyl cellulose, sodium carboxymethylcellulose, hydroxyethylcellulose, and soy-protein derived polymers, or combinations thereof; 
 from about 0.10 to about 1.00 weight % surfactant; 
 from about 0.05 to about 0.50 weight % defoamer; and 
 from about 0.01 to about 1.50 weight % formaldehyde-free and non-formaldehyde-emitting biocide, and wherein the acoustical tile is formaldehyde-free and does not emit formaldehyde. 
 
     
     
       2. The acoustical tile of  claim 1 , wherein the biocide is an isothiazolin-3-one. 
     
     
       3. The acoustical tile of  claim 1 , wherein the biocide is a combination of 1,2-benzisothiazolin-3-one and methyl-4-isothiazolin-3-one. 
     
     
       4. The acoustical tile of  claim 1 , wherein the core comprises a fiber selected from the group consisting of a glass fiber, a mineral wool fiber and mixtures thereof, wherein the mineral wool fiber is selected from the group consisting of slag wool, rock wool, basalt wool, and mixtures thereof, wherein the core further comprises a member selected from the group consisting of a calcium sulfate material, boric acid, kaolin clay, guar gum, sodium hexametaphosphate, and mixtures thereof, the tile comprises a backing selected from the group consisting of bleached paper, unbleached paper, and kraft/aluminum foil. 
     
     
       5. The acoustical tile of  claim 1  further comprising zinc 1-hydroxy-2(1H)-pyridinethione. 
     
     
       6. The acoustical tile of  claim 1 , wherein the tile has a formaldehyde release or emission that is below a quantifiable limit of about 1 μg/m 3 . 
     
     
       7. The acoustical tile of claim 1, wherein the core is formed of a mineral wool fiber. 
     
     
       8. The acoustical tile of claim 1, wherein the tile has a formaldehyde-free and non-formaldehyde-emitting fire resistant back coating. 
     
     
       9. A formaldehyde-free acoustical tile consisting essentially of a core and a surface treatment, wherein the surface treatment comprises a surface treatment composition that is applied to the core:
 wherein the surface treatment has a formaldehyde release or emission that is below a quantifiable limit of 1 μg/m 3  and the surface treatment composition prior to drying comprises:   from about 30 to about 50 weight % solvent;   from about 40 to about 60 weight % filler;   from about 2 to about 15 weight % TiO 2 ;   from about 2 to about 20 weight % latex that has a formaldehyde release or emission that is below a quantifiable limit of 1 μg/m 3 ;   from about 0.25 to about 1.00 weight % dispersant;   from about 0.01 to about 1.00 weight % thickener that has a formaldehyde release or emission that is below a quantifiable limit of 1 μg/m 3  and comprises a material selected from the group consisting of methyl cellulose, methylhydroxyethylcellulose, methylhydroxypropylcellulose, hydroxypropyl cellulose, sodium carboxymethylcellulose, hydroxyethylcellulose, and soy-protein derived polymers, or combinations thereof;   from about 0.10 to about 1.00 weight % surfactant;   from about 0.05 to about 0.50 weight % defoamer; and   from about 0.01 to about 1.50 weight % biocide that has a formaldehyde release or emission that is below a quantifiable limit of 1 μg/m 3  and is selected from the group consisting of 1,2,-benzisothiazolin-3-one, blends of 1,2,-benzisothiazolin-3-one and 2-methyl-4-isothiazolin-3-one, 5-chloro-2-methyl-4-isothiazolin-3-one, blends of 5-chloro-2-methyl-4-isothiazolin-3-one and 2-methyl-4-isothiazolin-3-one, zinc 1-hydroxy-2(1H)-pyridinethione, blends of zinc 1-hydroxy-2(1H)-pyridinethione and zinc oxide, and 2-n-octyl-4-isothiazolin-3-one; and   wherein the core comprises a fiber selected from the group consisting of glass fiber, mineral wool fiber and mixtures thereof, wherein the mineral wool fiber is selected from the group consisting of slag wool, rock wool, basalt wool, and mixtures thereof, wherein the core further comprises a member selected from the group consisting of a calcium sulfate material, boric acid, kaolin clay, guar gum, sodium hexametaphosphate, and mixtures thereof; and   wherein the acoustical tile has a formaldehyde release or emission that is below a quantifiable limit of 1 μg/m 3 .   
     
     
       10. The acoustical tile of claim 9, wherein the core is formed of a mineral wool fiber. 
     
     
       11. The acoustical tile of claim 9, wherein the tile has a fire resistant back coating having a formaldehyde release or emission that is below a quantifiable limit of 1 μg/m 3 .