Glass fiber reinforced facer mat

Patent metadata

Field	Value
Publication number	US-10428450-B2
Application number	US-201514979923-A
Country	US
Kind code	B2
Filing date	Dec 28, 2015
Priority date	Jul 25, 2012
Publication date	Oct 1, 2019
Grant date	Oct 1, 2019

Abstract

Embodiments of the invention provide fiber mat facers, ceiling panels, and method of manufacturing the same. A fiber mat facer may include a non-woven web of fibers having a first group of fibers with an average fiber diameter from about 6 μm to about 20 μm and a second group of fibers with an average fiber diameter from about 0.5 μm to about 5 μm. The fiber mat facer may also include a binder to bond together the non-woven web of fibers into the fiber mat. The binder may include a water repellant additive. The binder and/or fiber mat facer may further include an additive that enhances the opacity of the fiber mat facer. The fiber mat facer may also include a paint applied to an outer surface of the facer. The paint may include an additive that enhances the visual appeal of the facer and/or ceiling panel.

First claim

What is claimed is:

1. A fiber mat facer comprising:
a non-woven web of fibers comprising:
a first group of fibers having an average fiber diameter from about 6 μm to about 20 μm; and
a second group of fibers having an average fiber diameter from about 0.5 μm to about 5 μm;

a binder to bond together the non-woven web of fibers into a fiber mat, the binder including a water repellant additive and a dispersant additive;
an additive that enhances the opacity of the mat; and
a paint atop an outer surface of the fiber mat, wherein the paint comprises a weak acid having a pKa between −2 and 14, and wherein the weak acid comprises greater than about 0.08 wt. % and below about 0.1 wt. % of the dry weight of the paint; and
wherein the water repellant additive comprises a stearylated melamine water repellant comprising between about 0.5 wt. % and 0.7 wt. % of the total weight of the fiber mat, and wherein the fiber mat has a surface energy of between about 40 dyne/cm and about 50 dyne/cm.

2. The fiber mat facer of claim 1 , where in the weak acid comprises one or more acids selected from the group consisting of: sodium tetrafluoroborate and sodium hypochlorite.

3. The fiber mat facer of claim 1 , wherein the binder comprises an amount of an anti-oxidant.

4. The fiber mat facer of claim 3 , wherein the anti-oxidant comprises sodium tetrafluoroborate.

5. The fiber mat facer of claim 1 , wherein the first group of fibers have an average fiber diameter of about 11 μm.

6. The fiber mat facer of claim 1 , wherein the second group of fibers have an average fiber diameter of about 3 μm.

7. The fiber mat facer of claim 1 wherein the additive that enhances opacity comprises white pigment.

8. The fiber mat facer of claim 7 , wherein the white pigment comprises between about 0.5 wt. % and 2.0 wt. % of the total weight of the fiber mat.

9. The fiber mat facer of claim 1 , wherein the first group of fibers comprises between about 60 wt. % and 71 wt. % of the total weight of the fiber mat.

10. The fiber mat facer of claim 1 , wherein the second group of fibers comprises between about 5 wt. % and 20 wt. % of the total weight of the fiber mat.

11. The fiber mat facer of claim 1 , wherein the binder comprises between about 15 wt. % and 25 wt. % of the total weight of the fiber mat.

12. The fiber mat facer of claim 1 , wherein the binder comprises a hexamethoxymethylolmelamine crosslinking agent dispersed throughout the non-woven web of fibers.

13. The fiber mat facer of claim 1 , wherein fibers are glass fibers selected from the group consisting of E glass, C glass, T glass, sodium borosilicate glass, and mixtures thereof.

14. A faced ceiling panel comprising:
a fiber mat facer affixed to at least one surface of the ceiling panel, the fiber mat facer comprising:
a non-woven web of fibers comprising:
a first group of fibers having an average fiber diameter from about 6 μm to about 20 μm;
a second group of fibers having an average fiber diameter from about 0.5 μm to about 5 μm;

a binder chemistry to bond together the non-woven web of fibers into a fiber mat, the binder chemistry including a water repellant additive and an acrylic binder having a dispersant additive;
an additive that enhances the opacity of the fiber mat facer; and
a paint atop an outer surface of the fiber mat, wherein the paint comprises a weak acid having a pKa between −2 and 14, and wherein the weak acid comprises greater than about 0.08 wt. % and below about 0.1 wt. % of the dry weight of the paint;
wherein the fiber mat has a surface energy of between about 40 dyne/cm and about 50 dyne/cm.

15. The ceiling panel of claim 14 , wherein the ceiling panel comprises a panel selected from the group consisting of:
glass wool;
mineral wool;
fiberboard;
wood fibers; and
gypsum.

16. The fiber mat facer of claim 1 , wherein the surface energy comprises a dispersive component and a polar component balanced at an approximate ratio of 2:1.

17. The fiber mat facer of claim 16 , wherein the dispersive component has a value of about 30 dyne/cm, and wherein the polar component ranges between about 10 dyne/cm and about 20 dyne/cm.

18. The fiber mat facer of claim 1 , further comprises an inner surface configured to bind with a ceiling panel, wherein the second group of fibers decreases an air permeability value of the outer surface to a range between about 300 cfm/ft 2 and about 500 cfm/ft 2 so as to limit the paint to remain on the outer surface.

19. The fiber mat facer of claim 1 , wherein the weak acid has a pKa between about 4 and 12.

20. The ceiling panel of claim 1 , wherein the weak acid has a pKa between about 9 and 12.

21. The fiber mat facer of claim 14 , wherein the water repellant additive comprises a stearylated melamine water repellant, and wherein the stearylated melamine water repellant comprises between about 0.5 wt. % and 0.7 wt. % of the total weight of the fiber mat.

Assignees

• Johns Manville

Inventors

• Grove Iii Dale Addison
• Jaffee Alan Michael
• Weller Jr David Earl
• Giovannoni Richard Thomas

Classifications

• Y10T442/609

  Cross-sectional configuration of strand or fiber material is specified · CPC title

• D04H13/008 Primary

  Glass fibre products; Complete installations for making them · CPC title

• D04H1/58

  by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives (in combination with needling D04H1/488) · CPC title

• E04C2/043

  of plaster (E04C2/049 takes precedence) · CPC title

• E04F13/0866

  composed of several layers, e.g. sandwich panels or layered panels (layered products as such in general B32B; producing decorative panels or veneers B44C5/04; E04F13/0864, E04F13/0875 take precedence) · CPC title