Method for production of acoustical panels

Patent metadata

Field	Value
Publication number	US-10464846-B2
Application number	US-201715680074-A
Country	US
Kind code	B2
Filing date	Aug 17, 2017
Priority date	Aug 17, 2017
Publication date	Nov 5, 2019
Grant date	Nov 5, 2019

Abstract

A method of decreasing the water load needed to form a fibrous panel. The process includes admixing a mineral wool, a cellulose, and a binder to provide a pre-mixed slurry, admixing a mineral filler with water to provide a mineral filler slurry, admixing the pre-mixed slurry and the mineral filler slurry to form a dispersion, flowing the dispersion onto a foraminous support wire to provide a green board, dewatering the green board to form a dewatered green board and drying the dewatered green board to provide a fibrous panel.

First claim

What is claimed:

1. A method of preparing a fibrous panel, comprising:
admixing a mineral wool, a cellulosic fiber, and a binder with water to provide a pre-mixed slurry;
admixing a mineral filler with water to provide a mineral filler slurry;
introducing the pre-mixed slurry to a headbox of a forming machine;
injecting the mineral filler slurry into the headbox and mixing with the pre-mixed slurry to form a dispersion;
flowing the dispersion onto a moving foraminous support wire to provide a green board;

dewatering the green board to form a dewatered green board and;
drying the dewatered green board to provide a fibrous panel.

2. The method of claim 1 , wherein the cellulosic fiber is selected from recycled newsprint, Over Issued Newspaper (OIN), Old Magazine (OMG), and any combination thereof.

3. The method of claim 1 , wherein the cellulosic fiber is recycled newsprint.

4. The method of claim 1 , wherein the cellulosic fiber is present in an amount between about 10% to about 15% by weight of the total dry solids content of the fibrous panel.

5. The method of claim 1 , wherein the binder is selected from starch, reconstituted paper products, and any combination thereof.

6. The method of claim 1 , wherein the binder is an unmodified corn starch.

7. The method of claim 1 , wherein the binder is present in an amount between about 6% and 14% by weight of the total dry solids content of the fibrous panel.

8. The method of claim 1 , wherein the mineral wool is present in amount between about 15% to about 25% by weight of the total dry solids content of the fibrous panel.

9. The method of claim 1 , wherein the mineral filler is selected from expanded perlite, expanded vermiculite, expanded clay, and any combination thereof.

10. The method of claim 1 , wherein the mineral filler is expanded perlite.

11. The method of claim 1 , wherein the mineral filler is present in an amount between about 50% to about 70% by weight of the total dry solids content of the fibrous panel.

12. The method of claim 1 , wherein the green board comprises a flocculent.

13. The method of claim 1 , wherein the green board comprises a colorant.

14. The method of claim 1 , wherein the dewatering comprises supplying hot air and applying a vacuum.

15. The method of claim 1 , wherein the pre-mixed slurry is mixed for a period of time between about 30 minutes and about 3 hours before being introduced to the headbox.

16. The method of claim 1 , wherein the mineral filler slurry is mixed for a period of time between about 10 seconds and 60 seconds before being injected to the headbox.

17. The method of claim 1 , wherein the mineral filler slurry is mixed for a period of time between about 20 seconds and 40 seconds before being injected to the headbox.

18. The method of claim 1 , wherein the pre-mixed slurry and mineral filler slurry are mixed in the headbox for a period of time between about 10 seconds and about 45 seconds.

19. The method of claim 1 , wherein the pre-mixed slurry and mineral filler slurry are mixed in the headbox for a period of time between about 20 seconds and about 30 seconds.

20. The method of claim 1 , wherein the pre-mixed slurry and the mineral slurry are mixed in the headbox for a period of time between about 20 seconds and about 25 seconds.

21. The method of claim 1 , wherein the dispersion is flowed onto the moving foraminous support wire prior to the dispersion exhibiting any significant change in viscosity.

Assignees

• Usg Interiors Llc

Inventors

• Mayers Thomas M
• Xu Wei
• Brown Martin W

Classifications

• C04B2111/52

  Sound-insulating materials · CPC title

• C04B14/46

  Rock wool {; Ceramic or silicate fibres (C04B14/40, C04B14/42 take precedence)} · CPC title

• C04B24/383

  Cellulose or derivatives thereof · CPC title

• C04B2111/00603

  Ceiling materials · CPC title

• C04B2111/00612

  as one or more layers of a layered structure · CPC title