Ceiling tile compositions comprising microfibrillated cellulose and methods for making same

Patent metadata

Field	Value
Publication number	US-10669671-B2
Application number	US-201816205458-A
Country	US
Kind code	B2
Filing date	Nov 30, 2018
Priority date	Apr 4, 2016
Publication date	Jun 2, 2020
Grant date	Jun 2, 2020

Abstract

A composition for addition to a ceiling tile, flooring product, or other construction product may include microfibrillated cellulose and optionally an inorganic particulate material. The ceiling tile, flooring product, or other construction product may further include perlite, mineral wool, wood pulp, starch and other additives, where the wood pulp and other inorganic particulate materials are bonded to the microfibrillated cellulose. Methods of manufacturing the compound are also disclosed.

First claim

What is claimed is:

1. A ceiling tile comprising up to about 90% by weight mineral wool or perlite, or both mineral wool and perlite and from 0.1 to 40% by weight microfibrillated cellulose based on the total dry weight of the ceiling tile, wherein the microfibrillated cellulose has a d 50 μm of about 5 to about 500 μm and a fibre steepness of from 20 to 50.

2. The ceiling tile of claim 1 , wherein the ceiling tile further comprises wood pulp or paper pulp and, optionally, starch and/or a latex binding agent.

3. The ceiling tile of claim 2 , wherein the ceiling tile comprises 0.5% to 10% by weight of the microfibrillated cellulose composition, based on the total dry weight of the ceiling tile.

4. The ceiling tile according to claim 2 , wherein the ceiling tile comprises 30% to 90% by weight perlite, based on the total dry weight of the ceiling tile.

5. The ceiling tile according to claim 4 , wherein the ceiling tile comprises 0.5% to 25% by weight of microfibrillated cellulose, based on the total dry weight of the ceiling tile.

6. The ceiling tile according to claim 4 , wherein the ceiling tile comprises: 0.5% to 25% by weight of microfibrillated cellulose, based on the total dry weight of the ceiling tile; and up to 20% by weight of wood pulp or paper pulp, based on the total dry weight of the ceiling tile.

7. The ceiling tile according to claim 2 , wherein the ceiling tile comprises up to 25% by weight wood pulp or paper pulp, based on the total dry weight of the ceiling tile.

8. The ceiling tile according to claim 7 , wherein the ceiling tile comprises up to 10% by weight wood pulp or paper pulp, based on the total dry weight of the ceiling tile.

9. The ceiling tile according to claim 2 , wherein the microfibrillated cellulose composition further comprising one or more inorganic particulate material selected from the group consisting of calcium carbonate, magnesium carbonate, dolomite, gypsum, kaolin, halloysite, ball clay, metakaolin, kaolin, talc, mica, huntite, hydromagnesite, ground glass, diatomaceous earth, wollastonite, titanium dioxide, magnesium hydroxide, aluminium trihydrate, lime, graphite, or combinations thereof.

10. The ceiling tile according to claim 9 , wherein the inorganic particulate comprises calcium carbonate or kaolin.

11. The ceiling tile of claim 1 , wherein the ceiling tile comprises 0.5% to 10% by weight of the microfibrillated cellulose composition, based on the total dry weight of the ceiling tile.

12. The ceiling tile according to claim 1 , wherein the ceiling tile comprises 30% to 90% by weight perlite based on the total dry weight of the ceiling tile.

13. The ceiling tile according to claim 12 , wherein the ceiling tile comprises 0.5% to 25% by weight of microfibrillated cellulose, based on the total dry weight of the ceiling tile.

14. The ceiling tile according to claim 12 , wherein the ceiling tile comprises: 0.5% to 25% by weight of microfibrillated cellulose, based on the total dry weight of the ceiling tile; and up to 20% by weight of wood pulp or paper pulp, based on the total dry weight of the ceiling tile.

15. The ceiling tile according to claim 1 , wherein the ceiling tile has a flexural strength of at least 400 kPa.

16. The ceiling tile according to claim 1 , wherein the microfibrillated cellulose composition further comprising one or more inorganic particulate material selected from the group consisting of calcium carbonate, magnesium carbonate, dolomite, gypsum, kaolin, halloysite, ball clay, metakaolin, kaolin, talc, mica, huntite, hydromagnesite, ground glass, diatomaceous earth, wollastonite, titanium dioxide, magnesium hydroxide, aluminium trihydrate, lime, graphite, or combinations thereof.

17. The ceiling tile according to claim 16 , wherein the inorganic particulate comprises calcium carbonate or kaolin.

Assignees

• Fiberlean Tech Ltd

Inventors

• Skuse David
• Phipps Jonathan Stuart
• Ireland Sean
• Jin Yun

Classifications

• D21H17/675

  Oxides, hydroxides or carbonates · CPC title

• C04B24/26

  obtained by reactions only involving carbon-to-carbon unsaturated bonds {(C04B24/243 takes precedence)} · CPC title

• C04B18/241

  Paper, e.g. waste paper; Paper pulp · CPC title

• D21H13/40 Primary

  vitreous, e.g. mineral wool, glass fibres · CPC title

• C04B2111/52

  Sound-insulating materials · CPC title