Fire performance for wood veneer laminated ceiling tile

Patent metadata

Field	Value
Publication number	US-10745920-B2
Application number	US-201615334923-A
Country	US
Kind code	B2
Filing date	Oct 26, 2016
Priority date	Oct 28, 2015
Publication date	Aug 18, 2020
Grant date	Aug 18, 2020

Abstract

The present invention is directed to a building panel having a laminate structure, the laminate structure including a topcoat layer comprising a first intumescent composition, a cellulosic veneer layer, an adhesive layer formed from an adhesive composition comprising a second intumescent composition, and a metallic substrate layer and wherein the cellulosic veneer layer is at least partially bonded to the metallic substrate by the adhesive layer. The resulting building panel exhibits superior flame retardancy resulting in a Class A fire rating, according to ASTM E-84.

First claim

What is claimed is:

1. A ceiling panel comprising a laminate structure, the laminate structure comprising:
a cellulosic veneer layer adhesively bonded to a substrate by an adhesive comprising a polyurethane polymer; and
a topcoat layer applied to the cellulosic layer that is substantially impervious to ambient moisture and comprising an intumescent composition, the topcoat layer having an uppermost exposed surface, the topcoat layer comprising:
a barrier sub-layer that is substantially impervious to ambient moisture, the barrier sub-layer comprising a first polymer having a first glass transition temperature, the first polymer present in an amount ranging from about 70 wt. % to about 100 wt. % based on the total weight of the barrier sub-layer;
an intumescent sub-layer comprising the intumescent composition and a second polymer having a second glass transition temperature; wherein the barrier sub-layer is atop the intumescent sub-layer and the intumescent sub-layer is atop the cellulosic layer; and wherein the first glass transition temperature being equal to or less than the second glass transition temperature; and
wherein the barrier sub-layer contacts the intumescent sub-layer, and the uppermost exposed surface of the topcoat layer is formed by the barrier sub-layer.

2. The ceiling panel according to claim 1 , wherein the topcoat layer is substantially clear.

3. The ceiling panel according to claim 1 , wherein the topcoat layer directly contacts the first major surface of the cellulosic veneer layer and the adhesive layer directly contacts the second major surface of the cellulosic veneer layer.

4. The ceiling panel according to claim 1 , wherein the intumescent composition comprises:
a carbon donor compound; and
an acid donor compound comprising ammonium phosphate, di-ammonium phosphate, ammonium dihydrogen phosphate, ammonium polyphosphate, melamine phosphate, guanylurea phosphate, urea phosphate, p-toluenesulphonic acid, ammonium sulfate, ammonium borate, or combinations thereof.

5. The ceiling panel according to claim 1 , wherein the adhesive composition is a hot-melt composition and the thermoplastic polyurethane polymer comprises polyester modified polyurethane.

6. The ceiling panel according to claim 1 , wherein the substrate is metallic and has a thickness ranging from about 25 mils to 80 mils.

7. The ceiling panel according to claim 1 , wherein the first polymer of the barrier layer has a glass transition temperature ranging from 30° C. to 80° C.

8. The ceiling panel according to claim 1 , wherein the first polymer comprises one or more of vinyl or acrylic homopolymers or copolymers formed from ethylenically unsaturated monomers that are selected from the group consisting of ethylene, butadiene, styrene, vinyl acetate, vinyl propionate, vinyl butyrate, acrylic acid, methacrylic acid, esters of acrylic acid and esters of methacrylic acid.

Assignees

• Armstrong World Ind Inc
• Awi Licensing Llc

Inventors

• Bischel Marsha S
• Kehrer Kenneth P
• Lu Lida
• Wang Michelle X

Classifications

• E04B9/225 Primary

  with the slabs, panels, sheets or the like hanging at a distance below the supporting construction · CPC title

• E04B9/04

  comprising slabs, {panels,} sheets or the like · CPC title

• B32B2307/7246

  Water vapor barrier · CPC title

• E04B9/34

  {Grid-like or} open-work ceilings, e.g. lattice type {box-like modules, acoustic baffles} (E04B9/30 takes precedence) · CPC title

• B32B9/042

  of wood · CPC title