Acoustic products

Patent metadata

Field	Value
Publication number	US-12595656-B2
Application number	US-202118259813-A
Country	US
Kind code	B2
Filing date	Oct 1, 2021
Priority date	Dec 30, 2020
Publication date	Apr 7, 2026
Grant date	Apr 7, 2026

Abstract

The invention relates to a method of making an acoustic product and a novel acoustic product, wherein the acoustic product is made by adhering a facing to a first major surface of an acoustic insulation element by the use of an adhesive and curing the adhesive. The adhesive is an aqueous adhesive composition which is free of phenol and formaldehyde and comprises:
a component (i) in form of one or more lignosulfonate lignins having a carboxylic acid group content of 0.03 to 2.0 mmol/g, such as 0.03 to 1.4 mmol/g, such as 0.075 to 2.0 mmol/g, such as 0.075 to 1.4 mmol/g, based on the dry weight of the lignosulfonate lignins, a component (ii) in form of one or more cross-linkers.

First claim

The invention claimed is:

1 . A method of making an acoustic product, the method comprising:
providing an acoustic element comprising first and second major surfaces; providing a first facing; fixing the first facing to a first major surface of the acoustic element by the use of an adhesive; and curing the adhesive, wherein the adhesive is an aqueous adhesive composition which is free of phenol and formaldehyde and comprises: a component (i) in form of one or more lignosulfonate lignins having a carboxylic acid group content of 0.03 to 2.0 mmol/g, such as 0.03 to 1.4 mmol/g, such as 0.075 to 2.0 mmol/g, such as 0.075 to 1.4 mmol/g, based on the dry weight of the lignosulfonate lignins, a component (ii) in form of one or more cross-linkers.

2 . The method according to claim 1 , wherein the acoustic element is a man-made vitreous fibre (MMVF) panel.

3 . The method according to claim 2 , wherein the man-made vitreous fibre panel is formed of man-made vitreous fibres that are bonded by a cured binder wherein the binder before curing is a composition which is free of phenol and formaldehyde and comprises:
a component (i) in form of one or more lignosulfonate lignins having a carboxylic acid group content of 0.03 to 2.0 mmol/g, such as 0.03 to 1.4 mmol/g, such as 0.075 to 2.0 mmol/g, such as 0.075 to 1.4 mmol/g, based on the dry weight of the lignosulfonate lignins, a component (ii) in form of one or more cross-linkers.

4 . The method according to claim 1 , wherein the first facing is a glass fibre veil.

5 . The method according to claim 1 , wherein the first facing has two major surfaces and the method comprises applying adhesive to a major surface of the first facing and then applying said major surface of the first facing to a first major surface of the acoustic element.

6 . The method according to claim 5 , comprising applying the adhesive by use of rollers.

7 . The method according to claim 1 , wherein the step of curing the adhesive is carried out at a temperature of from 100 to 300° C., preferably 170 to 270° C., preferably 180 to 250° C., preferably 190 to 230° C.

8 . The method according to claim 1 , wherein the acoustic element has a density in the range of 40 to 180 kg/m 3 , such as 80 to 160 kg/m 3 , preferably 100 to 140 kg/m 3 .

9 . The method according to claim 1 , wherein the loss on ignition (LOI) of the acoustic element is within the range of 2 to 8 wt %, preferably 3 to 5 wt %.

10 . The method according to claim 1 , comprising fixing a second facing to the second major surface of the acoustic element.

11 . The method according to claim 10 , comprising cutting the cured element in a plane substantially parallel to the major surfaces and smoothing each cut surface by abrasion to form two acoustic products.

12 . The method according to claim 1 , wherein the acoustic product has a thickness in the range of 12 to 100 mm, such as 15 to 50 mm.

13 . The method according to claim 1 , wherein the acoustic product has a width in the range of 550 to 650 mm, preferably around 600 mm.

14 . The method according to claim 1 , wherein the acoustic product has a length in the range of 550 to 650 mm or 1100 to 1300 mm, preferably around 600 mm, preferably around 1200 mm.

15 . The method according to claim 1 , comprising applying the adhesive in an amount of 5 to 12 g/m 2 dry.

16 . The method according to claim 1 , wherein the acoustic product is a ceiling panel.

17 . The method according to claim 1 , wherein the acoustic product is a wall panel.

18 . The method according to claim 1 , wherein the acoustic product is a baffle.

19 . An acoustic product obtained by the method according to claim 1 .

20 . An acoustic product comprising an acoustic element comprising first and second major surfaces and a first facing, wherein the first facing is fixed to the first major surface of the acoustic element by an adhesive, wherein the adhesive composition is free of phenol and formaldehyde and comprises:
a component (i) in form of one or more lignosulfonate lignins having a carboxylic acid group content of 0.03 to 2.0 mmol/g, such as 0.03 to 1.4 mmol/g, such as 0.075 to 2.0 mmol/g, such as 0.075 to 1.4 mmol/g, based on the dry weight of the lignosulfonate lignins, a component (ii) in form of one or more cross-linkers.

21 . A suspended ceiling system comprising a plurality of acoustic products according to claim 19 suspended in a grid.

22 . A wall system comprising a plurality of acoustic products according to claim 19 suspended on a wall.

23 . An acoustic product according to claim 20 , the aqueous adhesive composition further comprising a component (iii) in form of one or more plasticizers.

24 . An acoustic product according to claim 20 , wherein component (i) is having a carboxylic acid group content of 0.05 to 0.6 mmol/g, based on the dry weight of lignosulfonate lignins.

25 . An acoustic product according to claim 20 , wherein component (i) is in form of one or more lignosulfonate lignins having an average carboxylic acid group content of less than 1.8 groups per macromolecule considering the M_n wt. average of component (i), such as less than 1.4, such as less than 1.1, such as less than 0.7, such as less than 0.4.

26 . An acoustic product according to claim 20 , wherein component (i) is having a content of phenolic OH groups of 0.3 to 2.5 mmol/g, such as 0.5 to 2.0 mmol/g, such as 0.5 to 1.5 mmol/g. based on the dry weight of lignosulfonate lignins.

27 . An acoustic product according to claim 20 , wherein component (i) is having a content of aliphatic OH groups of 1.0 to 8.0 mmol/g, such as 1.5 to 6.0 mmol/g, such as 2.0 to 5.0 mmol/g, based on the dry weight of lignosulfonate lignins.

28 . An acoustic product according to claim 20 , wherein the component (i) comprises ammoniumlignosulfonates and/or calciumlignosulfonates, and/or magnesiumlignosulfonates, and any combinations thereof.

29 . An acoustic product according to claim 20 , wherein component (i) comprises ammoniumlignosulfonates and calciumlignosulfonates, wherein the molar ratio of NH 4 + to Ca 2+ is in the range of 5:1 to 1:5, in particular 3:1 to 1:3.

30 . An acoustic product according to claim 20 , wherein the aqueous adhesive composition contains added sugar in an amount of 0 to less than 5 wt.-%, based on the weight of lignosulfonate and sugar.

31 . An acoustic product according to claim 20 , wherein the aqueous adhesive composition comprises component (i) in an amount of 50 to 98 wt.-%, such as 65 to 98 wt.-%, such as 80 to 98 wt.-%, based on the dry weight of components (i) and (ii).

32 . An acoustic product according to claim 20 , wherein the component (ii) is in form of one or more cross-linkers selected from
a. β-hydroxyalkylamide-cross-linkers, and/or b. oxazoline-cross-linkers, and/or c. the group consisting of multifunctional organic amines such as an alkanolamine, diamines, such as hexamethyldiamine, and/or d. epoxy compounds having a molecular weight of more than 500, such as an epoxidised oil based on fatty acid triglyceride or one or more flexible oligomer or polymer, such as a low Tg acrylic based polymer, such as a low Tg vinyl based polymer, such as low Tg polyether, which contains reactive functional groups such as carbodiimide gro

Assignees

• Rockwool As

Inventors

• Bartnik Johansson Dorte
• Nikolic Miroslav

Classifications

• E01C2201/20

  Drainage details · CPC title

• E01C2201/16

  Elements joined together · CPC title

• E01C2201/10

  having build-in shock absorbing devices · CPC title

• E01C13/08

  Surfaces simulating grass {; Grass-grown sports grounds (grass-like surfaces for skiing E01C13/12)} · CPC title

• B32B2250/02

  2 layers · CPC title