Acoustical ceiling tile

Patent metadata

Field	Value
Publication number	US-2017089014-A1
Application number	US-201514866055-A
Country	US
Kind code	A1
Filing date	Sep 25, 2015
Priority date	Sep 25, 2015
Publication date	Mar 30, 2017
Grant date	—

Abstract

An acoustical tile including: 8 to 25 wt % mineral wool, 9 to 15 wt % starch binder, 9 to 15 wt % cellulosic fiber, wherein preferably the cellulosic fiber is newsprint, and 40 to 65 wt % perlite, wherein the weight ratio of the starch to the cellulosic fiber is 0.6 to 1.3:1; and a process for making the acoustical tile.

First claim

1 . An acoustical tile comprising:
8 to 25 wt % mineral wool, 9 to 15 wt % starch binder, 9 to 15 wt % cellulosic fiber, and 40 to 65 wt % perlite, wherein a weight ratio of the starch to the cellulosic fiber is 0.6 to 1.3:1.

2 . The acoustical tile of claim 1 , wherein the acoustical tile has:
an absence of glass beads, an absence of clay, an absence of vermiculite, an absence of gypsum, an absence of calcium carbonate, an absence of magnesium carbonate, and an absence of Zinc pyrithione.

3 . The acoustical tile of claim 1 , wherein the cellulosic fiber comprises newsprint, wherein 0% of the cellulosic fiber is provided by paper sludge obtained from pulp and paper processing waste.

4 . The acoustical tile of claim 1 , wherein the acoustical tile has:
an absence of glass beads, an absence of clay, an absence of vermiculite, an absence of gypsum, an absence of calcium carbonate, an absence of magnesium carbonate, an absence of Zinc pyrithione, an absence of inorganic material other than perlite and mineral wool, and 0% of the cellulosic fiber is provided by paper sludge obtained from pulp and paper processing waste.

5 . The acoustical tile of claim 1 , wherein the starch to cellulosic fiber weight ratio is 0.7 to 1.1:1.0.

6 . The acoustical tile of claim 1 , wherein the starch to cellulosic fiber weight ratio is 0.7 to 0.9:1.0 and the cellulosic fiber comprises newsprint.

7 . The acoustical tile of claim 1 , wherein the acoustical tile comprises:
8.0 to 20.0 wt % mineral wool, 9.5 to 13.0 wt % starch binder, 10.0 to 14.5 wt % cellulosic fiber, and 45.0 to 65.0 wt % perlite; wherein the starch:cellulosic fiber weight ratio is 0.7-1.1:1.0.

8 . The acoustical tile of claim 1 , wherein the acoustical tile comprises:
15.0 to 20.0 wt % mineral wool, 9.5 to 10.5 wt % starch binder 12.0 to 14.0 wt % cellulosic fiber, wherein said cellulosic fiber is newsprint, and 55.0 to 65.0 wt % perlite; wherein the starch:cellulosic fiber weight ratio is 0.7-0.9:1.0.

9 . The acoustical tile of claim 1 , wherein the acoustical tile is about 4/8 inches to about 1 inch thick.

10 . The acoustical tile of claim 1 , wherein the acoustical tile is about ⅝ inches to about ⅞ inches thick.

11 . A process for manufacturing acoustical tile in a water-felting process, comprising:
mixing an aqueous slurry comprising water and, ingredients comprising on a water free-basis:
8 to 25 wt % mineral wool,
9 to 15 wt % starch binder,
9 to 15 wt % cellulosic fiber, and
40 to 65 wt % perlite,
wherein a weight ratio of the starch to the cellulosic fiber is 0.6 to 1.3:1.0;
continuously flowing the slurry onto a moving foraminous support wire to form a cake; dewatering the cake to form a base mat such that the cake has a drain time of less than 20 seconds; and drying the base mat to produce the acoustical tile.

12 . The process of claim 11 , wherein the acoustical tile has:
an absence of glass beads, an absence of clay, an absence of vermiculite, an absence of gypsum, an absence of calcium carbonate, an absence of magnesium carbonate, an absence of Zinc pyrithione.

13 . The process of claim 11 , wherein the cellulosic fiber comprises newsprint, wherein 0% of the cellulosic fiber is provided by paper sludge obtained from pulp and paper processing waste.

14 . The process of claim 11 , wherein the acoustical tile has:
an absence of glass beads, an absence of clay, an absence of vermiculite, an absence of gypsum, an absence of calcium carbonate, an absence of magnesium carbonate, an absence of Zinc pyrithione, an absence of inorganic material other than perlite and mineral wool, and 0% of the cellulosic fiber is provided by paper sludge obtained from pulp and paper processing waste.

15 . The process of claim 11 , wherein the starch to cellulosic fiber weight ratio is 0.7 to 1.1:1.0.

16 . The process of claim 11 , wherein the starch to cellulosic fiber weight ratio is 0.7 to 0.9:1.0 and the cellulosic fiber comprises newsprint.

17 . The process of claim 11 , wherein the acoustical tile comprises:
8.0 to 20.0 wt % mineral wool, 9.5 to 13.0 wt % starch binder, 10.0 to 14.5 wt % cellulosic fiber, and 45.0 to 65.0 wt % perlite; wherein the starch:cellulosic fiber weight ratio is 0.7-1.1:1.0.

18 . The process of claim 11 , wherein the acoustical tile comprises:
15.0 to 20.0 wt % mineral wool, 9.5 to 10.5 wt % starch binder 12.0 to 14.0 wt % cellulosic fiber, wherein said cellulosic fiber is newsprint, and 55.0 to 65.0 wt % perlite; wherein the starch:cellulosic fiber weight ratio is 0.7-0.9:1.0.

19 . The process of claim 11 , wherein the acoustical tile is about 4/8 inches to about 1 inch thick.

20 . The process of claim 11 , wherein the acoustical tile is about ⅝ inches to about ⅞ inches thick.

Assignees

• Usg Interiors Llc

Inventors

• Englert Mark H
• Frank William A

Classifications

• E04B2001/8476

  with acoustical cavities, with or without acoustical filling · CPC title

• C04B2111/10

  Compositions or ingredients thereof characterised by the absence or the very low content of a specific material · CPC title

• D21H23/04

  Addition to the pulp; After-treatment of added substances in the pulp · CPC title

• D21J1/20 Primary

  Insulating board · CPC title

• D21H17/68

  siliceous, e.g. clays · CPC title