Compositions and methods for providing increased strength in ceiling, flooring, and building products

Patent metadata

Field	Value
Publication number	US-2019100880-A1
Application number	US-201816205458-A
Country	US
Kind code	A1
Filing date	Nov 30, 2018
Priority date	Apr 4, 2016
Publication date	Apr 4, 2019
Grant date	—

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 construction product comprising a composition of microfibrillated cellulose and one or more inorganic particulate material.

2 . The construction product of claim 1 , wherein the construction product is a ceiling tile.

3 . The ceiling tile of claim 2 , wherein the ceiling tile further comprises mineral wool or perlite, or both mineral wool and perlite.

4 . The ceiling tile of claim 2 or 3 , wherein the ceiling tile further comprises wood pulp or paper pulp and, optionally, starch and/or a latex binding agent.

5 . The ceiling tile of any claims 2 - 4 , wherein the ceiling tile comprises up to about 50% by weight of the microfibrillated cellulose, based on the total dry weight of the ceiling tile.

6 . The ceiling tile of any of claims 2 - 5 , wherein the ceiling tile comprises up to about 25% by weight of the microfibrillated cellulose composition, based on the total dry weight of the ceiling tile.

7 . The ceiling tile of any of claims 2 - 6 , wherein the ceiling tile comprises up to about 10% by weight of the microfibrillated cellulose composition, based on the total dry weight of the ceiling tile.

8 . The ceiling tile according to any one of claims 2 - 7 , wherein the ceiling tile comprises up to about 80% by weight perlite or mineral wool, or both perlite and mineral wool, based on the total dry weight of the ceiling tile.

9 . The ceiling tile according to any one of claims 4 - 7 , wherein the ceiling tile comprises up to about 25% by weight wood pulp or paper pulp, based on the total dry weight of the ceiling tile.

10 . The ceiling tile according to claim 9 , wherein the ceiling tile comprises up to about 10% by weight wood pulp or paper pulp, based on the total dry weight of the ceiling tile.

11 . The ceiling tile according to any of claims 2 - 10 , wherein the ceiling tile has a flexural strength which is improved compared to a ceiling tile which does not comprise microfibrillated cellulose.

12 . The ceiling tile according to claim 11 , wherein the ceiling tile has a flexural strength of at least about 400 kPa.

13 . The ceiling tile according to claim 8 , wherein the ceiling tile further comprises:
(ii) up to about 20% by weight of microfibrillated cellulose, based on the total dry weight of the ceiling tile, for example, from about 10% by weight to about 20% by weight, or from about 1% by weight to about 10% by weight of the microfibrillated cellulose composition; and/or (i) up to 20% by weight of wood pulp or paper pulp, based on the total dry weight of the ceiling tile, for example, from about 5% by weight to about 20% by weight wood pulp, for example, from about 5% by weight to about 15% by weight wood pulp, or from about 8% by weight to about 12% by weight pulp.

14 . The construction product or ceiling tile according to any preceding claim, wherein the microfibrillated cellulose composition comprises microfibrillated cellulose and inorganic particulate material in a weight ratio of from about 5:1 to about 1:166.

15 . The ceiling tile according to any of claims 2 - 14 , wherein the inorganic particulate, when present, is or comprises calcium carbonate or kaolin.

16 . The construction product or ceiling tile according to any preceding claim, wherein the microfibrillated cellulose has a fibre steepness of from about 20 to about 50.

17 . Use of a microfibrillated cellulose composition in a construction product, for example, a ceiling tile.

18 . Use according to claim 17 , for improving the flexural strength of the ceiling tile.

19 . A method for making a construction product according to any preceding claim, comprising combining the microfibrillated composition with other component(s) of the construction product and forming the construction product therefrom.

20 . A method for making a ceiling tile according to any of claims 2 - 19 , comprising combining the microfibrillated cellulose composition with other component(s) of the ceiling product and forming a ceiling tile therefrom.

Assignees

• Fiberlean Tech Ltd

Inventors

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

Classifications

• C04B18/241

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

• C04B26/02

  Macromolecular compounds · CPC title

• C04B14/18

  Perlite · CPC title

• D21H17/33

  Synthetic macromolecular compounds · CPC title

• C04B26/285 Primary

  Cellulose or derivatives thereof (C04B26/24 takes precedence) · CPC title