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

Patent metadata

Field	Value
Publication number	US-2020248408-A1
Application number	US-202016855370-A
Country	US
Kind code	A1
Filing date	Apr 22, 2020
Priority date	Apr 4, 2016
Publication date	Aug 6, 2020
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

1 .- 20 . (canceled)

21 . A flooring product comprising from 0.5 to 25% by weight microfibrillated cellulose based on the total dry weight of the flooring product, wherein the microfibrillated cellulose has a d 50 of about 5 μm to about 500 μm and a fibre steepness of from about 20 to about 50.

22 . The flooring product according to claim 21 , wherein the flooring product further comprises wood pulp or paper pulp and, optionally, starch.

23 . The flooring product according to claim 21 , wherein the flooring product comprises 0.5% to 10% by weight of the microfibrillated cellulose composition, based on the total dry weight of the flooring product.

24 . The flooring product of claim 22 , wherein the ceiling tile comprises 0.5% to 10% by weight of the microfibrillated cellulose composition, based on the total dry weight of the flooring product.

25 . The flooring product of claim 22 , further comprising starch.

26 . The flooring product of claim 21 , further comprising mineral wool.

27 . The flooring product of claim 25 , further comprising mineral wool.

28 . The flooring product according to claim 21 , wherein the microfibrillated cellulose composition comprises microfibrillated cellulose and 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.

29 . The flooring product according to claim 22 , wherein the microfibrillated cellulose composition comprises microfibrillated cellulose and 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.

30 . The flooring product according to claim 25 , wherein the microfibrillated cellulose composition comprises microfibrillated cellulose and 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.

31 . The flooring product according to claim 27 , wherein the microfibrillated cellulose composition comprises microfibrillated cellulose and 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.

32 . The ceiling tile according to claim 28 , wherein the inorganic particulate comprises calcium carbonate or kaolin.

33 . The ceiling tile according to claim 29 , wherein the inorganic particulate comprises calcium carbonate or kaolin.

34 . The ceiling tile according to claim 30 , wherein the inorganic particulate comprises calcium carbonate or kaolin.

35 . The ceiling tile according to claim 31 , wherein the inorganic particulate comprises calcium carbonate or kaolin.

36 . The flooring product according to claim 28 , 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. 1 1 PCT claim 14 .

37 . The flooring product according to claim 29 , 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.

38 . The flooring product according to claim 30 , 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.

39 . The flooring product according to claim 31 , 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

40 . A construction product comprising from 0.5 to 25% by weight microfibrillated cellulose based on the total dry weight of the construction product, wherein the microfibrillated cellulose has a d 50 of about 5 μm to about 500 μm and a fibre steepness of from 20 to 50, wherein the construction product is a fiberboard, gypsum board, plasterboard, insulation core of structural insulated panels or sound proofing.

41 . The construction product according to claim 40 , wherein the construction product further comprises up to 35% by weight wood particles, based on the total dry weight of the ceiling tile.

42 . The construction product according to claim 41 , wherein the product is a fiberboard.

43 . The fiberboard of claim 42 , wherein the wood particle is spruce.

Assignees

• Fiberlean Tech Ltd

Inventors

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

Classifications

• Y02W30/91

  Use of waste materials as fillers for mortars or concrete · CPC title

• D21H13/40 Primary

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

• C04B26/285 Primary

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

• C04B24/383 Primary

  Cellulose or derivatives thereof · CPC title

• C04B2111/52

  Sound-insulating materials · CPC title