Low density acoustical panels

Patent metadata

Field	Value
Publication number	US-9279250-B2
Application number	US-201314140177-A
Country	US
Kind code	B2
Filing date	Dec 24, 2013
Priority date	Dec 24, 2013
Publication date	Mar 8, 2016
Grant date	Mar 8, 2016

Abstract

Described herein are building products comprising crimped bicomponent fibers and a non-woven fabric, which demonstrate, inter alia, improved acoustical performance. Methods of making and using the building products are also described.

First claim

The invention claimed is:

1. An acoustical substrate, comprising:
about 5 to about 25 wt. % of a crimped bicomponent fiber having a length greater than 3 mm and up to 30 mm; and
about 75 to about 95 wt. % of an inorganic fiber batt;
wherein the density of the acoustical substrate ranges from about 1 lb/ft 3 to about 4 lb/ft 3 .

2. The acoustical substrate of claim 1 , wherein the bicomponent fiber is a heat-fusible bicomponent fiber.

3. The acoustical substrate of claim 1 , wherein the bicomponent fiber comprises a first component and a second component.

4. The acoustical substrate of claim 3 , wherein the first component comprises a thermoplastic polymer.

5. The acoustical substrate of claim 3 , wherein the second component comprises a second thermoplastic polymer.

6. The acoustical substrate of claim 3 , wherein at least one of the first component and the second component is a thermoplastic olefinic polymer.

7. The acoustical substrate of claim 6 , wherein the olefinic polymer of the first component is selected from: polypropylene, a copolymer of propylene and an α-olefin; an ethylene polymer; and polymethyl pentene; and wherein the olefinic polymer of the second component is selected from: polypropylene, a copolymer of propylene and an α-olefin; and an ethylene polymer.

8. The acoustical substrate of claim 1 , wherein the first and second components comprise a polyester.

9. The acoustical substrate of claim 8 , wherein the polyester is selected from polyethylene terephthalate, glycol-modified terephthalate and polybutylene terephthalate.

10. The acoustical substrate of claim 3 , wherein the second component has a melting point higher than that of the first component.

11. The acoustical substrate of claim 3 , wherein the melting point of the first component is not greater than about 150° C.

12. The acoustical substrate of claim 11 , wherein the melting point of the second component is not greater than about 200° C.

13. The acoustical substrate of claim 1 , wherein the crimped bicomponent fiber is in a planar zig-zag or spiral shape.

14. The acoustical substrate of claim 1 , wherein the first component comprises from about 40 to about 60 wt. %, of the bicomponent fiber and the second component comprises from about 40 to about 60 wt. % of the bicomponent fiber.

15. The acoustical substrate of claim 3 , wherein the second component comprises a plurality of filaments.

16. The acoustical substrate of claim 1 , comprising from about 12 to about 17 wt. % of a bicomponent fiber.

17. The acoustical substrate of claim 16 , comprising from about 83 to about 88 wt. % of mineral wool.

18. The acoustical substrate of claim 1 , wherein the substrate is a ceiling tile.

19. The acoustical substrate of claim 1 , further comprising a scrim.

20. An acoustical substrate, comprising:
about 5 to about 25 wt. % of a crimped bicomponent fiber having a length ranging from about 6 mm to about 30 mm; and
about 75 to about 95 wt. % of an inorganic fiber batt;
wherein the bicomponent fiber comprises a first component and a second component and the second component has a melting point higher than that of the first component.

Assignees

• Armstrong World Ind Inc
• Awi Licensing Co

Inventors

• Wiker Anthony L

Classifications

• E04B9/366

  the principal plane of the slats being vertical · CPC title

• E04B2001/742

  Use of special materials; Materials having special structures or shape · CPC title

• E04B9/001 Primary

  characterised by provisions for heat or sound insulation · CPC title

• E04B2001/7687

  Crumble resistant fibrous blankets or panels using adhesives or meltable fibres · CPC title

• D04H1/4209 Primary

  Inorganic fibres · CPC title