Acoustic ceiling tiles with anti-sagging properties and methods of making same

Patent metadata

Field	Value
Publication number	US-9492961-B2
Application number	US-201514607504-A
Country	US
Kind code	B2
Filing date	Jan 28, 2015
Priority date	Aug 1, 2014
Publication date	Nov 15, 2016
Grant date	Nov 15, 2016

Abstract

An acoustic tile with excellent anti-sagging properties is provided. The tile comprises a soy-protein binder selected from the group consisting of soy flour, soy protein concentrate, soy protein isolate and any combination thereof. In further embodiments, the tile further comprises polyamide-epichlorohydrin. Other tiles include those made with a thermosetting binder selected from the group consisting of an acrylic binder, a polyester binder, an acrylo-polyester binder and any mixture thereof. Energy-efficient methods for making the tiles are also provided.

First claim

What is claimed is:

1. An acoustic tile comprising mineral wool and a soy protein binder selected from the group consisting of soy flour, soy protein concentrate, soy protein isolate and any combination thereof, wherein the mineral wool is mixed and cross-linked with the soy protein binder.

2. The acoustic tile of claim 1 , wherein the mineral wool comprises from 50% to 95% of the tile by weight.

3. The acoustic tile of claim 1 , wherein the soy protein binder comprises from 10% to 20% of the tile by weight.

4. The acoustic tile of claim 1 , wherein the soy-protein binder is soy flour, and wherein the soy flour and polyamide-epichlorohydrin are in the ratio range from 2.5:1 to 10:1.

5. The acoustic tile of claim 4 , wherein the soy-protein binder and polyamide-epichlorohydrin comprise up to 10% of the acoustic tile by weight.

6. The acoustic tile of claim 1 , wherein the tile further comprises a defoamer.

7. A method for obtaining an acoustic tile, the method comprising the following steps:
1) melting slag, basalt, concrete debris or any mixture thereof to produce molten mineral wool;
2) spinning mineral wool fibers from the molten mineral wool;
3) spraying a soy protein binder onto the mineral wool fibers; and
4) forming the acoustic panel from the mineral wool fibers sprayed with the soy protein binder.

8. The method of claim 7 , wherein the soy protein binder is selected from the group consisting of: soy flour, soy protein concentrate, soy protein isolate and any mixture thereof.

9. The method of claim 7 , wherein the method further comprises spraying polyamide-epichlorohydrin.

10. An acoustic tile comprising mineral wool and a thermosetting binder selected from the group consisting of an acrylic binder, a polyester binder, an acrylo-polyester binder and any mixture thereof, wherein the mineral wool is cross-linked with the thermosetting binder.

11. The acoustic tile of claim 10 , wherein the mineral wool comprises from 50% to 95% of the tile by weight.

12. The acoustic tile of claim 10 , wherein the thermosetting binder comprises up to 10% of the acoustic tile by weight.

13. The acoustic tile of claim 10 , wherein the thermosetting binder is an acrylic binder.

14. A method of making an acoustic panel, the method comprising:
1) melting slag, basalt, concrete debris or any mixture thereof to produce molten mineral wool;
2) spinning mineral wool fibers from the molten mineral wool;
3) spraying a thermosetting binder onto the mineral wool fibers; and
4) forming the acoustic panel from the mineral wool fibers sprayed with the thermosetting binder.

15. The method of claim 14 , wherein the thermosetting binder is selected from the group consisting of an acrylic binder, a polyester binder, an acrylo-polyester binder and any mixture thereof.

16. A method for making a cast acoustic tile, the method comprising:
1) mixing water with soy flour,
2) adding the mixture to stucco and mineral wool and thereby forming a slurry;
3) adding polyamide-epichlorohydrin to the slurry; and
4) forming an acoustic tile.

17. The method of claim 16 , wherein the ratio between soy flour and polyamide-epichlorohydrin is in the range from 2.5:1 to 10:1.

18. The method of claim 16 , wherein the amount of mineral wool is from 50% to 95% by weight of the tile.

19. The method of claim 16 , wherein a defoamer is added at the step of mixing water with soy flour.

Assignees

• Usg Interiors Llc

Inventors

• Xu Wei
• Kemp Brian A
• Englert Mark H
• Brown Martin W
• Rosenstiel Terry L

Classifications

• D04H1/4209 Primary

  Inorganic fibres · CPC title

• B29K2101/10

  Thermosetting resins · CPC title

• E04B9/001

  characterised by provisions for heat or sound insulation · CPC title

• D04H1/587

  characterised by the bonding agents used · CPC title

• B29L2031/104

  Tiles · CPC title