High noise reduction coefficient, low density acoustical tiles
AssigneeUSG Interiors, Inc.
InventorsWei Xu, Thomas M. Mayers, Scott C. Bakken
Life of this patent
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Abstract
Acoustical tile including a dried base mat of: about 70 to about 90 wt % mineral wool; about 5 to about 15 wt % perlite; 0 to about 10 wt % starch; about 3 to about 10 wt % latex; 0 to about 5 wt % gypsum; and less than 5 wt % water. The dried base mat without including glass fibers and without a laminate layer or coating and without perforations has a NRC of about 0.70 or greater, a density of about 10 pcf to about 12 pcf, and a thickness of about ½ to about 1 inch. The acoustical tile can further include a back coating at a surface weight of about 5 grams per square foot (gsf) to about 40 gsf to the dried base mat, wherein the acoustical tile has the CAC rating of about 30 to about 35.
Claims19
An acoustical the comprising a dried base mat comprising:
- 78 wt % to 80 wt % mineral wool;
- 8 wt % to 10 wt % perlite;
- 2 wt % to 4 wt % starch, wherein the starch is a starch binder for the base mat;
- 6 wt % to 8 wt % latex, wherein the latex is a latex binder for the base mat;
- 0.5 wt % to 3 wt % gypsum;
- and
- less than 5 wt % water, wherein the dried base mat has an absence of glass fibers;
- and
- wherein the dried base mat without a laminate layer;
- without a coating, and without perforations has a noise reduction coefficient (NRC) of about 0.70 to about 0.75, a density of about 11 pounds per cubic foot (pcf) to about 12 pcf, and a thickness of about ⅝ inch to about ⅞ inch;
- wherein the dried base mat was made from drying a slurry comprising water and ingredients comprising on a water free basis:
- said mineral wool;
- said perlite;
- said starch;
- said latex;
- and
- said gypsum.
An acoustical the comprising a dried base mat comprising:
- 70 wt % to 85 wt % mineral wool;
- 7 wt % to 12 wt % perlite;
- 1 wt % to 5 wt % starch, wherein the starch is a starch binder for the base mat;
- 5 wt % to 9 wt % latex;
- wherein the latex is a latex binder for the base mat;
- 0 wt % to 3 wt % gypsum;
- 0.1 wt % to 5 wt % glass fibers;
- and
- less than 5 wt % water;
- and
- wherein the dried base mat without a laminate layer;
- without a coating and without perforations has a noise reduction coefficient (NRC) of about 0.75, a density of about 10 to about 12 pcf, and a thickness of about ½ inch to about 1 inch;
- wherein the dried base mat was made from drying a slurry comprising water and ingredients comprising on a water free basis:
- said mineral wool;
- said perlite;
- said starch;
- said latex;
- said gypsum;
- and
- said glass fibers.
Dependencies are inferred from the claim text.