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US 11,598,093 B2Granted
Acoustic ceiling board with improved aesthetics
AssigneeAWI Licensing LLC
InventorsEric D. Kragness, Chris Wells, Oliver Ebert, Alfred Winkler
Life of this patent
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Abstract
Described herein are acoustical panels, comprising: a substrate; a non-woven veil having an airflow resistance of greater than 45 mks rayls, comprising: from about 20 wt. % to about 60 wt. % glass fibers; from about 40 wt. % to about 80 wt. % of a filler; and from about 110 dry g/m2 to about 135 dry g/m2 of a coating. Methods of making and using the panels are also described.
Claims20
A method of forming an acoustic panel comprising:
- applying a composition to a first major surface of a substrate in an amount ranging from about 155 g/m2 to about 200 g/m2, the composition comprising a solid component and a liquid carrier;
- drying the composition to form a coating atop the major surface of the substrate that is free of the liquid carrier, the coating being present atop the major surface of the substrate in an amount ranging from about 110 g/m2 to about 135 g/m2;
- wherein the combination of the coating and the substrate exhibit an airflow resistance of 300 mks or less;
- wherein the substrate comprises a fibrous filler having a fiber length from about 1 mm to about 4 mm;
- and
- wherein the solid component comprises polymer binder;
- and
- wherein the coating forms an outward surface of the acoustic panel.
5 more elements
A method of forming an acoustic panel comprising:
- providing a coated non-woven veil having a first major surface opposite a second major surface, the first major surface of the coated non-woven veil comprising a dry coating and the second major surface of the coated non-woven veil comprising non-woven fibers, and
- providing a fibrous body having a first major surface opposite a second major surface;
- adhering the coated non-woven veil to the fibrous body;
- wherein the dry coating is present atop the non-woven fibers in an amount ranging from about 110 g/m2 to about 135 g/m2;
- and
- wherein the coated non-woven veil has an airflow resistance of about 300 mks rayls or less;
- and
- wherein the dry coating forms an outward surface of the coated non-woven veil.
5 more elements
A method of forming an acoustic panel comprising:
- a) applying a composition to a first major surface of a non-woven veil in an amount ranging from about 155 g/m2 to about 200 g/m2, the composition comprising a polymer binder and a liquid carrier, and the non-woven veil having a second major surface opposite the first major surface;
- b) drying the composition to form a coating atop the first major surface of the non-woven veil that is free of the liquid carrier, whereby the coating is present atop the first major surface of the non-woven in an amount ranging from about 110 g/m2 to about 135 g/m2, and the combination of the coating and the non-woven veil form a coated-veil that has an outward surface opposite and inward surface, the outward surface formed by the coating and the inward surface formed by the second major surface of the non-wove veil, and the coated-veil exhibiting an airflow resistance of 300 mks or less;
- and
- b) providing a fibrous body having a first major surface opposite a second major surface, and adhering the inward surface of the coated veil to the first major surface of the fibrous body.
1 more element
Dependencies are inferred from the claim text.