Sag resistant acoustical ceiling panel with a filled latex binder system that enhances strength and durability
AssigneeAWI Licensing LLC
InventorsCharles G Krick, Bartolo J Torre, Anthony L Wiker, James D Pape
Life of this patent
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Abstract
Described herein is a building panel comprising a body, the body comprising: a fiber; a latex binder present in an amount ranging from about 3 wt. % to about 10 wt. % based on the total weight of the body; and an inorganic particle having an average particle size ranging from about 1 micron to about 13 microns; wherein the inorganic particle and the binder are present in a weight ratio ranging from about greater than 1:1 to about 6:1.
Claims18
A building panel comprising a body, the body comprising:
- a fiber;
- a latex binder present in an amount ranging from about 3 wt. % to about 10 wt. % based on the total weight of the body;
- calcium carbonate particle having an average particle size ranging from about 4 microns to about 6 microns;
- and
- an ionic charge-modifying component present in an amount ranging from about 30 wt. % to about 60 wt. % based on the total weight of the latex binder;
- wherein the ionic charge-modifying component comprises aluminum sulfate;
- wherein the calcium carbonate particle and the latex binder are present in a weight ratio of 3:1;
- and
- wherein the body comprises a first major surface opposite a second major surface and a plurality of side surfaces extending between the first major surface and the second major surface, wherein the body has a porosity ranging from about 80% to about 98% as measured between the first major surface, the second major surface, and the plurality of side surfaces.
A building panel comprising a body, the body comprising:
- an inorganic fiber in an amount ranging from about 70 wt. % to about 95 wt. % based on the total weight of the body;
- a latex binder in an amount ranging from about 3 wt. % to about 10 wt. %;
- and
- an inorganic particle comprising kaolin present in an amount ranging from about 3 wt. % to about 30 wt. % based on the total weight of the body, wherein the kaolin particle has an average size ranging from about 8 micron to about 13 microns;
- and
- wherein the body comprises a first major surface opposite a second major surface and a plurality of side surfaces extending between the first major surface and the second major surface, wherein the body has a porosity ranging from about 80% to about 98% as measured between the first major surface, the second major surface, and the plurality of side surfaces;
- and
- wherein the body has an airflow resistance less than about 200 MKS rayls as measured between the first major surface and the second major surface.
A building panel comprising a body having a first major surface opposite a second major surface, the body comprising:
- an inorganic fiber;
- a latex binder comprising a copolymer of poly(styrene-acrylate);
- calcium carbonate particle having an average size of about 5 microns;
- an ionic charge-modifying component comprising poly(diallyldimethylammonium chloride) present in an amount ranging from about 0.1 wt. % to about 4.0 wt. % based on the total dry-weight of the body;
- and
- wherein the calcium carbonate particle and the latex binder are present in a weight ratio of about 3:1, and wherein the body has an airflow resistance less than about 200 MKS rayls as measured between the first major surface and the second major surface.
Dependencies are inferred from the claim text.