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AssigneeUSG Interiors, Inc.
InventorsMirza A. Baig, Mark H. Englert, John C. Gaynor, Michael A. Kacner, Rajinder Singh
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A mineral wool-free acoustical tile composition and the acoustical tile made therefrom wherein an expanded perlite is used as a substitute for granulated mineral wool to provide porosity and good sound absorption properties. It is preferred that the composition and acoustical tile also contain an inorganic filler to provide texturability during the manufacturing process. In addition, the acoustical tile composition also contains a starch gel binder and a fiber reinforcing agent selected from the group consisting of cellulosic fibers, polymeric fibers and glass fibers. It has been found that the mineral wool-free acoustical tile compositions of this invention have acoustical properties comparable to the commercially available cast mineral wool tiles. In addition, the mineral wool-free compositions can be used to cast an acoustical tile using equipment and procedures currently used to produce cast mineral wool tiles.
A wetted, mineral wool-free pulp composition suitable for making acoustical tiles comprising at least about 10% by weight on a dry solids basis of expanded perlite, at least about 5% by weight on a dry solids basis of a starch gel binder, at least about 35% by weight on a dry solids basis of an inorganic mineral filler selected from the group consisting of calcium sulfate dihydrate, calcium sulfate hemihydrate, silicates, limestone and alumina, and from about 2% to about 10% by weight of a fiber reinforcing agent selected from the group consisting of polymeric fibers and glass fibers.
A dry mineral wool-free acoustical tile comprising at least about 10% by weight of expanded perlite, at least about 5% by weight of a starch binder, at least about 35% by weight of an inorganic mineral filler selected from the group consisting of calcium Sulfate dihydrate, Calcium Sulfate hemihydrate, silicates, limestone and alumina, and from about 2% to about 10% by weight of a fiber reinforcing agent selected from the group consisting of polymeric fibers and glass fibers.
A dry mineral wool-free acoustical tile comprising about 40% by weight of expanded perlite, about 40% by weight of tabular acicular gypsum, about 15% by weight of a starch binder and about 5% by weight of a glass fiber reinforcing agent.
Dependencies are inferred from the claim text.