Acoustical tile composition
AssigneeUSG Interiors, Inc.
InventorMirza A. Baig
Life of this patent
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Abstract
A composition suitable for making acoustical tiles in a water-felting process comprises expanded perlite, clay, a binder component selected from the group consisting of starch, latex, cellulosic fiber and mixtures thereof and optionally mineral wool. The use of an expanded perlite having a relatively high density, preferably between about 9 pounds per cubic foot to about 20 pounds per cubic foot, enables the formation of a suitable slurry with a relatively low amount of water and enables a more complete dewatering of the mat prior to drying.
Claims16
In a continuous process for making acoustical tiles in a water-felting process which includes the steps of forming an aqueous slurry comprising expanded perlite, clay, optionally mineral wool and a binder component selected from the group consisting of starch, latex, cellulosic fiber and mixtures thereof with water, continuously flowing said slurry onto a moving foraminous support wire to form a cake, dewatering said cake to form a basemat, and drying said basemat to produce acoustical tile, the improvement comprising, in order to enable an increase in the speed of the process, forming said slurry from expanded perlite having a density a from about 9 pounds per cubic foot to about 20.0 pounds per cubic foot, and operating said process at a speed selected to continuously dewater said cake to form a high solids basemat and to continuously dry water from said high solids basemat to produce acoustical tile.
Dependencies are inferred from the claim text.