Scratch resistant discontinuous acoustical surface coating
AssigneeAWI Licensing LLC
InventorsHector Belmares, Kenneth G. Caldwell
Life of this patent
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Abstract
The present invention provides for both a composition and method for producing a scratch resistant coating applied to an acoustical panel. The coating primarily comprises binder, filler and mica and is typically applied as a spray. The coating can be characterized as a discontinuous film, whereby sound can pass through the coating to the panel for attenuating sound. The coating is thus enabled to provide a finish and color without compromising the acoustical performance of the substrate. The process primarily comprises combining and mixing the dry components of filler, binder and mica and then combining the same with water and mixing to create an aqueous mix that can be applied to the acoustical panel and dried.
Claims26
A scratch resistant discontinuous acoustical surface film on a dry weight percent basis comprising:
- about 4 to about 80% mica;
- about 10 to about 45% binder selected from the group consisting of polyacrylic acid and its copolymers, protein/epoxy combinations, carboxylated polymer/epoxy combinations and mixtures thereof;
- about 10 to about 86% filler,
- wherein the film includes pores formed therein through which sound passes.
A composition for forming a scratch resistant discontinuous acoustical surface film, comprising:
- about 4 to about 80% by dry weight mica;
- about 10 to about 45% by dry weight binder;
- about 10 to about 86% by dry weight filler;
- and
- water in an amount between about 25% to about 90% by weight of the wet composition.
A method for creating a discontinuous acoustical surface film comprising:
- forming a wet mixture comprising:
- about 4 to about 80% by dry weight of mica,
- about 10 to about 45% by dry weight of binder,
- about 10 to about 86% by dry weight of filler, and about 25 to about 90% water by weight of the wet mixture;
- applying the wet mixture onto a panel to form a film thereon;
- and
- forming pores in the film through which sound passes.
A method for creating a discontinuous acoustical surface film, comprising:
- forming a wet mixture comprising;
- about 4 to about 80% by dry weight of mica,
- about 10 to about 45% by dry weight of binder,
- about 10 to about 86% by dry weight of filler, and
- about 25 to about 90% water by weight of the wet mixture;
- and
- spraying the mixture onto a panel at a rate of between about 12 and about 26 g/ft.2;
- and
- forming pores in the sprayed mixture through which sound passes.
An acoustical ceiling panel comprising a substrate and a surface film with pores through which sound passes, the surface film comprising mica, binder and filler, at least one of which is in sufficient quantity to improve by 2 units a finger scratch test of the ceiling panel as compared to an acoustical panel with a mica-free surface film.
An acoustical panel comprising a substrate and a surface film with pores through which sound passes, the surface film comprising mica, binder and filler, at least one of which is in sufficient quantity to improve by 2 units a finger scratch test of the panel as compared to an acoustical panel with a mica-free surface film, wherein the binder is selected from the group consisting of polyacrylic acid and its copolymers, protein/epoxy combinations, carboxylated polymer/epoxy combinations and mixtures thereof.
Dependencies are inferred from the claim text.