Ceiling tile with non uniform binder composition
AssigneeUSG Interiors, Inc.
InventorsMirza A. Baig, William A. Schmitt
Life of this patent
Estimating the term…
Abstract
A ceiling tile product and method in which a slurry formed mat primarily comprising mineral wool and binder is provided with a binder enhancement zone at its face. The binder enhancement zone can reduce the total required latex content, reduce the amount of finish or paint needed to achieve a commercially acceptable color and improve noise reduction.
Claims8
A ceiling tile comprising a slurry formed mat of a nominal thickness of between about ½ inch and about ¾ inch and having at least 75% mineral wool content and 3% binder by weight, the binder being distributed substantially throughout the thickness of the mat and serving to rigidify the mineral wool fibers, and a binder enhancement zone on a face side of the mat, the zone having a binder content per unit thickness substantially greater than the binder content per unit thickness of a main portion of the mat whereby approximately ⅕ to ¼ of the total binder content is in the binder enhancement zone and the remaining respective approximately ⅘ to ¾ binder content is distributed in the mat out of the binder enhancement zone whereby the hardness of the zone is greater than the hardness of the main portion of the mat such that the durability of the tile in resisting physical damage is increased while the overall binder content of the tile can be reduced and consequently the costs of the tile can be reduced.
A ceiling tile comprising a base mat formed from a water slurry of uniformly mixed mineral wool and binder, the mineral wool forming the majority of the weight of the tile, the mat having a relatively low density and being relatively porous, a binder enhancement zone on a face side of the mat formed as a coat of binder on the body of mineral wool and binder from the slurry, the concentration of binder, that serves to hold the mineral wool together and rigidify it, per unit thickness in the binder enhancement zone being substantially greater than the concentration of binder in the mat per unit thickness whereby approximately ⅕ to ¼ of the total binder content is in the binder enhancement zone and the remaining respective approximately ⅘ to ¾ binder content is distributed in the mat out of the binder enhancement zone, the stratified binder distribution producing a higher NRC than a tile of like components but of uniform, greater total binder content.
Dependencies are inferred from the claim text.