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US 8,062,565 B2Granted
Low density non-woven material useful with acoustic ceiling tile products
AssigneeUSG Interiors, Inc.
InventorsDonald S. Mueller, Bangji Cao, Weixin D. Song, Qing Yu
Life of this patent
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Abstract
A non-woven material, that can be formed into an acoustic ceiling tile, is provided. The material includes a substantially planar and self-supporting core of an inorganic base fiber and a synthetic thermal bonding fiber. The synthetic thermal bonding fiber preferably has an increased bonding surface area that improves adhesion and porosity to provide a base mat or core with a low density to provide sound absorption required by an acoustic ceiling tile.
Claims7
A method of forming an acoustic ceiling tile comprising:
- preparing an aqueous slurry that includes synthetic thermal bonding fibers and inorganic base fibers, the synthetic thermal bonding fibers having a plurality of microbranches extending from outer surfaces thereof to provide a bonding surface area;
- forming the aqueous slurry into a non-woven material having a substantially planar and self-supporting core of up to about 7 pcf to about 13 pcf;
- and
- forming the core into the acoustic ceiling tile to exhibit a noise reduction coefficient of at least about 0.55.
1 more element
Dependencies are inferred from the claim text.