Acoustic ceiling tiles with anti-sagging properties and methods of making same
AssigneeUSG Interiors, Inc.
InventorsWei Xu, Brian A. Kemp, Mark H. Englert, Martin W. Brown, Terry L. Rosenstiel
Life of this patent
Estimating the term…
Abstract
An acoustic tile with excellent anti-sagging properties is provided. The tile comprises a soy-protein binder selected from the group consisting of soy flour, soy protein concentrate, soy protein isolate and any combination thereof. In further embodiments, the tile further comprises polyamide-epichlorohydrin. Other tiles include those made with a thermosetting binder selected from the group consisting of an acrylic binder, a polyester binder, an acrylo-polyester binder and any mixture thereof. Energy-efficient methods for making the tiles are also provided.
Claims19
An acoustic tile comprising mineral wool and a soy protein binder selected from the group consisting of soy flour, soy protein concentrate, soy protein isolate and any combination thereof, wherein the mineral wool is mixed and cross-linked with the soy protein binder.
A method for obtaining an acoustic tile, the method comprising the following steps:
- 1) melting slag, basalt, concrete debris or any mixture thereof to produce molten mineral wool;
- 2) spinning mineral wool fibers from the molten mineral wool;
- 3) spraying a soy protein binder onto the mineral wool fibers;
- and
- 4) forming the acoustic panel from the mineral wool fibers sprayed with the soy protein binder.
An acoustic tile comprising mineral wool and a thermosetting binder selected from the group consisting of an acrylic binder, a polyester binder, an acrylo-polyester binder and any mixture thereof, wherein the mineral wool is cross-linked with the thermosetting binder.
A method of making an acoustic panel, the method comprising:
- 1) melting slag, basalt, concrete debris or any mixture thereof to produce molten mineral wool;
- 2) spinning mineral wool fibers from the molten mineral wool;
- 3) spraying a thermosetting binder onto the mineral wool fibers;
- and
- 4) forming the acoustic panel from the mineral wool fibers sprayed with the thermosetting binder.
A method for making a cast acoustic tile, the method comprising:
- 1) mixing water with soy flour,
- 2) adding the mixture to stucco and mineral wool and thereby forming a slurry;
- 3) adding polyamide-epichlorohydrin to the slurry;
- and
- 4) forming an acoustic tile.
Dependencies are inferred from the claim text.