Usg Interiors, Inc.

United States Gypsum Company

Mark H Englert

Richard B Stevens

Steven W Sucech

Qing Claire Yu

Michael J Porter

William A Frank

Martin W Brown

Runhai Lu

Bruce Lynn Petersen

David G Izard

Adelaida L Carbo

Russell A Dombeck

Therese A Fults

Daniel E Boss

Qiang Yu

Salvatore C Immordino, Jr

Srinivas Veeramasuneni

Terry L Rosenstiel

Mirza A Baig

Raymond John Mlinac

W David Song

Wei Xu

Matthew T Langdon

Rodney Phillip Musselman

Brian A Kemp

Rajinder Singh

Jim Thulin

Michael A Kacner

John C Gaynor

James C Thulin

Rodney Philip Musselman

An acoustical tile including: 8 to 25 wt % mineral wool, 9 to 15 wt % starch binder, 9 to 15 wt % cellulosic fiber, wherein preferably the cellulosic fiber is newsprint, and 40 to 65 wt % perlite, wherein the weight ratio of the starch to the cellulosic fiber is 0.6 to 1.3:1; and a process for making the acoustical tile.

Acoustical ceiling tile

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.

Acoustic ceiling tiles with anti-sagging properties and methods of making same

The invention, provides a curable, formaldehyde free coating composition comprising a composition comprising a polyacid copolymer crosslinked with a hydroxyl group-containing compound and calcium aluminosilicate powder, panels coated with the coating composition, and a method of coating a panel with the coating composition.

Formaldehyde free coatings for panels

An acoustical ceiling panel comprising a flat core and an acoustically transparent face sheet adhesively attached to one of two oppositely facing major sides of the core, the core comprising a multitude of layers of corrugated fiberboard laminated together, the corrugated fiberboard layers each having a corrugated medium adhesively attached to a flat liner board, the corrugated medium forming regularly spaced flutes of curvilinear cross-section, the flutes of the layers of fiberboard being arranged in parallel directions extending perpendicularly to the major faces of the core.

Ceiling panels made from corrugated cardboard

An acoustical panel construction useful as a suspended ceiling tile having a rectangular shape bounded by edges and establishing a face area comprising at least one corrugated layer or layers of a total thickness, the layer or layers having a multitude of parallel flutes extending across an expanse of the rectangular shape substantially from one edge of the panel to an opposite edge, the flutes being formed by walls of the layer or layers and being of known volume, a series of apertures each of known area through the wall or walls of the flutes communicating with the atmosphere at the face, the aperture area, flute cavity volume associated with an aperture, and the total thickness of the corrugated layers associated with an aperture being arranged to produce a maximum absorption frequency between 200 and 2,000 Hz.

Corrugated acoustical panel

Ceiling tile

An acoustical panel is made by applying a thin, acoustically-transparent coating to an acoustical base mat. A pulp is made from one or more fillers, a fibrous filler, a binder and water. A thickener solution is prepared from a thickener and water. A portion of the pulp and the thickener solution are mixed under high shear conditions to degrade the fibrous filler and form a smooth coating. The coating is applied to and distributed over a base mat and the coated base mat is then cut and dried to form a coated acoustical panel. The panel is free of visible mineral nodules on the surface of the coating. Optionally, the pulp is a portion of a pulp used to make the base mat. Other embodiments include the use of recycled dust or fine particles of the acoustical panel obtained from cutting or shaping the base mat or coated panels.

Method of making a coating and a coated acoustical panel using degraded fibers

The acoustical product of the present invention comprises an acoustical product including a matrix of calcium sulfate dihydrate crystals and expanded perlite distributed throughout the matrix. The expanded perlite has a particle size distribution with at least 10% of the perlite having a particle diameter of 700 microns or more, and the amount of expanded perlite to calcium sulfate dihydrate is about 35% to about 75% by weight, based upon the dry weight of the calcium sulfate dihydrate. A dispersing agent and glass fibers having a particle length of about &#xbc; inch to about 1 inch are dispersed throughout the gypsum matrix.

Acoustical gypsum board panel and method of making it

A lightweight cast article that is made by the method of the present invention. A foamed acoustical product is prepared by blending a starch with cold water, then heating the starch/water blend to form a starch gel. Mineral wool is added to the starch gel to form a pulp and the pulp is wet-mixed until wool nodules are formed. The pulp is then combined with a surfactant and an amount of foam water. The foaming agent is selected from the group consisting of a linear sodium dodecylbenzene sulfonate, a cocamidopropyl betaine, a cocamidopropyl hydroxysultaine, their salts and mixtures thereof. Mixing of the foaming agent and pulp continues to form a foamed pulp. The foamed pulp is cast into a mold and allowing the foamed pulp to dry forming a foamed product. The foamed product is removed from the mold.

Molding a lightweight cast acoustical product

A composition for a slurry for manufacture of a building panel includes one or more fillers, one or more binders and water. One or more fillers is an expanded perlite at least partially covered with a film-forming, thermoplastic polymer coating Some embodiments use calcined or uncalcined gypsum as a binder or filler. One embodiment is a building panel that includes a solid matrix of calcium sulfate dihydrate crystals bound to expanded perlite. A method of making the panel includes acquiring expanded perlite and coating it with film-forming, thermoplastic polymer coating. After the expanded perlite is prepared, it is combined with water other optional fillers and one or more binders to form a slurry. The slurry is shaped into a panel and allowed to dry.

Slurry and acoustical panel with reduced bound water

A process useful for producing low density high mineral wool based acoustical panels with improved acoustical absorption properties using a water felting process is disclosed. The process includes forming a dilute slurry mixture including water, mineral wool, a thermoplastic binder and/or starch; and distributing the dilute slurry on a porous carrier to have the slurry dewatered to a base mat by gravity drainage to remove water by gravity. A vacuum is adjusted to gradually apply vacuum to the gravity dewatered base mat to further dewater the base mat without subjecting the mat to static pressure that would compress the base mat. The base mat is dried to form an acoustical ceiling product that has a low density and excellent acoustical absorption properties.

Process for producing a low density acoustical panel with improved sound absorption

An acoustical panel comprising a continuous phase of an interlocking set gypsum matrix and a method of preparing an acoustical panel are disclosed.

Acoustical panel comprising interlocking matrix of set gypsum and method for making same

An acoustical panel includes an acoustical layer having an interlocking matrix of calcium sulfate dihydrate, polyethylene glycol and at least one of the group fibers, a lightweight aggregate and mixtures thereof. The acoustical layer has voids in the interlocking matrix that are configured to absorb sound. The polyethylene glycol is selected to agglomerate dust at temperatures generated by friction when the panel is cut. A method of making the acoustical panel includes making a slurry comprising calcium sulfate hemihydrate, polyethylene glycol, water and at least one of the group consisting of a lightweight aggregate, fibers and combinations thereof. Foam is added to the slurry, preferably at the mixer discharge. A continuous strip of acoustical layer material is formed from the slurry. The acoustical panels are formed by cutting the strip into individual panels. Finally, the partially hydrated calcium sulfate hemihydrate is allowed to fully set.

Reduced dust acoustic panel

The invention provides a board forming system comprising a forming table comprising a belt with a surface for conveying a backing layer; a mixer fitted with a mechanism capable of depositing cementitious slurry material over a top surface of the backing layer; and a slurry spreader positioned downstream of the mixer, wherein a portion of the slurry spreader comprises a plurality of apertures which are connected to a source of pressurized fluid. The slurry spreader is configured such that the pressurized fluid flows out of the slurry spreader through the apertures so as to provide a continuous film of fluid across an outer surface of the slurry spreader. The slurry spreader is positioned such that it can contact at least a portion of the cementitious slurry after the slurry exits the discharge and before the slurry is spread across the width of the backing layer such that the thickness of the slurry is approximately equal to the desired slurry thickness for board formation. The invention further provides methods for forming cementitious board comprising the use of the slurry spreader.

Growing community of inventors

Libertyville, IL, United States of America

Mark H Englert