Usg Interiors, Inc.

United States Gypsum Company

Wei Xu

Martin W Brown

Thomas M Mayers

Brian A Kemp

Alfred C Li

Mark H Englert

Terry L Rosenstiel

Mark B Scalf

Lori Tuttle

Michael J Hough

David Song

Derrick Hutchinson

Christopher J Rokke

Scott C Bakken

Composite roofing structures can include mineral fiber roof cover boards with high concentration of mineral wool or mineral wool and perlite. The roofing structure may include: a roof cover board including a dried base mat including: 8-25% mineral wool, 40-65% perlite, 9-15% binder, 9-15% cellulosic fiber, and 0.25-2% sizing agent, all % by weight; an insulation layer; and a roofing membrane. The roof cover board is over the insulation layer, the roofing membrane is over the roof cover board. The roof cover board is attached to the insulation layer. The roofing membrane is attached to the roof cover board. Alternatively dried base mat may include: 30-70% mineral wool, 10-50% perlite, 5-15% binder, 2-20% cellulosic fiber, and 0.25-2% sizing agent. Alternatively the dried base mat may include: 60-90% mineral wool, 0-10% fiber, 0-10% perlite, 4-10% binder, 0-5% gypsum, and 0.25-2% sizing agent.

Mineral fiber roof cover boards

Acoustical tile including a dried base mat of: about 70 to about 90 wt % mineral wool; about 5 to about 15 wt % perlite; 0 to about 10 wt % starch; about 3 to about 10 wt % latex; 0 to about 5 wt % gypsum; and less than 5 wt % water. The dried base mat without including glass fibers and without a laminate layer or coating and without perforations has a NRC of about 0.70 or greater, a density of about 10 pcf to about 12 pcf, and a thickness of about &#xbd; to about 1 inch. The acoustical tile can further include a back coating at a surface weight of about 5 grams per square foot (gsf) to about 40 gsf to the dried base mat, wherein the acoustical tile has the CAC rating of about 30 to about 35.

High noise reduction coefficient, low density acoustical tiles

A method of decreasing the water load needed to form a fibrous panel. The process includes admixing a mineral wool, a cellulose, and a binder to provide a pre-mixed slurry, admixing a mineral filler with water to provide a mineral filler slurry, admixing the pre-mixed slurry and the mineral filler slurry to form a dispersion, flowing the dispersion onto a foraminous support wire to provide a green board, dewatering the green board to form a dewatered green board and drying the dewatered green board to provide a fibrous panel.

Method for production of acoustical panels

A gypsum product with improved elasticity and increased nail-pull strength is provided, the product made with a glass fiber mat in which glass fibers are cross-linked with a polymeric resin. Further embodiments provide methods for making the glass fiber mats and gypsum products.

Gypsum products with improved glass fiber mat

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

A less costly multi-layer acoustical panel having improved noise absorption properties includes a fiberglass layer and a mineral wool layer wherein the fiberglass layer has a fibrous content comprising at least about 50% by weight of glass fiber and the mineral wool layer has a fibrous content comprising at least about 50% by weight of mineral wool fiber. The noise absorption coefficient of the panel is linearly related to increases in the thickness of the fiberglass layer. A lamination technique for making the panels is also disclosed.

Growing community of inventors

Vernon Hills, IL, United States of America

Wei Xu