CA2496333A1 - Abuse-resistant cast acoustical ceiling tile having an excellent sound absorption value - Google Patents
Abuse-resistant cast acoustical ceiling tile having an excellent sound absorption value Download PDFInfo
- Publication number
- CA2496333A1 CA2496333A1 CA002496333A CA2496333A CA2496333A1 CA 2496333 A1 CA2496333 A1 CA 2496333A1 CA 002496333 A CA002496333 A CA 002496333A CA 2496333 A CA2496333 A CA 2496333A CA 2496333 A1 CA2496333 A1 CA 2496333A1
- Authority
- CA
- Canada
- Prior art keywords
- aggregate particles
- ceiling tile
- pulp
- microns
- aggregate
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
- 238000010521 absorption reaction Methods 0.000 title abstract 3
- 239000002245 particle Substances 0.000 claims abstract 23
- VTYYLEPIZMXCLO-UHFFFAOYSA-L Calcium carbonate Chemical compound [Ca+2].[O-]C([O-])=O VTYYLEPIZMXCLO-UHFFFAOYSA-L 0.000 claims abstract 10
- 229910000019 calcium carbonate Inorganic materials 0.000 claims abstract 5
- 229920002472 Starch Polymers 0.000 claims 2
- 239000011888 foil Substances 0.000 claims 2
- 239000008107 starch Substances 0.000 claims 2
- 235000019698 starch Nutrition 0.000 claims 2
- 239000004927 clay Substances 0.000 claims 1
- 239000000835 fiber Substances 0.000 claims 1
- 239000011521 glass Substances 0.000 claims 1
- 239000004579 marble Substances 0.000 claims 1
- 239000002557 mineral fiber Substances 0.000 claims 1
- 239000011490 mineral wool Substances 0.000 claims 1
- 239000000203 mixture Substances 0.000 claims 1
- 239000010451 perlite Substances 0.000 claims 1
- 235000019362 perlite Nutrition 0.000 claims 1
- 239000004576 sand Substances 0.000 claims 1
- 239000004575 stone Substances 0.000 claims 1
- 239000010455 vermiculite Substances 0.000 claims 1
- 229910052902 vermiculite Inorganic materials 0.000 claims 1
- 235000019354 vermiculite Nutrition 0.000 claims 1
- 238000005266 casting Methods 0.000 abstract 1
- 230000006835 compression Effects 0.000 abstract 1
- 238000007906 compression Methods 0.000 abstract 1
- 239000000463 material Substances 0.000 abstract 1
Classifications
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B9/00—Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation
- E04B9/04—Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation comprising slabs, panels, sheets or the like
- E04B9/045—Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation comprising slabs, panels, sheets or the like being laminated
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/62—Insulation or other protection; Elements or use of specified material therefor
- E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
- E04B1/82—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to sound only
- E04B1/84—Sound-absorbing elements
- E04B2001/8457—Solid slabs or blocks
- E04B2001/8461—Solid slabs or blocks layered
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24355—Continuous and nonuniform or irregular surface on layer or component [e.g., roofing, etc.]
- Y10T428/24372—Particulate matter
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24355—Continuous and nonuniform or irregular surface on layer or component [e.g., roofing, etc.]
- Y10T428/24372—Particulate matter
- Y10T428/24421—Silicon containing
- Y10T428/2443—Sand, clay, or crushed rock or slate
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24479—Structurally defined web or sheet [e.g., overall dimension, etc.] including variation in thickness
- Y10T428/24595—Structurally defined web or sheet [e.g., overall dimension, etc.] including variation in thickness and varying density
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24479—Structurally defined web or sheet [e.g., overall dimension, etc.] including variation in thickness
- Y10T428/24595—Structurally defined web or sheet [e.g., overall dimension, etc.] including variation in thickness and varying density
- Y10T428/24603—Fiber containing component
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24802—Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]
- Y10T428/24893—Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.] including particulate material
Abstract
An abuse-resistant, cast acoustical ceiling tile having improved impact resistance and excellent sound absorption values. The ceiling tiles have aggregate particles applied to the surface of a wet pulp in the casting process and the particles are embedded in the pulp by compression with a roll and/or smooth plates. The aggregate particles have an average particle diameter of at least about 1,000 microns.
The ceiling tiles have excellent sound absorption properties with a noise reduction coefficient (NRC) of at least about 0.50. Calcium carbonate is the preferred aggregate particle material.
The ceiling tiles have excellent sound absorption properties with a noise reduction coefficient (NRC) of at least about 0.50. Calcium carbonate is the preferred aggregate particle material.
Claims (14)
1. An abuse-resistant, cast acoustical ceiling tile having a core made from a starch gel and mineral wool fiber composition, wherein the front surface of the tile is coated with aggregate particles having an average particle mean diameter of at least about 1,000 microns.
2. The ceiling tile of claim 1 wherein the aggregate particles are selected from the group consisting of calcium carbonate, crushed marble, sand, clay, perlite, vermiculite, crushed stone and glass.
3. The ceiling tile of claim 2 wherein the aggregate particles are calcium carbonate.
4. The ceiling tile of claim 3 wherein the aggregate particles have an average particle mean diameter ranging from about 1,000 microns to about 3,000 microns.
5. The ceiling tile of claim 3 wherein the aggregate particles have an average particle mean diameter ranging from about 1,400 microns to about 2,500 microns.
6. The ceiling tile of claim 1 which has a noise reduction coefficient (NRC) value of at least about 0.50.
7. The ceiling tile of claim 2 which has a noise reduction coefficient (NRC) value of at least about 0.50.
8. The ceiling tile of claim 3 which has a noise reduction coefficient (NRC) value of at least about 0.50.
9. The ceiling tile of claim 4 which has a noise reduction coefficient (NRC) value of at least about 0.50.
10. A process for making an abuse-resistant, cast ceiling tile wherein a wet mineral fiber/starch gel pulp is fed to a paper, foil or paper backed foil lined tray from a headbox;
the pulp-filled tray is passed under a hopper which contains aggregate particles;
the aggregate particles are fed from the hopper onto the surface of the wet pulp in the tray so as to provide a uniform layer of aggregate particles across the surface of the wet pulp;
the wet pulp covered by a layer of aggregate particles is passed under a means to press the particles into the pulp; and then the tray containing the aggregate particle covered wet pulp is passed into a drier.
the pulp-filled tray is passed under a hopper which contains aggregate particles;
the aggregate particles are fed from the hopper onto the surface of the wet pulp in the tray so as to provide a uniform layer of aggregate particles across the surface of the wet pulp;
the wet pulp covered by a layer of aggregate particles is passed under a means to press the particles into the pulp; and then the tray containing the aggregate particle covered wet pulp is passed into a drier.
11. The process of claim 10 wherein the aggregate particles are fed from the hopper onto the surface of the wet pulp at a rate ranging from about 0.1 to about 1 pound per square foot of surface.
12. The process of claim 10 wherein the aggregate particles are fed from the hopper onto the surface of the wet pulp at a rate ranging from about 0.2 to about 0.5 pound per square foot of surface.
13. The process of claim 10 wherein the aggregate particles are calcium carbonate.
14. The process of claim 11 wherein the aggregate particles are calcium carbonate.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US10/789,000 US8337976B2 (en) | 2004-02-26 | 2004-02-26 | Abuse-resistant cast acoustical ceiling tile having an excellent sound absorption value |
| US10/789,000 | 2004-02-26 |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CA2496333A1 true CA2496333A1 (en) | 2005-08-26 |
| CA2496333C CA2496333C (en) | 2012-10-23 |
Family
ID=34887156
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA2496333A Expired - Fee Related CA2496333C (en) | 2004-02-26 | 2005-02-07 | Abuse-resistant cast acoustical ceiling tile having an excellent sound absorption value |
Country Status (3)
| Country | Link |
|---|---|
| US (1) | US8337976B2 (en) |
| CA (1) | CA2496333C (en) |
| MX (1) | MXPA05001936A (en) |
Families Citing this family (19)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| USRE44070E1 (en) | 2005-06-09 | 2013-03-12 | United States Gypsum Company | Composite light weight gypsum wallboard |
| US7731794B2 (en) | 2005-06-09 | 2010-06-08 | United States Gypsum Company | High starch light weight gypsum wallboard |
| US11306028B2 (en) | 2005-06-09 | 2022-04-19 | United States Gypsum Company | Light weight gypsum board |
| US11338548B2 (en) | 2005-06-09 | 2022-05-24 | United States Gypsum Company | Light weight gypsum board |
| US9802866B2 (en) | 2005-06-09 | 2017-10-31 | United States Gypsum Company | Light weight gypsum board |
| US9840066B2 (en) | 2005-06-09 | 2017-12-12 | United States Gypsum Company | Light weight gypsum board |
| US20070102237A1 (en) * | 2005-11-04 | 2007-05-10 | Usg Interiors, Inc. | Acoustical gypsum board for ceiling panel |
| US8262820B2 (en) | 2006-04-28 | 2012-09-11 | United States Gypsum Company | Method of water dispersing pregelatinized starch in making gypsum products |
| US7862687B2 (en) | 2007-11-20 | 2011-01-04 | United States Gypsum Company | Process for producing a low density acoustical panel with improved sound absorption |
| US8303159B2 (en) * | 2008-09-05 | 2012-11-06 | United States Gypsum Company | Efficient wet starch preparation system for gypsum board production |
| US8062565B2 (en) * | 2009-06-18 | 2011-11-22 | Usg Interiors, Inc. | Low density non-woven material useful with acoustic ceiling tile products |
| US20130196151A1 (en) * | 2010-10-18 | 2013-08-01 | Usg Interiors, Llc | Water resistant ceiling tile |
| US10072366B2 (en) | 2014-10-29 | 2018-09-11 | Nonwoven Network LLC | Moldable automotive fibrous products with enhanced heat deformation |
| US9533630B2 (en) | 2014-10-29 | 2017-01-03 | Nonwoven Network LLC | High performance moldable composite |
| US9938659B2 (en) | 2015-06-27 | 2018-04-10 | Nonwoven Network LLC | Apparatus and method of making a nonwoven ceiling tile and wall panel |
| HRP20230920T1 (en) * | 2015-09-11 | 2023-11-24 | Rockwool A/S | Acoustic panel |
| US9670673B2 (en) * | 2015-11-09 | 2017-06-06 | Awi Licensing Llc | Ceiling system |
| US10696594B2 (en) | 2017-08-11 | 2020-06-30 | Usg Interiors, Llc | High noise reduction coefficient, low density acoustical tiles |
| US10464846B2 (en) | 2017-08-17 | 2019-11-05 | Usg Interiors, Llc | Method for production of acoustical panels |
Family Cites Families (17)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US1925282A (en) | 1929-10-11 | 1933-09-05 | Lancaster Asphalt Inc | Roofing elements and method of applying surfacing materials thereto |
| US1966069A (en) | 1932-10-26 | 1934-07-10 | Burgess Lab Inc C F | Acoustic tile and method of manufacturing the same |
| US3184372A (en) * | 1962-03-28 | 1965-05-18 | Celotex Corp | Felted inorganic fiber panel |
| US3357516A (en) | 1964-04-20 | 1967-12-12 | Wood Conversion Co | Acoustical panels |
| US3870540A (en) | 1970-06-24 | 1975-03-11 | Fred C Norgard | Surface texture for fibrous boards |
| US3968274A (en) | 1971-05-12 | 1976-07-06 | Johns-Manville Corporation | Textural panel |
| US3963847A (en) | 1972-04-05 | 1976-06-15 | Johns-Manville Corporation | Surface texture for fibrous boards |
| US3933561A (en) * | 1974-03-27 | 1976-01-20 | North Star Research Institute | Process for manufacturing ultrathin polymer membranes and products derived therefrom |
| US4463039A (en) * | 1982-01-06 | 1984-07-31 | United States Gypsum Company | Sprayable acoustical composition |
| US4585685A (en) * | 1985-01-14 | 1986-04-29 | Armstrong World Industries, Inc. | Acoustically porous building materials |
| US5076985A (en) | 1989-10-02 | 1991-12-31 | Knauf Fiber Glass, Gmbh | Method for forming ceiling tile |
| ID17684A (en) | 1996-02-08 | 1998-01-22 | Bpb Plc | SHOULDER BOARD |
| US5858095A (en) | 1996-04-30 | 1999-01-12 | Owens Corning Fiberglas Technology, Inc. | Shuttle cutoff for applying granules to an asphalt coated sheet |
| US5753871A (en) * | 1996-07-23 | 1998-05-19 | Usg Interiors, Inc. | Sag resistant, cast acoustical ceiling tile and method for making the same |
| US6268042B1 (en) * | 1999-05-11 | 2001-07-31 | United States Gypsum Company | High strength low density board for furniture industry |
| US20020096278A1 (en) * | 2000-05-24 | 2002-07-25 | Armstrong World Industries, Inc. | Durable acoustical panel and method of making the same |
| US6443256B1 (en) * | 2000-12-27 | 2002-09-03 | Usg Interiors, Inc. | Dual layer acoustical ceiling tile having an improved sound absorption value |
-
2004
- 2004-02-26 US US10/789,000 patent/US8337976B2/en not_active Expired - Fee Related
-
2005
- 2005-02-07 CA CA2496333A patent/CA2496333C/en not_active Expired - Fee Related
- 2005-02-18 MX MXPA05001936A patent/MXPA05001936A/en active IP Right Grant
Also Published As
| Publication number | Publication date |
|---|---|
| US20050191465A1 (en) | 2005-09-01 |
| US8337976B2 (en) | 2012-12-25 |
| CA2496333C (en) | 2012-10-23 |
| MXPA05001936A (en) | 2005-08-30 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| EEER | Examination request | ||
| MKLA | Lapsed |
Effective date: 20210208 |