CA2813558A1 - Water resistant ceiling tile - Google Patents

Water resistant ceiling tile Download PDF

Info

Publication number
CA2813558A1
CA2813558A1 CA 2813558 CA2813558A CA2813558A1 CA 2813558 A1 CA2813558 A1 CA 2813558A1 CA 2813558 CA2813558 CA 2813558 CA 2813558 A CA2813558 A CA 2813558A CA 2813558 A1 CA2813558 A1 CA 2813558A1
Authority
CA
Canada
Prior art keywords
water
core
tile
coating
ceiling tile
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.)
Abandoned
Application number
CA 2813558
Other languages
French (fr)
Inventor
Fares Saghbini
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
USG Interiors LLC
Original Assignee
USG Interiors LLC
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by USG Interiors LLC filed Critical USG Interiors LLC
Publication of CA2813558A1 publication Critical patent/CA2813558A1/en
Abandoned legal-status Critical Current

Links

Classifications

    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04BGENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B9/00Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation
    • E04B9/04Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation comprising slabs, panels, sheets or the like
    • CCHEMISTRY; METALLURGY
    • C09DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09DCOATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D5/00Coating compositions, e.g. paints, varnishes or lacquers, characterised by their physical nature or the effects produced; Filling pastes
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04BGENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B9/00Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation
    • E04B9/04Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation comprising slabs, panels, sheets or the like
    • E04B9/045Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation comprising slabs, panels, sheets or the like being laminated
    • YGENERAL 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
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/27Web or sheet containing structurally defined element or component, the element or component having a specified weight per unit area [e.g., gms/sq cm, lbs/sq ft, etc.]
    • Y10T428/273Web or sheet containing structurally defined element or component, the element or component having a specified weight per unit area [e.g., gms/sq cm, lbs/sq ft, etc.] of coating
    • YGENERAL 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
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/31504Composite [nonstructural laminate]
    • Y10T428/3154Of fluorinated addition polymer from unsaturated monomers

Landscapes

  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Chemical & Material Sciences (AREA)
  • Civil Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Structural Engineering (AREA)
  • Wood Science & Technology (AREA)
  • Organic Chemistry (AREA)
  • Materials Engineering (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Finishing Walls (AREA)
  • Paints Or Removers (AREA)

Abstract

A ceiling tile comprising a core, an appearance coating on a face side of the tile, and a waterproof coating on a backside of the tile, the core including a filler, binder, and fiber elements dried from a water based slurry or paste of said elements, the core being water permeable and containing a non-white stain producing material susceptible to being leached out of the core by water percolating through the core, the appearance coating exhibiting a high light reflectivity by virtue of containing a white colored constituent and being pervious to water, the waterproof coating serving to repel and bead- up water droplets deposited on the backside of the tile.

Description

WATER RESISTANT CEILING TILE
BACKGROUND OF THE INVENTION
[0001] The invention relates to improvements in construction panels and, in particular, to ceiling tiles made from a water slurry or a water based paste.
PRIOR ART
[0002] Construction panels, particularly, water pervious ceiling tiles have a tendency to become stained when exposed to water. One mechanism that occurs to bring water droplets in contact with a ceiling tile is condensation on pipes and ductwork existing in the space above the ceiling. The condensate can drip onto the backside of the ceiling tile and migrate to the visible appearance side of a tile. Staining can occur because the water can carry off contaminants from surfaces it contacts and, often, because the water droplets migrate through a ceiling tile and leach tannin from recycled newsprint or other plant based cellulose materials and staining agents from other components used in the tile composition bringing such staining agents to the front surface of the tile.
[0003] As is typical of most products, cost is critical and there is a need for an economical solution to minimize water stains on the appearance sides of construction panels, particularly, water pervious ceiling tiles.
SUMMARY OF THE INVENTION
[0004] The invention provides an economical solution to water staining at the visible face of construction panels due to water migration through the panel. More specifically, the invention involves the realization that by creating a barrier to water droplets locally at the backside of a panel, the droplets can be caused to evaporate before their liquid content can migrate through a panel.
[0005] It has been discovered that commercially available material used to impart water repellency to fabric is an excellent medium for accomplishing the objective of the invention. Such material is widely available, non-toxic, and relatively inexpensive in the limited coverage found to be effective in practicing the invention. The preferred waterproof material can be applied with a water carrier by a simple application of the same to the backside of a rigid mat from which the tile is fabricated. The very light coverage and consequent low cost of the waterproofing treatment and the simplicity of application makes it practical for use in even the less expensive product lines of a panel manufacturer.
[0006] The core mat or tile is preferably subjected to an elevated temperature to quickly force dry or cure the waterproofing material before the carrier water can be absorbed through the core mat. Preferably, this drying process can be done simultaneously with the conventional process step used to dry a finish coat or paint on the visible side of the tile or panel.
BRIEF DESCRIPTION OF THE DRAWING
[0007] FIG. 1 is a diagrammatic isometric view of a ceiling tile embodying the invention; and [0008] FIG. 2 is a schematic diagram of a process utilizing the invention.

DESCRIPTION OF THE PREFERRED EMBODIMENT
65% perlite filler 18% paper fiber 7% unmodified starch binder, and 10% mineral wool fiber.
considerably, say up to about 25% and in such a case, the perlite can be reduced accordingly. Besides paper fiber, other cellulose sources can be used such as wood or woody plant materials. When these constituents have been properly mixed in a water slurry and spread on a screen, in the case of a water felted product, or similar constituents are spread on a pan in the case of a cast tile, they are dewatered and/or dried into a rigid board. Thereafter, the appearance or front side of the board or tile preform is coated with an appearance coating or paint usually a water based material having some latex or other binder component.
In the case of a water felted mat or core, the finish side of the mat, if necessary, can be ground to create a flat surface prior to coating with a finish or top coating.
Additionally, prior to application of the finish coat, a primer coat, that may be clay based, for example, can be applied to the face side of the mat. The tile 10 of FIG. 1 is shown in its installed orientation and includes an appearance coating 11 on its lower, visible face, a primer coat 12, a water felted mat or core 13, and a waterproof coating 14, discussed below, on its back or upper face.
[0011] The appearance coat 11 on the finish side of the tile 10, as mentioned, is typically a water based coating with a white pigment color to provide high light reflectivity. It has been discovered that commercially available fabric waterproofing material can be used to successfully waterproof the back of the tile 10 by coating the mat 13 with such material. Surprisingly, it has been found that only relatively small quantities of such material need be used to achieve satisfactory results.
An example of a product suitable for practicing the invention is a fluorocarbon polymer emulsion such as that marketed by Daikin Chemical Europe GmbH, Dusseldorf, Germany, under the brand TG-5601. This product is a water based emulsion which can be greatly diluted with water while remaining effective even when the application rate is imprecise. The result of the dilution of the original emulsion is a very light coating of waterproofing solids of about 1/5 to 1/4 grams/sq. ft. Despite such a low concentration of solids, it has been found that a surprising degree of waterproofing and resistance is achieved. With the disclosed solids coverage rate, water droplets on the coating 14 simply bead-up and eventually evaporate.
[0012] FIG. 2 illustrates an example of a process for practicing the invention. A dried mat or board 13 made by a conventional water felting process with a solids content such as described above is carried on a conveyor 20 into a spray booth 21 where a water based top coat or paint 11 is applied. The top coat or appearance coat 11 faces up in this process but when the tile is installed in a ceiling, the top coat faces down. The mat 13 is conveyed from the spray booth to a dryer 22 by a roller conveyor 23.
A sprinkler 24 carrying a plurality of spray nozzles extends between a pair of rolls of the conveyor 23 across the width of the conveyor. The sprinkler 24 sprays the underside of the mat 13 with dilute waterproofing liquid 14 described above. The mat 13 coated with the top coat 11 and waterproof material 14 is conveyed by a conveyor 26 through the dryer 22 where these coatings are preferably simultaneously dried and/or cured for example, at a temperature of about 220 C. for a duration of about 45 seconds. Other methods of applying the top coat and waterproofing material are contemplated. For example, roll coating or flooding can be employed.
[0013] Water condensate dripping from piping and ducts within the space or plenum above a suspended ceiling can fall onto the backside of a prior art ceiling tile eventually causing discoloration on the face or appearance side. This mechanism of discoloration or staining can be attributed to percolation of the condensate water through a tile. The condensate may be contaminated by surfaces it passes over before reaching the tile. Additionally, as the water percolates through the body of the tile, it can leach stain producing material such as tannins present in the paper or cellulose fibers. The contaminated water can leak through the appearance coating and thereby stain it. Water passage through a tile, where the invention is not employed, is commonplace where there is a source of water, since it is desirable that the ceiling tile be porous to exhibit good sound absorbing characteristics. Adding to the desired porosity of a typical ceiling tile is its original water based character which inherently leaves it permeable to water.
[0014] It should be evident that this disclosure is by way of example and that various changes may be made by adding, modifying or eliminating details without departing from the fair scope of the teaching contained in this disclosure. The invention is therefore not limited to particular details of this disclosure except to the extent that the following claims are necessarily so limited.

Claims (8)

1. A ceiling tile comprising a core, an appearance coating on a face side of the tile, and a waterproof coating on a backside of the tile, the core including a filler, binder, and fiber elements dried from a water based slurry or paste of said elements, the core being water permeable and containing a non-white stain producing material susceptible to being leached out of the core by water percolating through the core, the appearance coating exhibiting a high light reflectivity by virtue of containing a white colored constituent and being pervious to water, the waterproof coating serving to repel and bead-up water droplets deposited on the backside of the tile.
2. A ceiling tile as set forth in claim 1, wherein the fiber element includes mineral fiber.
3. A ceiling tile as set forth in claim 1, wherein the appearance coating is a dried water based white paint layer.
4. A ceiling tile as set forth in claim 1, wherein the waterproof material is a dried and cured water carried material.
5. A ceiling tile as set forth in claim 4, wherein the waterproof material is a fluorocarbon polymer emulsion.
6. A ceiling tile as set forth in claim 5, wherein the waterproof material is applied with a coverage of solids at a rate of about 1/5 to 1/4 grams/sq. ft.
7. A method of making a waterproof ceiling tile comprising creating a core by mixing materials in the presence of water, drying the materials to form a rigid board, applying a water based appearance coating on the appearance side of the core, and a waterproof water based coating to a side of the core opposite to the face side.
8. A method of making a suspended ceiling tile as set forth in claim 7, wherein said appearance coating and waterproof coating are applied and are thereafter simultaneously dried by exposing said coatings to a heated environment at about 220° C. for about 45 seconds.
CA 2813558 2010-10-18 2010-10-18 Water resistant ceiling tile Abandoned CA2813558A1 (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
PCT/US2010/052988 WO2012054014A1 (en) 2010-10-18 2010-10-18 Water resistant ceiling tile

Publications (1)

Publication Number Publication Date
CA2813558A1 true CA2813558A1 (en) 2012-04-26

Family

ID=45975498

Family Applications (1)

Application Number Title Priority Date Filing Date
CA 2813558 Abandoned CA2813558A1 (en) 2010-10-18 2010-10-18 Water resistant ceiling tile

Country Status (11)

Country Link
US (1) US20130196151A1 (en)
EP (1) EP2630312A4 (en)
JP (1) JP5740001B2 (en)
CN (1) CN103154400B (en)
AU (1) AU2010362657A1 (en)
BR (1) BR112013008123A2 (en)
CA (1) CA2813558A1 (en)
HK (1) HK1181830A1 (en)
MX (1) MX2013003872A (en)
RU (1) RU2552268C2 (en)
WO (1) WO2012054014A1 (en)

Families Citing this family (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US8734613B1 (en) * 2013-07-05 2014-05-27 Usg Interiors, Llc Glass fiber enhanced mineral wool based acoustical tile
US9702142B1 (en) 2016-04-27 2017-07-11 Awi Licensing Llc Water stain and sag resistant acoustic building panel
US20180079691A1 (en) * 2016-09-20 2018-03-22 Usg Interiors, Llc Silicate coating for improved acoustical panel performance and methods of making same
CN109763615A (en) * 2017-11-09 2019-05-17 阿姆斯特郎世界工业公司 The sound-absorbing building panelling of water resistant spot and sag resistance

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BE416877A (en) *
JPS62335Y2 (en) * 1981-05-06 1987-01-07
CA1234472A (en) * 1984-12-04 1988-03-29 Francis J. Mortimer Suspended ceiling tile refurbishing system
ATE117972T1 (en) * 1988-11-18 1995-02-15 Usg Enterprises Inc COMPOSITE MATERIAL AND METHOD OF MANUFACTURING.
JPH0346630U (en) * 1989-08-05 1991-04-30
JPH0598771A (en) * 1991-10-02 1993-04-20 Natl House Ind Co Ltd Moisture-proof gypsum board and its manufacture
JP3046630U (en) * 1997-08-27 1998-03-10 株式会社ウンノハウス Ceiling panel
JPH11181946A (en) * 1997-12-24 1999-07-06 Ig Tech Res Inc Ceiling construction
DE19860040A1 (en) * 1998-12-23 2000-06-29 Gruenzweig & Hartmann Process for the production of mineral wool products bound with binder, device for carrying them out, mineral wool product produced thereby and composite mineral wool product produced thereby and use of these products
WO2002020676A1 (en) * 2000-09-07 2002-03-14 Nederlandse Organisatie Voor Toegepast-Natuurwetenschappelijk Onderzoek Tno Coating compositions containing perfluoropolyether surfactants
DE10063739B4 (en) * 2000-12-21 2009-04-02 Ferro Gmbh Substrates with self-cleaning surface, process for their preparation and their use
JP2004291537A (en) * 2003-03-28 2004-10-21 Daiken Trade & Ind Co Ltd Decorative sheet
WO2005044926A1 (en) * 2003-11-10 2005-05-19 Kansai Paint Co., Ltd. Powder material containing needle single crystal inorganic powder, coating material, liquid powder dispersion and method for using them
JP2005179402A (en) * 2003-12-16 2005-07-07 E I Du Pont De Nemours & Co Aqueous emulsion containing fluorocarbon silane hydrolyzate and oil- and stain-resistant/water- and oil-repellent coated material
US8337976B2 (en) * 2004-02-26 2012-12-25 Usg Interiors, Inc. Abuse-resistant cast acoustical ceiling tile having an excellent sound absorption value
JP2005289021A (en) * 2004-03-31 2005-10-20 Daiken Trade & Ind Co Ltd Manufacturing method of inorganic decorative sheet
DE602005004645T2 (en) * 2005-02-04 2009-01-29 E.I. Dupont De Nemours And Co., Wilmington Compositions comprising fluorocarbon-grafted polysiloxanes
US8182922B2 (en) * 2005-08-24 2012-05-22 Usg Interiors, Llc Composite ceiling tile
US7703243B2 (en) * 2006-02-13 2010-04-27 Usg Interiors, Inc. Ceiling tile construction

Also Published As

Publication number Publication date
CN103154400A (en) 2013-06-12
BR112013008123A2 (en) 2017-10-10
RU2552268C2 (en) 2015-06-10
EP2630312A4 (en) 2014-10-29
HK1181830A1 (en) 2013-11-15
CN103154400B (en) 2015-12-16
MX2013003872A (en) 2013-06-28
JP5740001B2 (en) 2015-06-24
WO2012054014A1 (en) 2012-04-26
EP2630312A1 (en) 2013-08-28
RU2013120405A (en) 2014-11-27
AU2010362657A1 (en) 2013-04-18
US20130196151A1 (en) 2013-08-01
JP2013544990A (en) 2013-12-19

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Legal Events

Date Code Title Description
FZDE Discontinued

Effective date: 20161019