US20100146887A1 - Fire and Sag Resistant Acoustical Panel and Substantially Clear Coating Therefor - Google Patents
Fire and Sag Resistant Acoustical Panel and Substantially Clear Coating Therefor Download PDFInfo
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- US20100146887A1 US20100146887A1 US12/619,284 US61928409A US2010146887A1 US 20100146887 A1 US20100146887 A1 US 20100146887A1 US 61928409 A US61928409 A US 61928409A US 2010146887 A1 US2010146887 A1 US 2010146887A1
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- Prior art keywords
- fire retardant
- mat
- scrim
- fire
- binder
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Classifications
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- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
- D21H21/00—Non-fibrous material added to the pulp, characterised by its function, form or properties; Paper-impregnating or coating material, characterised by its function, form or properties
- D21H21/14—Non-fibrous material added to the pulp, characterised by its function, form or properties; Paper-impregnating or coating material, characterised by its function, form or properties characterised by function or properties in or on the paper
- D21H21/34—Ignifugeants
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/04—Layered products comprising a layer of synthetic resin as impregnant, bonding, or embedding substance
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- 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
- E04B1/92—Protection against other undesired influences or dangers
- E04B1/94—Protection against other undesired influences or dangers against fire
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- 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
- E04B9/001—Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation characterised by provisions for heat or sound insulation
-
- 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
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
- E04C2/26—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F13/00—Coverings or linings, e.g. for walls or ceilings
- E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
- E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
- E04F13/16—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements of fibres or chips, e.g. bonded with synthetic resins, or with an outer layer of fibres or chips
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- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
- D21H13/00—Pulp or paper, comprising synthetic cellulose or non-cellulose fibres or web-forming material
- D21H13/36—Inorganic fibres or flakes
- D21H13/38—Inorganic fibres or flakes siliceous
- D21H13/40—Inorganic fibres or flakes siliceous vitreous, e.g. mineral wool, glass fibres
-
- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
- D21H17/00—Non-fibrous material added to the pulp, characterised by its constitution; Paper-impregnating material characterised by its constitution
- D21H17/63—Inorganic compounds
- D21H17/66—Salts, e.g. alums
-
- 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
- Y10T428/249921—Web or sheet containing structurally defined element or 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
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/10—Scrim [e.g., open net or mesh, gauze, loose or open weave or knit, etc.]
- Y10T442/184—Nonwoven scrim
- Y10T442/198—Coated or impregnated
Definitions
- the present invention is directed to fire and sag resistant panel, and, more particularly, to an enhanced fire rated, sag resistant acoustical ceiling panel having an enhanced fire rated natural fiber mat incorporated therein as well as a substantially clear coating applied thereto.
- Natural fibers such as hemp, kenaf, jute, sisal and flax, are gaining interest as a component in a variety of manufactured products, including products for the interior building environment, as natural fibers are a renewable resource and do not emit potentially hazardous materials into the environment. Though renewable and environmentally friendly, natural fibers, and the binder material which holds the fibers together, are highly flammable.
- Articles intended for use specifically in a construction which is utilized as a conduit for return air must achieve an exceptional Class A fire resistance rating: namely a flame spread index value of 25 or less and a smoke generation index value of 50 or less, as measured by ASTM E 84. Additionally, when an article is suspended horizontally in a room space, such as in an acoustical ceiling system, not only must the efficacy of any flame retardant applied to natural fibers be substantial but it is also desired that these panels be: highly acoustically permeable; dimensionally stable; self-supporting; and sag resistant with respect to fluctuations in relative humidity.
- the invention is a ceiling panel structure which includes a fire retardant mat.
- the fire retardant mat includes a fire retardant fiber component and a binder material which binds the fibers.
- the fire retardant fiber component includes natural fibers treated with a fire retardant.
- the fire retardant mat has flame spread index of 25 or less and a smoke generation index of 50 or less, as measured by ASTM E 84 that is uniform throughout the mat.
- the ceiling panel structure also includes a scrim attached to the bottom surface of the fire retardant mat as well as a substantially clear coating on the exposed surface of the scrim opposite the fire retardant mat.
- the ceiling panel structure also achieves a flame spread index value of 25 or less and a smoke generation index value of 50 or less, as measured by ASTM E 84 that is uniform throughout the structure.
- FIG. 1 is a side view of a fire retardant mat according to an embodiment of the invention.
- FIG. 2 is a side view of a ceiling panel structure incorporating the fire retardant mat of FIG. 1 .
- FIG. 1 shows a fire retardant mat 1 according to an embodiment of the invention.
- a fiber component comprising natural fibers treated with the fire retardant is mixed with a binder to form a blend.
- the fiber component may be mixed with the binder, for example, by carding and co-mingling the fiber component with the binder in an air stream, which separates the natural fibers from one another and intimately blends the natural fibers with the binder.
- the blend, or furnish is then deposited onto a foraminous wire and is compressed to a desired final thickness. Heat is then applied through the fiber web to either melt a thermoplastic binder or cure a thermosetting binder.
- the blend may be conveyed through an oven that blows heat through the mixture while the mixture is simultaneously being compressed with one or more wire screens.
- the fiber component includes natural fibers treated with a fire retardant.
- Bast fibers such as kenaf, hemp, flax, ramie, or jute are examples of natural fibers.
- the natural fiber ingredient may comprise a single type of fiber or a combination thereof. Additionally, a portion or all of the natural fibers may be recycled fibers. Kenaf, jute, hemp, or combinations thereof are preferred where strength and/or rigidity is sought as these particular fibers are inherently less flexible than other natural fibers.
- the fire retardant may be in the form of a powder or liquid and can be, for example, ammonium phosphates, sodium pentaborates, ammonium sulfates, boric acids and mixtures thereof.
- the fiber component comprises from about 70-99% by dry weight of the mat, and more preferably from about 70 to about 83% by dry weight of the mat.
- the ratio of the natural fiber to fire retardant in the fiber component is in the range from about 4:1 to about 11.5:1 and more preferably about 5:1.
- the amount of binder in the mat in the mat is in the range from about 1 to about 30% by dry weight of the fiber mat.
- the binder can be either thermoplastic (including bio-based polymers) or thermosetting.
- the material range is more preferably from about 11 to about 30%; most preferably about 13 to about 21%.
- the material range is more preferably from about 1 to about 15%; most preferably about 2 to about 8%.
- thermoplastic binder fiber is the bi-component sheath-core configuration having a first thermoplastic material coated or encased within a second thermoplastic material having a lower softening temperature.
- the first thermoplastic material may be, for example, polyethylene terephthalate glycol (PETG)
- PET polyethylene terephthalate
- jute fiber was treated either with a system of ammonium phosphate and borate or with di-ammonium sulfate.
- the results according to ASTM E 84 for measuring the flame spread and smoke generation index values are shown in Tables 1 and 2.
- the preferred mat density for use in a ceiling tile structure is in the range from about 4 to about 8 lb/ft 3 and, more preferably from about 5 to about 6.5 lb/ft 3 ; most preferably about 5.5 lb/ft 3 .
- the preferred thickness of the mat for use in a ceiling tile structure is in the range from about 0.25 to about 2 inches, more preferably about 0.0.375 to about 1.5 inches and most preferably from about 0.4 to about 0.7 inches.
- a facing scrim 3 and a scrim coating 6 composite was then adhered to sample mats 4 - 8 of Table 2.
- the scrim applied to sample mats 4 - 8 was a fiberglass scrim available from Owens Corning, item number A80PKR-YK111, however, the scrim 3 may be any suitable scrim that is resistant to flame spread and preferably has a Class A fire rating of 25/50, examples of which are fiberglass or flame retardant blends of fiberglass, cellulose and polyester.
- the fiberglass scrim is bound with a flame retarded polymeric binder.
- the scrim 3 can be attached to a surface of the fire retardant mat 1 using any suitable attachment method.
- the fiberglass scrim is affixed to the mat with flame-retarded vinyl-acetate glue 5 .
- the air flow resistance of the A80PKR-YK111 scrim is 40 MKS Rayls.
- the scrim was then painted with DURABRITE paint available from Armstrong World Industries.
- the paint was applied at an application level of 29 g/ft2.
- What is key for achieving the desired acoustic performance in the fully constructed ceiling panel is that the combination of the scrim, the glue application and the paint application must have an air-flow permeability that allows sound to enter and be absorbed in the structure.
- a composite air flow resistance of about 400 to about 600 MKS Rayls has been found to achieve an noise reduction coefficient (NRC) greater than 0.80.
- NRC noise reduction coefficient
- the scrim weight In order to achieve the desired air flow resistance, and thus, the desired NRC, the scrim weight must be in the range from about 4.5 to about 10.5 g/ft2 and the glue application rate must be in the range from about 3 to about 10 g/ft2 (dry weight). The paint application rate must be in the range from about 10 to about 50 g/ft2 (dry weight).
- Table 3 illustrates examples of fully constructed two feet by two feet panels comprising the fire retardant mat samples shown in Table 2.
- the completed structural panels utilizing sample mates 4 - 8 were indeed found to obtain the desired fire resistance, sag and acoustical properties. Specifically, a completed structural panel achieved a noise reduction coefficient (NRC) of at least 0.85.
- the noise reduction coefficient (NRC) is a useful indicator of the acoustical properties of a given material.
- the Noise Reduction Coefficient (NRC) is a scalar representation of the amount of sound energy absorbed upon striking a particular surface. It is well known in the art that NRC is the average of four sound absorption coefficients of the particular surface at frequencies of 250 Hz, 500 Hz, 1000 Hz, and 2000 Hz.
- the desired sag performance was also achieved; namely a statistical value more positive than negative 0.150 inches.
- To measure the sag performance several 2 ⁇ 2 inch panels were suspended horizontally from a perimeter support frame and deflection was measured over the course of four 24-hour cycles in which relative humidity was varied: namely 8 hours at 90% relative humidity and then 6 hours at 35% relative humidity. The negative most deflection from horizontal was recorded for each panel formulation.
- an average negative value minus 2 standard deviations that is more negative than negative 0.150 inches represents a threshold performance value for a 2 ⁇ 2 panel at which the sag in the middle of the panel becomes apparent and begins to show an unsightly pillowed appearance in a horizontal installation.
- the coating 6 may be colored, opaque, or substantially clear depending on the desired appearance of the ceiling tile structure 2 .
- suitable substantially clear coatings include Safe-T-Guard, WT-103, No. 133A, Flamex PF, JB-1D, Fabric Seal concentrate, Flamort 6-3, Disflammoll DPO, and DPK.
- a substantially clear coating may comprise, for example, a fire retardant, a binder, a clay, a dispersant, and a defoamer.
- the fire retardant may be halogen free and may comprise at least one material selected from the group consisting, for example, of ammonium polyphosphate (Exolit AP 420, 412, 422, and 423) and melamine polyphosphate (Flamestab Nor 116, Melapur MC 15, MP, and 200).
- the binder may be selected to prevent yellowing, offer moisture resistance, and provide durability.
- the binder may be, for example, an acrylic binder. Suitable binders include, for example, vinyl acrylic Rovace 9100, Flexbond 325, acrylic Rhoplex AC 260, ethylene vinyl chloride Airflex 4530, and polyvinyl acetate Vinac 828 m.
- the fire retardant dosage is in the range from about 5%- to about 95% by weight and the binder level is in the range from about 3% to about 95% by weight.
- the solids of the substantially clear coating are in the range from about 30% to about 60% by weight; the application rate is in the range from about 8 to about 42 g/ft2 and the filler/binder ratio is about 0.05:1 to about 33:1.
- the substantially clear coating comprises about 85 to about 87% by weight ammonium polyphosphate (e.g. Exolit AP 423), about 4 to about 7% by weight clay (e.g. EG 44), about 6 to about 8% by weight acrylic binder (e.g. Rhoplex AC 261), about 0.1 to about 0.4% by weight dispersant (e.g. Nopcote 63900), and about 0.01 to about 0.05% by weight defoamer (e.g. Tego Foamex 1488).
- the solids of the substantially clear coating are about 35-42% weight with Brookfield viscosity approximately 300-500 cps at 10 rpm with a #1 spindle.
- the filler/binder ratio is about 10:1 and about 14:1 and the application rate is about 6-32 grams per feet squared.
- substantially clear coating shown and described herein is fire retardant and is substantially durable and moisture resistant such that the coating 6 adequately protects the scrim 3 and provides RH 70 & RH 90 sag resistance for the fire retardant mat 1 when the scrim 3 is attached thereto. Additionally, because the coating 6 is substantially clear, the natural fiber elements of the scrim 3 are visible, which causes the ceiling tile structure 2 to have an aesthetically pleasing and natural look. Further, the coating 6 is environmentally friendly in that it does not contain formaldehyde, acetaldehyde, or halogen.
- a second coating 4 may be applied to the surface of the fire retardant mat 1 opposite the scrim 3 to help provide rigidity and stability against sag induced by fluctuations in relative humidity.
- This coating must have a low surface flame-spread smoke generation and allows the product to meet the Class A 25/50 requirement.
- the back coating 4 may be a filled styrene acrylate latex resin which is a non-cross linking thermoplastic resin of substantially high T(g).
- the T(g) of the latex is important with respect to sag and should be in the range of about 0° C. to about 100° C. For a filled styrene acrylate latex resin the T(g) is 33° C.
- the application weight of the back coat is in the range from about 20 to about 70 g/ft2 dry wt. and preferably about 45 g/ft2 dry wt.
- a filler/binder ratio range for the back-coat would be in the range from about 30:1 to about 5:1, and preferably 20:1.
- the back-coat can optionally be formulated with a reactive thermosetting or hydrogen bonding binder.
- thermosetting binders are: acrylic, (i.e. our Armstrong ESP back-coat), phenol-formaldehyde, melamine or urea formaldehyde, epoxy, polyurethane, or poly-urea.
- hydrogen bonding binders are polyvinyl alcohol and starch, or other polysaccharide or polyol binders. Effective filler/binder ratio and back-coat application weight ranges would be from about 10/1 t about 1/1 and from about 5 to about 30 g/ft2, respectively.
- the back-side could have a fiberglass or other stable scrim adhered thereto.
- the scrim may or may not need to be painted on its opposite face depending on the ability of such a scrim to resist flame-spread and smoke generation to the point that the product meets Class A 25/50 performance.
- an inert paint could be applied to the scrim at a low level to reduce surface flame-spread without impacting the products acoustical performance.
Abstract
A ceiling panel structure which includes a fire retardant mat, a scrim and a substantially clear scrim coating. The fire retardant mat includes a fire retardant fiber component and a binder material which binds the fibers. The fire retardant fiber component includes natural fibers treated with a fire retardant. The scrim being attached to a surface of the mat and the substantially clear coating is applied to the surface of the scrim opposite a surface of the scrim positioned next to the mat. The ceiling panel structure has flame spread index of 25 or less and a smoke generation index of 50 or less, as measured by ASTM E 84 that is uniform throughout the mat.
Description
- This application claims the benefit under 35 U.S.C. §119(e) of U.S. provisional application Ser. No. 61/114,778, filed Nov. 14, 2008, entitled “Fire Retardant Mat And Ceiling Tile Structure Incorporating The Same.”
- The present invention is directed to fire and sag resistant panel, and, more particularly, to an enhanced fire rated, sag resistant acoustical ceiling panel having an enhanced fire rated natural fiber mat incorporated therein as well as a substantially clear coating applied thereto.
- Natural fibers such as hemp, kenaf, jute, sisal and flax, are gaining interest as a component in a variety of manufactured products, including products for the interior building environment, as natural fibers are a renewable resource and do not emit potentially hazardous materials into the environment. Though renewable and environmentally friendly, natural fibers, and the binder material which holds the fibers together, are highly flammable.
- Articles intended for use specifically in a construction which is utilized as a conduit for return air must achieve an exceptional Class A fire resistance rating: namely a flame spread index value of 25 or less and a smoke generation index value of 50 or less, as measured by ASTM E 84. Additionally, when an article is suspended horizontally in a room space, such as in an acoustical ceiling system, not only must the efficacy of any flame retardant applied to natural fibers be substantial but it is also desired that these panels be: highly acoustically permeable; dimensionally stable; self-supporting; and sag resistant with respect to fluctuations in relative humidity. As one of ordinary skill in the art would understand, increasing the amount of binder to improve such features as the self-supporting nature of the fibrous mass, in turn, makes the fibrous article more flammable. As a result of such inverse relationships, an article possessing a combination of the aforementioned properties has not been heretofore achieved.
- The invention is a ceiling panel structure which includes a fire retardant mat. The fire retardant mat includes a fire retardant fiber component and a binder material which binds the fibers. The fire retardant fiber component includes natural fibers treated with a fire retardant. The fire retardant mat has flame spread index of 25 or less and a smoke generation index of 50 or less, as measured by ASTM E 84 that is uniform throughout the mat. The ceiling panel structure also includes a scrim attached to the bottom surface of the fire retardant mat as well as a substantially clear coating on the exposed surface of the scrim opposite the fire retardant mat. The ceiling panel structure also achieves a flame spread index value of 25 or less and a smoke generation index value of 50 or less, as measured by ASTM E 84 that is uniform throughout the structure.
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FIG. 1 is a side view of a fire retardant mat according to an embodiment of the invention. -
FIG. 2 is a side view of a ceiling panel structure incorporating the fire retardant mat ofFIG. 1 . -
FIG. 1 shows a fireretardant mat 1 according to an embodiment of the invention. In order to form the fireretardant mat 1, a fiber component comprising natural fibers treated with the fire retardant is mixed with a binder to form a blend. The fiber component may be mixed with the binder, for example, by carding and co-mingling the fiber component with the binder in an air stream, which separates the natural fibers from one another and intimately blends the natural fibers with the binder. The blend, or furnish, is then deposited onto a foraminous wire and is compressed to a desired final thickness. Heat is then applied through the fiber web to either melt a thermoplastic binder or cure a thermosetting binder. Alternatively, the blend may be conveyed through an oven that blows heat through the mixture while the mixture is simultaneously being compressed with one or more wire screens. - As previously mentioned, the fiber component includes natural fibers treated with a fire retardant. Bast fibers such as kenaf, hemp, flax, ramie, or jute are examples of natural fibers. The natural fiber ingredient may comprise a single type of fiber or a combination thereof. Additionally, a portion or all of the natural fibers may be recycled fibers. Kenaf, jute, hemp, or combinations thereof are preferred where strength and/or rigidity is sought as these particular fibers are inherently less flexible than other natural fibers.
- The fire retardant may be in the form of a powder or liquid and can be, for example, ammonium phosphates, sodium pentaborates, ammonium sulfates, boric acids and mixtures thereof. The fiber component comprises from about 70-99% by dry weight of the mat, and more preferably from about 70 to about 83% by dry weight of the mat. The ratio of the natural fiber to fire retardant in the fiber component is in the range from about 4:1 to about 11.5:1 and more preferably about 5:1.
- The amount of binder in the mat in the mat is in the range from about 1 to about 30% by dry weight of the fiber mat. The binder can be either thermoplastic (including bio-based polymers) or thermosetting. For a thermoplastic binder, the material range is more preferably from about 11 to about 30%; most preferably about 13 to about 21%. For a thermosetting binder, the material range is more preferably from about 1 to about 15%; most preferably about 2 to about 8%.
- It is well understood in the art that the softening or curing temperature be below the temperature that would cause undesired thermal degradation of the natural fibers. A well known thermoplastic binder fiber is the bi-component sheath-core configuration having a first thermoplastic material coated or encased within a second thermoplastic material having a lower softening temperature. The first thermoplastic material may be, for example, polyethylene terephthalate glycol (PETG), and the second thermoplastic material may be, for example, polyethylene terephthalate (PET).
- In the following examples, jute fiber was treated either with a system of ammonium phosphate and borate or with di-ammonium sulfate. The results according to ASTM E 84 for measuring the flame spread and smoke generation index values are shown in Tables 1 and 2. It should be noted that the preferred mat density for use in a ceiling tile structure is in the range from about 4 to about 8 lb/ft3 and, more preferably from about 5 to about 6.5 lb/ft3; most preferably about 5.5 lb/ft3. The preferred thickness of the mat for use in a ceiling tile structure is in the range from about 0.25 to about 2 inches, more preferably about 0.0.375 to about 1.5 inches and most preferably from about 0.4 to about 0.7 inches.
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TABLE 1 % of fibrous Basis Flame- Smoke component Binder Weight Mat Mat spread Generation that is FR Binder Amount of Mat Thickness Density Index Index Mat FR (dry wt %) Type (dry wt %) (g/m2) (in) (lb/ft3) Value Value 1 Ammonium 15 110 C. 15 1127 0.42 6.6 25 2 Phosphate/ Low- Borate melt Bico 2 Ammonium 15 110 C. 18.5 923 0.528 4.3 32 9 Phosphate/ Low- Borate melt Bico 3 Ammonium 15 110 C. 20 1145 0.512 5.5 34 7 Phosphate/ Low- Borate melt Bico -
TABLE 2 % of fibrous component Binder Basis Flame- that is Amount Weight Mat Mat spread Smoke FR (dry wt Binder (dry wt of Mat Thickness Density Index Generation Mat FR %) Type %) (g/m2) (in) (lb/ft3) Value Index Value 4 Diammonium 15.6 110 C. 13% 1472 0.62 5.8 10 5-10 Sulfate Low- melt Bico 5 Diammonium 15.6 110 C. 15% 1422 0.67 5.2 10 5-10 Sulfate Low- melt Bico 6 Diammonium 15.6 110 C. 17% 1513 0.66 5.64 10 10 Sulfate Low- melt Bico 7 Diammonium 15.6 110 C. 19% 1571 0.64 6.03 10 10 Sulfate Low- melt Bico 8 Diammonium 15.6 110 C. 21% 1596 0.64 6.12 10 10 Sulfate Low- melt Bico
As shown in Table 1, onlysample 1 having a binder level of 15% by wt. of the mat achieved the exceptional Class A fire rating sought when using the system of ammonium phosphate and borate, i.e. a flame spread index reached the 25 value threshold. In contrast when 18.5% bonder or greater was utilized, the flame spread index value was too high. The use of di-ammonium sulfate achieved the exceptional Class A rating both at lower and higher binder levels. Moreover, flame spread index value reached 10 and the smoke generation index value reached 5 when the di-ammonium sulfate was used. - It should be noted that this exceptional Class A fire rating for each of the examples is uniform throughout the entire fire
retardant mat 1. What is meant by “uniform throughout the entire fire retardant mat” is that any cross-sectional surface of the fireretardant mat 1 has the same fire rating as any outside surface of the fireretardant mat 1. - A facing
scrim 3 and ascrim coating 6 composite was then adhered to sample mats 4-8 of Table 2. The scrim applied to sample mats 4-8 was a fiberglass scrim available from Owens Corning, item number A80PKR-YK111, however, thescrim 3 may be any suitable scrim that is resistant to flame spread and preferably has a Class A fire rating of 25/50, examples of which are fiberglass or flame retardant blends of fiberglass, cellulose and polyester. The fiberglass scrim is bound with a flame retarded polymeric binder. Thescrim 3 can be attached to a surface of the fireretardant mat 1 using any suitable attachment method. Here, the fiberglass scrim is affixed to the mat with flame-retarded vinyl-acetate glue 5. The air flow resistance of the A80PKR-YK111 scrim is 40 MKS Rayls. - In the example embodiments set forth above, the scrim was then painted with DURABRITE paint available from Armstrong World Industries. The paint was applied at an application level of 29 g/ft2. What is key for achieving the desired acoustic performance in the fully constructed ceiling panel is that the combination of the scrim, the glue application and the paint application must have an air-flow permeability that allows sound to enter and be absorbed in the structure. A composite air flow resistance of about 400 to about 600 MKS Rayls has been found to achieve an noise reduction coefficient (NRC) greater than 0.80. In order to achieve the desired air flow resistance, and thus, the desired NRC, the scrim weight must be in the range from about 4.5 to about 10.5 g/ft2 and the glue application rate must be in the range from about 3 to about 10 g/ft2 (dry weight). The paint application rate must be in the range from about 10 to about 50 g/ft2 (dry weight).
- Table 3 illustrates examples of fully constructed two feet by two feet panels comprising the fire retardant mat samples shown in Table 2.
-
TABLE 3 Binder Flame- Amount Sag spread Smoke in mat NRC of Performance Index of Index of Sample (dry wt Panel of Panel Panel Panel Mat %) Structure Structure Structure Structure 4 13% 0.85-0.90 −162, −224 0 0 5 15% 0.85-0.90 −150 10 5 6 17% 0.85 −128 10/5 5/0 7 19% N.D. N.D. 8 21% N.D. N.D. - The completed structural panels utilizing sample mates 4-8 were indeed found to obtain the desired fire resistance, sag and acoustical properties. Specifically, a completed structural panel achieved a noise reduction coefficient (NRC) of at least 0.85. The noise reduction coefficient (NRC) is a useful indicator of the acoustical properties of a given material. The Noise Reduction Coefficient (NRC) is a scalar representation of the amount of sound energy absorbed upon striking a particular surface. It is well known in the art that NRC is the average of four sound absorption coefficients of the particular surface at frequencies of 250 Hz, 500 Hz, 1000 Hz, and 2000 Hz.
- In addition, the desired sag performance was also achieved; namely a statistical value more positive than negative 0.150 inches. To measure the sag performance, several 2×2 inch panels were suspended horizontally from a perimeter support frame and deflection was measured over the course of four 24-hour cycles in which relative humidity was varied: namely 8 hours at 90% relative humidity and then 6 hours at 35% relative humidity. The negative most deflection from horizontal was recorded for each panel formulation. Statistically, an average negative value minus 2 standard deviations that is more negative than negative 0.150 inches represents a threshold performance value for a 2×2 panel at which the sag in the middle of the panel becomes apparent and begins to show an unsightly pillowed appearance in a horizontal installation.
- The foregoing illustrates some of the possibilities for practicing the invention. Many other embodiments are possible within the scope and spirit of the invention. For example, although the
fire retardant mat 1 is shown and described herein as being incorporated in theceiling tile structure 2, it will be appreciated by those skilled in the art, however, that thefire retardant mat 1 may have other applications, for example, in the building, furniture, or automotive industry. It is, therefore, intended that the foregoing description be regarded as illustrative rather than limiting, and that the scope of the invention is given by the appended claims together with their full range of equivalents. - For example, the
coating 6 may be colored, opaque, or substantially clear depending on the desired appearance of theceiling tile structure 2. For example, suitable substantially clear coatings include Safe-T-Guard, WT-103, No. 133A, Flamex PF, JB-1D, Fabric Seal concentrate, Flamort 6-3, Disflammoll DPO, and DPK. A substantially clear coating may comprise, for example, a fire retardant, a binder, a clay, a dispersant, and a defoamer. The fire retardant may be halogen free and may comprise at least one material selected from the group consisting, for example, of ammonium polyphosphate (Exolit AP 420, 412, 422, and 423) and melamine polyphosphate (Flamestab Nor 116, Melapur MC 15, MP, and 200). The binder may be selected to prevent yellowing, offer moisture resistance, and provide durability. The binder may be, for example, an acrylic binder. Suitable binders include, for example, vinyl acrylic Rovace 9100, Flexbond 325, acrylic Rhoplex AC 260, ethylene vinyl chloride Airflex 4530, and polyvinyl acetate Vinac 828 m. The fire retardant dosage is in the range from about 5%- to about 95% by weight and the binder level is in the range from about 3% to about 95% by weight. The solids of the substantially clear coating are in the range from about 30% to about 60% by weight; the application rate is in the range from about 8 to about 42 g/ft2 and the filler/binder ratio is about 0.05:1 to about 33:1. - The substantially clear coating according to one embodiment of the invention comprises about 85 to about 87% by weight ammonium polyphosphate (e.g. Exolit AP 423), about 4 to about 7% by weight clay (e.g. EG 44), about 6 to about 8% by weight acrylic binder (e.g. Rhoplex AC 261), about 0.1 to about 0.4% by weight dispersant (e.g. Nopcote 63900), and about 0.01 to about 0.05% by weight defoamer (e.g. Tego Foamex 1488). The solids of the substantially clear coating are about 35-42% weight with Brookfield viscosity approximately 300-500 cps at 10 rpm with a #1 spindle. The filler/binder ratio is about 10:1 and about 14:1 and the application rate is about 6-32 grams per feet squared.
- Moreover, such substantially clear coating shown and described herein is fire retardant and is substantially durable and moisture resistant such that the
coating 6 adequately protects thescrim 3 and provides RH 70 & RH 90 sag resistance for thefire retardant mat 1 when thescrim 3 is attached thereto. Additionally, because thecoating 6 is substantially clear, the natural fiber elements of thescrim 3 are visible, which causes theceiling tile structure 2 to have an aesthetically pleasing and natural look. Further, thecoating 6 is environmentally friendly in that it does not contain formaldehyde, acetaldehyde, or halogen. - Yet another modification is that a
second coating 4 may be applied to the surface of thefire retardant mat 1 opposite thescrim 3 to help provide rigidity and stability against sag induced by fluctuations in relative humidity. This coating must have a low surface flame-spread smoke generation and allows the product to meet the Class A 25/50 requirement. In one example embodiment, theback coating 4 may be a filled styrene acrylate latex resin which is a non-cross linking thermoplastic resin of substantially high T(g). The T(g) of the latex is important with respect to sag and should be in the range of about 0° C. to about 100° C. For a filled styrene acrylate latex resin the T(g) is 33° C. The application weight of the back coat is in the range from about 20 to about 70 g/ft2 dry wt. and preferably about 45 g/ft2 dry wt. A filler/binder ratio range for the back-coat would be in the range from about 30:1 to about 5:1, and preferably 20:1. - The back-coat can optionally be formulated with a reactive thermosetting or hydrogen bonding binder. Examples of thermosetting binders are: acrylic, (i.e. our Armstrong ESP back-coat), phenol-formaldehyde, melamine or urea formaldehyde, epoxy, polyurethane, or poly-urea. Examples of hydrogen bonding binders are polyvinyl alcohol and starch, or other polysaccharide or polyol binders. Effective filler/binder ratio and back-coat application weight ranges would be from about 10/1 t about 1/1 and from about 5 to about 30 g/ft2, respectively.
- Alternatively, instead of a coating, the back-side could have a fiberglass or other stable scrim adhered thereto. The scrim may or may not need to be painted on its opposite face depending on the ability of such a scrim to resist flame-spread and smoke generation to the point that the product meets Class A 25/50 performance. If necessary, an inert paint could be applied to the scrim at a low level to reduce surface flame-spread without impacting the products acoustical performance.
Claims (7)
1. A ceiling tile structure comprising:
a fire retardant mat and a scrim attached to a surface thereof, wherein the fire retardant mat comprises a binder and a fiber component, the fiber component including natural fibers treated with a fire retardant material; and
a substantially clear coating on a surface of the scrim opposite a surface of the scrim positioned next to the fire retardant mat, the coating comprising a fire retardant, a binder, a clay, a dispersant, and a defoamer;
wherein the fire retardant mat having a fire rating that is uniform throughout all planes of the fire retardant mat, and wherein the fire rating includes a flame spread index value of 25 or less and a smoke generation index value of 50 or less, as measured by ASTM E 84.
2. The ceiling tile structure of claim 1 , comprising a coating on a surface of the fire retardant mat opposite the scrim.
3. The ceiling tile structure of claim 1 , wherein the flame spread index value is 10 or less and the smoke generation index value is 10 or less, as measured by ASTM E 84.
4. The ceiling tile structure of claim 1 , wherein the fire retardant material is di-ammonium sulfate.
5. The ceiling tile structure of claim 4 , wherein the flame spread index value is 10 or less and the smoke generation index value is 10 or less, as measured by ASTM E 84.
6. The ceiling tile structure of claim 1 , wherein the density of the fire retardant mat in the range from about 4 to about 8 lb/ft3.
7. The ceiling tile structure of claim 1 , wherein the thickness of the fire retardant mat in the range from about 0.25 to about 2 inches.
Priority Applications (1)
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US12/619,284 US20100146887A1 (en) | 2008-11-14 | 2009-11-16 | Fire and Sag Resistant Acoustical Panel and Substantially Clear Coating Therefor |
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US11477808P | 2008-11-14 | 2008-11-14 | |
US12/619,284 US20100146887A1 (en) | 2008-11-14 | 2009-11-16 | Fire and Sag Resistant Acoustical Panel and Substantially Clear Coating Therefor |
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US20100146887A1 true US20100146887A1 (en) | 2010-06-17 |
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ID=42170225
Family Applications (2)
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US12/590,874 Abandoned US20100189982A1 (en) | 2008-11-14 | 2009-11-16 | Fire and SAG resistanct acoustical panel |
US12/619,284 Abandoned US20100146887A1 (en) | 2008-11-14 | 2009-11-16 | Fire and Sag Resistant Acoustical Panel and Substantially Clear Coating Therefor |
Family Applications Before (1)
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US12/590,874 Abandoned US20100189982A1 (en) | 2008-11-14 | 2009-11-16 | Fire and SAG resistanct acoustical panel |
Country Status (5)
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US (2) | US20100189982A1 (en) |
EP (1) | EP2356283A4 (en) |
CN (1) | CN102272381B (en) |
RU (2) | RU2698677C2 (en) |
WO (1) | WO2010056372A1 (en) |
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US20110147119A1 (en) * | 2009-12-22 | 2011-06-23 | Usg Interiors, Inc. | Porous nonwoven scrims in acoustical panels |
FR2978374A1 (en) * | 2011-07-28 | 2013-02-01 | Oleg Muzyrya | Sound and thermal insulating material for use in structural component of e.g. building, has core layer formed as web that comprises specific mass percent of jute fiber and specific mass percent of bonding agent |
FR2978375A1 (en) * | 2011-07-28 | 2013-02-01 | Oleg Muzyrya | |
US20130149926A1 (en) * | 2011-12-13 | 2013-06-13 | Federal-Mogul Powertrain, Inc. | Non-Woven, Flame Retardant, Moisture Resistant Panel and Method of Construction Thereof |
US20150314564A1 (en) * | 2014-05-05 | 2015-11-05 | Chicago Flameproof & Wood Specialties Corp. | Laminated magnesium cement wood fiber construction materials |
US9279250B2 (en) | 2013-12-24 | 2016-03-08 | Awi Licensing Company | Low density acoustical panels |
WO2017074771A1 (en) * | 2015-10-28 | 2017-05-04 | Armstrong World Industries, Inc. | Scrim attachment system |
WO2017201219A1 (en) * | 2016-05-18 | 2017-11-23 | Armstrong World Industries, Inc. | Humidity and sag resistant building panel |
WO2018132447A1 (en) * | 2017-01-16 | 2018-07-19 | Armstrong World Industries, Inc. | Sag resistant acoustical ceiling panel with a filled latex binder system that enhances strength and durability |
WO2018222843A1 (en) * | 2017-05-31 | 2018-12-06 | Armstrong World Industries, Inc. | Flame retardant clear coatings for building panels |
WO2018222833A1 (en) * | 2017-05-31 | 2018-12-06 | Armstrong World Industries, Inc. | Flame retardant clear coatings for building panels |
WO2019006314A1 (en) * | 2017-06-30 | 2019-01-03 | Certainteed Corporation | Flame retardant vapor retarding membranes |
US20210245471A1 (en) * | 2020-02-07 | 2021-08-12 | Armstrong World Industries, Inc. | Sound attenuating building panels |
US11124134B2 (en) * | 2018-06-06 | 2021-09-21 | Hanwha Azdel, Inc. | Composite articles including textured films and recreational vehicle articles including them |
US11136755B2 (en) | 2017-06-30 | 2021-10-05 | Certainteed Llc | Vapor retarding building materials and methods for making them |
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US10745920B2 (en) | 2015-10-28 | 2020-08-18 | Awi Licensing Llc | Fire performance for wood veneer laminated ceiling tile |
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US20110147119A1 (en) * | 2009-12-22 | 2011-06-23 | Usg Interiors, Inc. | Porous nonwoven scrims in acoustical panels |
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FR2978374A1 (en) * | 2011-07-28 | 2013-02-01 | Oleg Muzyrya | Sound and thermal insulating material for use in structural component of e.g. building, has core layer formed as web that comprises specific mass percent of jute fiber and specific mass percent of bonding agent |
FR2978375A1 (en) * | 2011-07-28 | 2013-02-01 | Oleg Muzyrya | |
US20130149926A1 (en) * | 2011-12-13 | 2013-06-13 | Federal-Mogul Powertrain, Inc. | Non-Woven, Flame Retardant, Moisture Resistant Panel and Method of Construction Thereof |
CN104114342A (en) * | 2011-12-13 | 2014-10-22 | 费德罗-莫格尔动力系公司 | Nonwoven, flame retardant, moisture resistant panel and method of construction thereof |
US9279250B2 (en) | 2013-12-24 | 2016-03-08 | Awi Licensing Company | Low density acoustical panels |
US20150314564A1 (en) * | 2014-05-05 | 2015-11-05 | Chicago Flameproof & Wood Specialties Corp. | Laminated magnesium cement wood fiber construction materials |
WO2017074771A1 (en) * | 2015-10-28 | 2017-05-04 | Armstrong World Industries, Inc. | Scrim attachment system |
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US10352041B2 (en) | 2015-10-28 | 2019-07-16 | Awi Licensing Llc | Scrim attachment system |
WO2017201219A1 (en) * | 2016-05-18 | 2017-11-23 | Armstrong World Industries, Inc. | Humidity and sag resistant building panel |
US10639865B2 (en) | 2016-05-18 | 2020-05-05 | Awi Licensing Llc | Humidity and sag resistant building panel |
US11633935B2 (en) | 2016-05-18 | 2023-04-25 | Awi Licensing Llc | Humidity and sag resistant building panel |
WO2018132447A1 (en) * | 2017-01-16 | 2018-07-19 | Armstrong World Industries, Inc. | Sag resistant acoustical ceiling panel with a filled latex binder system that enhances strength and durability |
WO2018222843A1 (en) * | 2017-05-31 | 2018-12-06 | Armstrong World Industries, Inc. | Flame retardant clear coatings for building panels |
US11274439B2 (en) | 2017-05-31 | 2022-03-15 | Awi Licensing Llc | Flame retardant clear coatings for building panels |
WO2018222833A1 (en) * | 2017-05-31 | 2018-12-06 | Armstrong World Industries, Inc. | Flame retardant clear coatings for building panels |
US11761200B2 (en) | 2017-05-31 | 2023-09-19 | Awi Licensing Llc | Flame retardant clear coatings for building panels |
US11136755B2 (en) | 2017-06-30 | 2021-10-05 | Certainteed Llc | Vapor retarding building materials and methods for making them |
US11236237B2 (en) | 2017-06-30 | 2022-02-01 | Certainteed Llc | Flame retardant vapor retarding membranes |
WO2019006314A1 (en) * | 2017-06-30 | 2019-01-03 | Certainteed Corporation | Flame retardant vapor retarding membranes |
US11795684B2 (en) | 2017-06-30 | 2023-10-24 | Certainteed Llc | Vapor retarding building materials and methods for making them |
US11124134B2 (en) * | 2018-06-06 | 2021-09-21 | Hanwha Azdel, Inc. | Composite articles including textured films and recreational vehicle articles including them |
US20210245471A1 (en) * | 2020-02-07 | 2021-08-12 | Armstrong World Industries, Inc. | Sound attenuating building panels |
FR3109783A1 (en) * | 2020-04-29 | 2021-11-05 | Jannick Jacques SIMERAY | Prefabricated inflatable building and panels that compose it. |
Also Published As
Publication number | Publication date |
---|---|
EP2356283A1 (en) | 2011-08-17 |
RU2015132744A (en) | 2018-12-25 |
US20100189982A1 (en) | 2010-07-29 |
CN102272381B (en) | 2014-02-19 |
CN102272381A (en) | 2011-12-07 |
RU2015132744A3 (en) | 2019-02-20 |
RU2698677C2 (en) | 2019-08-28 |
EP2356283A4 (en) | 2013-05-22 |
WO2010056372A1 (en) | 2010-05-20 |
RU2011124040A (en) | 2012-12-20 |
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