WO2005016844A1 - Fiberboard panel having improved acoustics and durability - Google Patents
Fiberboard panel having improved acoustics and durability Download PDFInfo
- Publication number
- WO2005016844A1 WO2005016844A1 PCT/US2004/025115 US2004025115W WO2005016844A1 WO 2005016844 A1 WO2005016844 A1 WO 2005016844A1 US 2004025115 W US2004025115 W US 2004025115W WO 2005016844 A1 WO2005016844 A1 WO 2005016844A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- panel
- perlite
- range
- mineral
- fibers
- Prior art date
Links
Classifications
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B26/00—Compositions of mortars, concrete or artificial stone, containing only organic binders, e.g. polymer or resin concrete
- C04B26/02—Macromolecular compounds
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B26/00—Compositions of mortars, concrete or artificial stone, containing only organic binders, e.g. polymer or resin concrete
- C04B26/02—Macromolecular compounds
- C04B26/28—Polysaccharides or derivatives thereof
-
- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21J—FIBREBOARD; MANUFACTURE OF ARTICLES FROM CELLULOSIC FIBROUS SUSPENSIONS OR FROM PAPIER-MACHE
- D21J1/00—Fibreboard
- D21J1/16—Special fibreboard
- D21J1/20—Insulating board
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
- C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
- C04B2111/00612—Uses not provided for elsewhere in C04B2111/00 as one or more layers of a layered structure
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
- C04B2111/52—Sound-insulating materials
-
- 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
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
- Y02W30/00—Technologies for solid waste management
- Y02W30/50—Reuse, recycling or recovery technologies
- Y02W30/91—Use of waste materials as fillers for mortars or concrete
-
- 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
- Y10T428/249922—Embodying intertwined or helical component[s]
-
- 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
- Y10T428/249924—Noninterengaged fiber-containing paper-free web or sheet which is not of specified porosity
-
- 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
- Y10T428/29—Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
- Y10T428/2913—Rod, strand, filament or fiber
-
- 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
- Y10T428/29—Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
- Y10T428/2913—Rod, strand, filament or fiber
- Y10T428/2922—Nonlinear [e.g., crimped, coiled, etc.]
-
- 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
- Y10T428/29—Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
- Y10T428/2913—Rod, strand, filament or fiber
- Y10T428/2927—Rod, strand, filament or fiber including structurally defined particulate matter
Definitions
- the present invention relates to the field of fiberboard panels. More particularly, the invention relates to fiberboard panel formulations which can be fabricated into durable acoustical panels having a fine textured appearance using a wet-felting process. Fiberboard panels can provide aesthetic appeal, acoustical modification or dampening, accessibility to space above the ceiling plane, and simple installation and removal. To accommodate these features at a relatively low cost, panels are constructed using strong but relatively inexpensive panel-forming materials, such as mineral fiber, cellulosic fiber, perlite and binder. Two of several fiberboard performance properties sought to be optimized are acoustical resistivity and board hardness.
- the wet-felting process is a known process for fabricating acoustical panels.
- an aqueous slurry of the panel-forming materials is deposited onto a moving wire screen, such as a fourdrinier or cylinder former.
- a wet mat is formed by dewatering the aqueous slurry by gravity and then optionally by vacuum suction.
- the wet mat is pressed to a desired thickness between press rolls and the wire screen for additional dewatering.
- the pressed mat is dried in ovens or kilns and then cut to produce acoustical panels.
- the combination of low level resistivity and high level board hardness has not been achieved in single layer fiberboards produced using conventional wet-felting technology.
- One known way to obtain the aforementioned combination of performance properties via the wet-felting process is to use overlays having nodulated mineral fibers. Wet-formed panels having nodulated mineral fiber overlays, are described in U.S. Patent Application No. 09/860,271.
- the disadvantages of the overlay technology are the high capital cost necessary to produce and adhere the overlay and the overall increased process complexity.
- the aforementioned performance properties can also be achieved in fiberboard panels using the well know cast process.
- a mixture of mineral fiber, cellulosic fiber, perlite, binder and other board-forming ingredients are deposited on trays which have been covered with paper or foil.
- the filled trays are typically placed in an oven in order to dry the mixture.
- the dried sheets are typically surface treated to obtain a desired thickness and are cut into panels.
- One of the disadvantages of using the cast technology to achieve the desired performance properties is the high cost to produce the panels which results from the slow production rate.
- the fine textured fiberboard panel of the invention exhibits a combination of performance properties, including a low resistivity value and a high board hardness value, which heretofore have not been achieved in a single layer wet-felted unpunched product.
- the fiberboard panel of the invention includes mineral fibers, perlite, cellulosic fibers, and binder.
- the mineral fibers comprise from about 50% to about 85%, the perlite comprises from 0% to about 18%, the cellulosic fiber comprises from about 2% to about 7% and the binder comprises from about 6% to about 15% of the panel on a dry solids weight basis.
- the concentration of mineral fibers includes from about 30% to about 65% nodulated mineral fiber.
- the perlite has a density in the range from about 7 to about 20 pcf.
- the resulting performance properties of the board include a resistivity value in the range from about 200,000 to about 400,000 mks rayls/m and a hardness value in the range from about 85 to about 130 lbf.
- the solids content of the slurry is from about 50% to about 85% mineral fiber.
- Useful mineral fibers include metal slag wool, fiberglass, rock wool and mineral wool.
- the formulation also contains 0% to about 18% by weight perlite particles.
- the perlite suitably has a density in the range from about 7 to about 20 pcf.
- the slurry also contains from about 2% to about 7% weight percent cellulosic fibers on a dry solids basis.
- Useful cellulosic fibers include secondary groundwood fibers, primary or secondary wood fibers or plant fibers.
- the formulation also contains a binding agent in the range from about 6% to about 15% weight percent on a dry solids basis.
- a binding agent including pearl cornstarch, wheat starch, potato starch, chemically modified starch, polystyrene, polyvinyl acetate, polystyrene acrylics and styrene butadiene.
- the formulation may also contain 0% to about 20% weight dry solids basis filler.
- Useful fillers include kaolin clay, calcium carbonate, silica, vermiculite, bentonite or ball clay, talc, mica and gypsum.
- Other auxiliary additives can be added into the formulation. These substances include broke, flocculants, defoaming agents and biocides. The proper amounts of such auxiliary additives can readily be determined by those skilled in the art.
- the formed panel can contain up to about 30%, and more preferably 25% (dry weight basis), broke.
- Broke is usually recycled panel or panel-forming components such as flat scrap, sander dust and edge trimmings.
- Fiberboard panels made in accordance with the aforementioned material ranges of solids had the following physical properties:
Landscapes
- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Ceramic Engineering (AREA)
- Materials Engineering (AREA)
- Structural Engineering (AREA)
- Organic Chemistry (AREA)
- Dry Formation Of Fiberboard And The Like (AREA)
- Paper (AREA)
Abstract
Description
Claims
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
EP20040780022 EP1654205A1 (en) | 2003-08-07 | 2004-08-04 | Fiberboard panel having improved acoustics and durability |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US10/636,405 | 2003-08-07 | ||
US10/636,405 US6919132B2 (en) | 2003-08-07 | 2003-08-07 | Fiberboard panel having improved acoustics and durability |
Publications (1)
Publication Number | Publication Date |
---|---|
WO2005016844A1 true WO2005016844A1 (en) | 2005-02-24 |
Family
ID=34116420
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/US2004/025115 WO2005016844A1 (en) | 2003-08-07 | 2004-08-04 | Fiberboard panel having improved acoustics and durability |
Country Status (4)
Country | Link |
---|---|
US (1) | US6919132B2 (en) |
EP (1) | EP1654205A1 (en) |
RU (1) | RU2006106912A (en) |
WO (1) | WO2005016844A1 (en) |
Families Citing this family (13)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US7703243B2 (en) * | 2006-02-13 | 2010-04-27 | Usg Interiors, Inc. | Ceiling tile construction |
US8309231B2 (en) * | 2006-05-31 | 2012-11-13 | Usg Interiors, Llc | Acoustical tile |
US20080176053A1 (en) * | 2007-01-24 | 2008-07-24 | United States Cypsum Company | Gypsum Wallboard Containing Acoustical Tile |
CN101781870B (en) * | 2010-02-04 | 2011-09-28 | 广东省造纸研究所 | High-strength insulation vulcanized fiber board and manufacture process thereof |
US8536259B2 (en) | 2010-06-24 | 2013-09-17 | Usg Interiors, Llc | Formaldehyde free coatings for panels |
US9896807B2 (en) | 2015-09-25 | 2018-02-20 | Usg Interiors, Llc | Acoustical ceiling tile |
US9796635B1 (en) | 2016-06-22 | 2017-10-24 | Usg Interiors, Llc | Large diameter slag wool, composition and method of making same |
US20180079691A1 (en) | 2016-09-20 | 2018-03-22 | Usg Interiors, Llc | Silicate coating for improved acoustical panel performance and methods of making same |
US10208477B2 (en) | 2016-10-20 | 2019-02-19 | Usg Interiors, Llc | Veil finishing process |
US10094614B2 (en) | 2016-12-14 | 2018-10-09 | Usg Interiors, Llc | Method for dewatering acoustical panels |
US10696594B2 (en) | 2017-08-11 | 2020-06-30 | Usg Interiors, Llc | High noise reduction coefficient, low density acoustical tiles |
US11111174B2 (en) | 2017-09-13 | 2021-09-07 | United States Gypsum Company | Mineral fiber roof cover boards |
US11753550B2 (en) | 2018-06-14 | 2023-09-12 | Usg Interiors, Llc | Borate and silicate coating for improved acoustical panel performance and methods of making same |
Citations (7)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US1972493A (en) * | 1932-01-29 | 1934-09-04 | Johns Manville | Insulating block and process of making the same |
US2773764A (en) * | 1954-04-22 | 1956-12-11 | Armstrong Cork Co | Mineral fiber product |
US3093533A (en) * | 1960-02-01 | 1963-06-11 | Wood Conversion Co | Production of fiberboard containing mineral fiber |
EP0347810A2 (en) * | 1988-06-23 | 1989-12-27 | The Celotex Corporation | Acoustical mineral fiberboard and method of manufacturing same |
EP0347809A1 (en) * | 1988-06-23 | 1989-12-27 | The Celotex Corporation | Method of producing acoustical mineral fiberboard |
WO1999008977A1 (en) * | 1997-08-20 | 1999-02-25 | Usg Interiors, Inc. | Acoustical tile composition |
EP1158095A2 (en) * | 2000-05-24 | 2001-11-28 | Armstrong World Industries, Inc. | Durable acoustical panel and method of making the same |
Family Cites Families (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US5250153A (en) * | 1987-01-12 | 1993-10-05 | Usg Interiors, Inc. | Method for manufacturing a mineral wool panel |
US5071511A (en) * | 1988-06-23 | 1991-12-10 | The Celotex Corporation | Acoustical mineral fiberboard |
-
2003
- 2003-08-07 US US10/636,405 patent/US6919132B2/en not_active Expired - Lifetime
-
2004
- 2004-08-04 RU RU2006106912/04A patent/RU2006106912A/en not_active Application Discontinuation
- 2004-08-04 WO PCT/US2004/025115 patent/WO2005016844A1/en active Application Filing
- 2004-08-04 EP EP20040780022 patent/EP1654205A1/en not_active Withdrawn
Patent Citations (7)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US1972493A (en) * | 1932-01-29 | 1934-09-04 | Johns Manville | Insulating block and process of making the same |
US2773764A (en) * | 1954-04-22 | 1956-12-11 | Armstrong Cork Co | Mineral fiber product |
US3093533A (en) * | 1960-02-01 | 1963-06-11 | Wood Conversion Co | Production of fiberboard containing mineral fiber |
EP0347810A2 (en) * | 1988-06-23 | 1989-12-27 | The Celotex Corporation | Acoustical mineral fiberboard and method of manufacturing same |
EP0347809A1 (en) * | 1988-06-23 | 1989-12-27 | The Celotex Corporation | Method of producing acoustical mineral fiberboard |
WO1999008977A1 (en) * | 1997-08-20 | 1999-02-25 | Usg Interiors, Inc. | Acoustical tile composition |
EP1158095A2 (en) * | 2000-05-24 | 2001-11-28 | Armstrong World Industries, Inc. | Durable acoustical panel and method of making the same |
Also Published As
Publication number | Publication date |
---|---|
US20050031842A1 (en) | 2005-02-10 |
US6919132B2 (en) | 2005-07-19 |
EP1654205A1 (en) | 2006-05-10 |
RU2006106912A (en) | 2006-07-10 |
Similar Documents
Publication | Publication Date | Title |
---|---|---|
CA2709690C (en) | Acoustic ceiling tiles made with paper processing waste | |
CA2139368C (en) | A gypsum/cellulosic fiber acoustical tile composition | |
US6919132B2 (en) | Fiberboard panel having improved acoustics and durability | |
AU783445B2 (en) | Durable acoustical panel and method of making the same | |
US3379608A (en) | Water-felted mineral wool building and insulation product including nonfibrous cellulose binder | |
JP5392469B2 (en) | Composite board | |
EP2222925A1 (en) | Process for producing a low density acoustical panel with improved sound absorption | |
NZ546876A (en) | Fibers reinforced cement sheet product and production method thereof | |
CN103328737A (en) | Acoustic building material employing chitosan | |
CN108138492A (en) | It is suitable for use as the light gypsum fiber panel of roof slab | |
CN102206957B (en) | The manufacture method of Wood cement board | |
US3379609A (en) | Water-felted building product including nonfibrous cellulose binder | |
JPH02243335A (en) | Rigid,self-standing sound-proof inorganic fiber board | |
US5539028A (en) | Water-resistant fiberboard and method | |
US20070001334A1 (en) | Ceiling tiles and a process for the manufacture thereof | |
WO2023004288A1 (en) | High acoustic and low density basemat | |
JPH08295551A (en) | Cement-base inorganic board | |
JPH03169509A (en) | Manufacture of inorganic sheet | |
JP5714923B2 (en) | INORGANIC PLATE AND METHOD FOR PRODUCING INORGANIC PLATE | |
KR20120101946A (en) | Inorganic board and a method of manufacturing said inorganic board | |
AU2004277443A1 (en) | Cement sheet product and production method thereof | |
MXPA95000732A (en) | A composition of antisonous thickness based on cellulose defibs / y |
Legal Events
Date | Code | Title | Description |
---|---|---|---|
AK | Designated states |
Kind code of ref document: A1 Designated state(s): AE AG AL AM AT AU AZ BA BB BG BR BW BY BZ CA CH CN CO CR CU CZ DE DK DM DZ EC EE EG ES FI GB GD GE GH GM HR HU ID IL IN IS JP KE KG KP KR KZ LC LK LR LS LT LU LV MA MD MG MK MN MW MX MZ NA NI NO NZ OM PG PH PL PT RO RU SC SD SE SG SK SL SY TJ TM TN TR TT TZ UA UG US UZ VC VN YU ZA ZM ZW |
|
AL | Designated countries for regional patents |
Kind code of ref document: A1 Designated state(s): BW GH GM KE LS MW MZ NA SD SL SZ TZ UG ZM ZW AM AZ BY KG KZ MD RU TJ TM AT BE BG CH CY CZ DE DK EE ES FI FR GB GR HU IE IT LU MC NL PL PT RO SE SI SK TR BF BJ CF CG CI CM GA GN GQ GW ML MR NE SN TD TG |
|
121 | Ep: the epo has been informed by wipo that ep was designated in this application | ||
DPEN | Request for preliminary examination filed prior to expiration of 19th month from priority date (pct application filed from 20040101) | ||
WWE | Wipo information: entry into national phase |
Ref document number: 2004780022 Country of ref document: EP |
|
WWE | Wipo information: entry into national phase |
Ref document number: 2006106912 Country of ref document: RU |
|
WWP | Wipo information: published in national office |
Ref document number: 2004780022 Country of ref document: EP |