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WO2025208036A1 - Revêtements durables pour structures acoustiques et leurs procédés de fabrication - Google Patents

Revêtements durables pour structures acoustiques et leurs procédés de fabrication

Info

Publication number
WO2025208036A1
WO2025208036A1 PCT/US2025/022029 US2025022029W WO2025208036A1 WO 2025208036 A1 WO2025208036 A1 WO 2025208036A1 US 2025022029 W US2025022029 W US 2025022029W WO 2025208036 A1 WO2025208036 A1 WO 2025208036A1
Authority
WO
WIPO (PCT)
Prior art keywords
coating composition
acoustic panel
panel according
present
dry weight
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.)
Pending
Application number
PCT/US2025/022029
Other languages
English (en)
Inventor
Ying Chang
Timothy ASTON
Brian N. BAKEY
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.)
Armstrong World Industries Inc
Original Assignee
Armstrong World Industries Inc
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 Armstrong World Industries Inc filed Critical Armstrong World Industries Inc
Publication of WO2025208036A1 publication Critical patent/WO2025208036A1/fr
Pending legal-status Critical Current
Anticipated expiration legal-status Critical

Links

Classifications

    • G—PHYSICS
    • G10—MUSICAL INSTRUMENTS; ACOUSTICS
    • G10K—SOUND-PRODUCING DEVICES; METHODS OR DEVICES FOR PROTECTING AGAINST, OR FOR DAMPING, NOISE OR OTHER ACOUSTIC WAVES IN GENERAL; ACOUSTICS NOT OTHERWISE PROVIDED FOR
    • G10K11/00—Methods or devices for transmitting, conducting or directing sound in general; Methods or devices for protecting against, or for damping, noise or other acoustic waves in general
    • G10K11/16—Methods or devices for protecting against, or for damping, noise or other acoustic waves in general
    • G10K11/162—Selection of materials
    • 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
    • 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
    • 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

Definitions

  • the binder includes a blend of two or more binders, wherein at least one of the two or more binders is a crosslinking binder, and wherein at least one of the two or more binders is not crosslinking.
  • the pigment includes titanium dioxide present at a concentration of about 0.1 wt. % to about 35 wt. %, from about 0.5 wt. % to about 25 wt. %, or from about 1 wt. % to about 20 wt. %, based upon the dry weight of the coating composition.
  • the pigment includes calcined diatomaceous earth present in an amount from about 3 wt. % to about 20 wt. %, from about 5 wt. % to about 17.5 wt. %, or from about 7.5 wt. % to about 15 wt. %, based on the dry weight of the coating composition.
  • the pigment includes aluminum hydroxide present in an amount from about 3 wt. % to about 20 wt. %, from about 5 wt. % to about 18 wt. %, or from about 10 wt. % to about 15 wt. %, based on the dry weight of the coating composition.
  • the pigment includes calcium carbonate present in an amount from about 20 wt. % to about 60 wt. %, from about 25 wt. % to about 45 wt. %, or from about 27.0 wt. % to about 35 wt. %, based on the dry weight of the coating composition.
  • the coating composition further includes clay.
  • the clay is present in an amount from about 0.01 wt. % to about 5 wt. %, from about 0.03 wt. % to about 2 wt. %, or from about 0.03 wt. % to about 0.5 wt. %, based on the dry weight of the coating composition.
  • the clay is a hectorite clay.
  • the coating composition further includes a defoamer.
  • the defoamer includes wax and mineral oil.
  • the defoamer is present in an amount from about 0.01 wt. % to about 2 wt. %, from about 0.01 wt.
  • the coating composition further includes biocide.
  • the biocide is present in an amount from about 0.01 wt. % to about 1 wt. %, from about 0.05 wt. % to about 0.8 wt. %, or from about 0.3 wt. % to about 0.7 wt. %, based on the dry weight of the coating composition.
  • the pigment further includes precipitated synthetic silicate. In one example, the precipitated synthetic silicate is present in an amount from 1 wt. % to about 5 wt.
  • the applying includes spraying the coating composition at a predetermined application rate over the side surface.
  • curing includes drying the substrate at a temperature ranging from about 275 °F to about 480 °F.
  • the crosslinking binder includes a blend of two or more binders, wherein at least one of the two or more binders is a crosslinking binder, and wherein at least one of the two or more binders is not crosslinking.
  • Figure 1 is top perspective view of a coated building panel according to an example of the present disclosure
  • Figure 2 is a cross-sectional view of the coated building panel according to an example of the present disclosure.
  • ranges are used as shorthand for describing each and every value that is within the range. Any value within the range can be selected as the terminus of the range.
  • a composition in the dry state may refer to a composition having about 95% solids, about 98% solids, preferably about 99% solids, or more preferably about 100% solids.
  • reference to a molecule, or to molecules, being present “based on the wet weight of the coating composition” refers to that molecule, or molecules, being present in the coating composition based on the total weight of the coating composition which includes at least 5 wt. % of solvent.
  • Relative terms such as “lower,” “upper,” “horizontal,” “vertical,”, “above,” “below,” “up,” “down,” “top” and “bottom” as well as derivatives thereof (e.g., “horizontally,” “downwardly,” “upwardly,” etc.) should be construed to refer to the orientation as then described or as shown in the drawing (if applicable) under discussion. These relative terms are for convenience of description only and, unless specified otherwise, do not require that the apparatus be constructed or operated in a particular orientation.
  • the present disclosure relates acoustic structures, such as ceiling and wall panels, having high impact resistance, high strength, and high sag resistance.
  • the disclosed acoustic panels 100 may exhibit improved impact resistance due to the inclusion of crosslinking adhesives and binders and disclosed herein.
  • acoustic panels such as ceiling or wall panels.
  • the acoustic panels are acoustical panels having appropriate acoustical characteristics for the specified application.
  • panel materials that may be used include, without limitation, mineral fiber board, fiberglass, metals, polymers, wood, composites, combinations thereof, or other.
  • panels have a sufficiently high noise reduction coefficient (NRC) and ceiling attenuation class (CAC) rating to be characterized as an acoustical substrate in contrast to gypsum-based drywall having substantially lower NRCs (e.g. 0.05) characteristic of sound reflecting, not absorbing materials.
  • NRC noise reduction coefficient
  • CAC ceiling attenuation class
  • NRC is a measure of sound energy absorption of a material.
  • An NRC rating of 0 is a perfect sound reflection material.
  • An NRC rating of 1 is a perfect sound absorption material.
  • CAC is a measure for rating the performance of a ceiling material as a barrier to block airborne sound transmission through the material to/from the plenum above the ceiling. In one or more examples, the disclosed acoustic panel 100 yields a NRC rating of about 0.8.
  • ASTM E84- 20 provides methods to determine the relative burning behavior of the material.
  • ASTM E84-20 provides methods for determining the Flame Spread Index (FSI) which characterizes how far flames generated on the test material spread. The FSI is measured from 0 (indicating no flames) to 200 (which indicates spreading flames).
  • ASTM E84-20 also provides methods for determining the Smoke Developed Index (SDI) which states how much smoke is generated. SDI is measured on a scale of 0 to 450, which correlates to no smoke generated (value of 0) to thick, heavy smoke (value of 450).
  • FSI Flame Spread Index
  • SDI Smoke Developed Index
  • FSI and SDI values are then compiled and applied to a three-tiered class system: Class A, Class B, and Class C, with Class A rated materials producing minimal to no flames or smoke, while Class C materials producing the most flames or smoke.
  • a flame spread index (FSI) of 25 or less and smoke developed index (SDI) at 450 or less must be exhibited.
  • the acoustic panel 100 has a flame spread index (FSI) of about 0 to about 10, as determined by ASTM E84-20.
  • the building panel has a flame spread index (FSI) of about 10 as determined by ASTM E84-20.
  • the acoustic panel 100 has a flame spread index (FSI) of about 0 as determined by ASTM E84-20. In certain examples, the building panel has a smoke developed index (SDI) of about 450, or less, as determined by ASTM E84-20. In certain examples, the acoustic panel 100 has a smoke developed index (SDI) of about 350, or less, as determined by ASTM E84-20.
  • FSI flame spread index
  • SDI smoke developed index
  • SDI smoke developed index
  • FIG. 4 shows an example of a ceiling system 1 comprising one or more of the building panels 100 installed in an interior space, whereby the interior space comprises a plenum space 3 and an active room environment 2.
  • the acoustic panels 100 may be joined together via a joint compound. Any all- purpose, commercially-available joint compound material may be used without departing from the scope of the disclosure.
  • the present disclosure is designed such that the coating 200 may be applied over both the building panels 100 and joint compound connecting the building panels 100 and offer desirable hiding power for both the acoustic panels 100, scrim 130 if present over the acoustic panels 100, and joint compound.
  • the plenum space 3 provides space for mechanical lines within a building (e.g., HVAC, plumbing, etc.).
  • the active space 2 provides room for the building occupants during normal intended use of the building (e.g., in an office building, the active space would be occupied by offices containing computers, lamps, etc.).
  • the building panels 100 may be supported in the interior space by one or more parallel support struts 5.
  • Each of the support struts 5 may comprise an inverted T-bar having a horizontal flange 31 and a vertical web 32.
  • the first major surface 111 of the acoustic panel 100 may face the active room environment 2 and the second major surface 112 of the acoustic panel 100 may face the plenum space 3.
  • the acoustic panel 100 may be installed according to at least two variations.
  • the acoustic panel 100 is positioned entirely above the horizontal flange 31 of the support struts 5.
  • at least a portion of the first major surface may be concealed from the active room environment 2 by the horizontal flange 31 because the horizontal flange 31 contacts the first major surface 111, thereby supporting it in the ceiling system 1.
  • the entire side surface 113 - including the upper portion 113a and the lower portion 113b - may be concealed from the active room environment 2 by the horizontal flange 311.
  • the present disclosure includes an acoustic panel 100 (sometimes referred to herein as “building panel”) comprising a first major surface 111 opposite a second major surface 112 and a side surface 113 that extends between the first major surface 111 and the second major surface 112, thereby defining a perimeter of the acoustic panel 100.
  • the side surface 113 may comprise an upper portion 113a and a lower portion 113b, wherein the upper portion 113a is adjacent to the first major surface 111 and the lower portion 113b is adjacent to the second major surface 112.
  • the acoustic panel 100 may have an acoustic panel thickness to as measured from the first major surface 111 to the second major surface 112.
  • the acoustic panel thickness to may range from about 5 mm to about 40 mm - including all values and sub-ranges there-between.
  • the acoustic panel 100 may have a length Lp ranging from about 30 cm to about 310 cm - including all values and sub-ranges there-the acoustic panel 100 may have a width Wp ranging from about 10 cm to about 125 cm - including all values and sub-ranges there-between.
  • the density of the building panel may vary.
  • the density of the building panel is from about 0.3 g/cm 3 to about 1.5 g/cm 3 . In certain examples, the building panel density is from about 0.4 g/cm 3 to about 0.9 g/cm 3 . In further examples, the building panel density is from about 0.5 g/cm 3 to about 0.7 g/cm 3 .
  • the acoustic panel 100 comprises a substrate 120 having a first major surface 121 opposite a second major surface 122 and a substrate side surface 123 that extends between the first major surface 121 and the second major surface 122, thereby defining a perimeter of the substrate 120.
  • the substrate 120 may have a body thickness ti that extends from the first major surface 121 to the second major surface 122.
  • the body thickness ti may range from about 5 mm to about 40 mm - including all values and sub-ranges there-between.
  • the substrate 120 may be porous, thereby allowing airflow through the substrate 120 between the first major surface 121 and the second major surface 122.
  • the substrate 120 may be comprised of a binder and fibers.
  • the substrate 120 may further comprise a filler and/or additive.
  • the substrate 100 substrate includes mineral fiber board, fiberglass, jute fiber, wood, or a composite material.
  • the disclosed substrate 120 may include one or more fire retardants.
  • the fire retardant is selected from magnesium oxide, sodium silicate, magnesium sulfate, calcium carbonate, ammonium polyphosphate, or a combination thereof. The one or more fire retardants may be present at various amounts or concentrations.
  • the acoustic panel 100 further includes a coating composition 200 the side surface 113 of the acoustic panel 100.
  • the coating composition 200 includes a pigment and a crosslinking binder.
  • the coating composition 200 defines an edge coating 220 having an inside surface 222 and an outside surface 221.
  • the coating composition 200 has a ratio of pigment-to-binder that ranges from about 0.5 : 1 to about 20: 1 In another example, the pigment-to-binder ratio ranges from about 1 : 1 to about 5: 1.
  • the crosslinking binder includes vinyl acrylic polymer.
  • the crosslinking binder includes a crosslinker present in an amount ranging from about 0.5 wt. % to about 30 wt. %, based on the dry weight of the coating composition. In one example, the crosslinking binder is present in an amount from about 10 wt. % to about 60 wt. %, from about 20 wt. % to about 50 wt.
  • the crosslinking binder includes a blend of at least two binders, wherein at least one binder is non-crosslinkable and the other binder is crosslinking.
  • the pigment may include a single pigment of a blend of two or more pigments.
  • the pigment includes titanium dioxide present at a concentration of about 0.1 wt. % to about 35 wt. %, from about 0.5 wt. % to about 25 wt. %, or from about 1 wt. % to about 20 wt. %, based upon the dry weight of the coating composition.
  • the pigment includes calcined diatomaceous earth present in an amount from about 3 wt. % to about 20 wt. %, from about 5 wt. % to about 17.5 wt. %, or from about 7.5 wt. % to about 15 wt. %, based on the dry weight of the coating composition.
  • the pigment includes aluminum hydroxide present in an amount from about 3 wt. % to about 20 wt. %, from about 5 wt. % to about 18 wt. %, or from about 10 wt. % to about 15 wt. %, based on the dry weight of the coating composition.
  • the pigment includes calcium carbonate present in an amount from about 20 wt. % to about 60 wt. %, from about 25 wt. % to about 45 wt. %, or from about 27.0 wt. % to about 35 wt. %, based on the dry weight of the coating composition.
  • coating composition further includes water.
  • the water may be present in an amount from about 4 wt. % to about 60 wt. %, from about 10 wt. % to about 50 wt. %, or from about 20 wt. % to about 40 wt. %, based upon the wet weight of the coating composition.
  • the coating composition further includes a hydrophobic polymer emulsion.
  • the hydrophobic polymer emulsion may be present in an amount from about 0.1 wt. % to about 10 wt. %, from about 0.5 wt. % to about 5.0 wt. %, or from about 0.75 wt. % to about 3 wt. %, based on the dry weight of the coating composition.
  • the coating composition further includes a wetting and dispersing additive comprising an anionic copolymer.
  • the wetting and dispersing additive may have an acid value of about 2 mg KOH/g.
  • the wetting and dispersing additive is present in an amount from about 0.1 wt. % to about 5 wt. %, from about 0.1 wt. % to about 2 wt. %, or from about 0.1 wt. % to about 0.5 wt. %, based on the dry weight of the coating composition.
  • the coating composition further includes clay.
  • the clay may be present in an amount from about 0.01 wt. % to about 5 wt. %, from about 0.03 wt. % to about 2 wt. %, or from about 0.03 wt. % to about 0.5 wt. %, based on the dry weight of the coating composition.
  • the clay is a hectorite clay.
  • the coating composition further includes a defoamer.
  • the defoamer may include wax and mineral oil.
  • the defoamer is present in an amount from about 0.01 wt. % to about 2 wt. %, from about 0.01 wt. % to about 1 wt. %, or from about 0.01 wt. % to about 0.1 wt. %, based on the dry weight of the coating composition.
  • the coating composition further includes biocide.
  • the biocide may be present in an amount from about 0.01 wt. % to about 1 wt. %, from about 0.05 wt. % to about 0.8 wt. %, or from about 0.3 wt. % to about 0.7 wt. %, based on the dry weight of the coating composition.
  • the pigment further includes precipitated synthetic silicate.
  • the precipitated synthetic silicate may be present in an amount from 1 wt. % to about 5 wt. %, from about 1.5 wt. % to about 3.5 wt. %, or from about 2 wt. % to about 3 wt. %%, based on the dry weight of the coating composition.
  • the pigment further includes a calcined extender.
  • the calcined extender may be present in an amount from about 1 wt. % to about 25 wt. %, from about 2 wt. % to about 5 wt. %, or from about 3 wt. % to about 4 wt. %, based on the dry weight of the coating composition.
  • the acoustic panel 100 may further include a top surface coating 210 having an inside surface 212 and an outside surface 211.
  • the top surface coating 210 may have a composition that is the same as the edge coating 220 or may be different from the edge coating 220.
  • the acoustic panel 100 may include a scrim 130 having a first major scrim surface 132 opposite a second major scrim surface 134.
  • the scrim 130 may be present on the first major substrate surface 121.
  • the scrim 130 may be adhered to the substrate 120 via an adhesive adhering the first major substrate surface 121 to the second major scrim surface 134.
  • the scrim 130 includes laminated non-woven glass fibers in a resin matrix.
  • the adhesive includes polyvinyl acetate emulsion.
  • the adhesive includes a blend of two or more adhesives.
  • the adhesive may be crosslinking.
  • the adhesive includes a blend of two or more adhesives.
  • the adhesive includes a blend of two or more adhesives wherein at least one of the adhesives is non-crosslinkable and wherein at least one of the adhesives is crosslinking.
  • the adhesive includes a crosslinker. The adhesive may be present in an amount ranging from about 5 g/ft 2 to about 40 g/ft 2 .
  • the present disclosure may be implemented in a building system 1.
  • the present disclosure includes a building system 1 comprising one or more of the acoustic building panels 100 or plurality of acoustic building panels 202 installed in an interior space 8.
  • FIG. 5 shows the acoustic panel 100 installed, however, the following discussion applies to any configuration disclosed herein.
  • the interior space 8 may comprise a floor surface 4, equivalent to ground level as disclosed herein, that is opposite a ceiling surface 5.
  • the interior space 8 may further comprise a cavity space 3 and an active room environment 2.
  • the cavity space 3 may provide a free volume for joists and/or wall stud 9 to be located within the acoustic building system 1.
  • the active room environment 2 provides room for the acoustic building occupants during normal intended use of the acoustic building (e.g., in an office building, the active space would be occupied by offices containing computers, lamps, etc.).
  • the floor surface 4 provides for building occupants to walk on within the room environment 2.
  • the floor surface 4 may extend into the cavity space 3.
  • the floor surface 4 may be formed a building material (e.g., wood flooring, concrete flooring, metal grate, etc.).
  • the acoustic building panels 100, plurality of acoustic building panels 100 may be supported in the interior space 8 by one or more of the wall studs 9 (for acoustic building panels 100 that function as wall panels) and/or one or more of the ceiling joists (for acoustic building panels 100 that function as ceiling panels - not pictured).
  • the plurality of acoustic building panels 100 supported by the wall studs 9 may form a wall surface 50.
  • the plurality of building panels 100 supported by the ceiling joists may form a ceiling surface 5.
  • the plurality of wall studs 9 may be arranged substantially parallel to each other.
  • the plurality of wall studs 9 may be offset from each other by a distance DWS of about 16 inches - as measured on center from each adjacent wall stud 9.
  • the distance DWS between wall studs 9 may provide for an open cavity volume 11.
  • the open cavity volume 11 may be an unoccupied space within the acoustic building system 1.
  • insulation may be installed into the open cavity volume 11 - non-limiting examples of insulation include sound insulation, thermal insulation, and combinations thereto.
  • the wall studs 9 may be an elongated body having a substantially vertical orientation - extending in a direction that spans between the floor surface 4 and the ceiling surface 5. Depending on the room layout design, the wall studs 9 may be oriented orthogonal to the floor surface 4 - i.e., resulting in a wall surface 50 that is completely vertical (also referred to as a “vertical wall surface” 50). In other embodiments, the wall studs 9 may be oriented at an angle between about 46° to about 89° relative to the floor surface 4 - i.e., resulting in a wall surface 50 that is slanted (also referred to as a “slanted wall surface” 50).
  • the ceiling surface 5 may be substantially parallel to the floor surface 4 - i.e., resulting in a ceiling surface 5 that is completely horizontal (also referred to as a “horizontal ceiling surface” 5). In other embodiments, the ceiling surface 5 may be oriented at an angle between about 1° to about 44° relative to the floor surface 4 - i.e., resulting in a ceiling surface 5 that is slanted (also referred to as a “slanted ceiling surface” 5).
  • the cavity space 3 may exist behind each one of the plurality of acoustic building panels 202.
  • the active room environment 2 may exists in front of each one of the plurality of acoustic building panels 202.
  • the first exposed major surface 116 of each acoustic panel 100 may face the active room environment 2.
  • the second exposed major surface 118 of each acoustic panel 100 may face the cavity space 3.
  • the acoustic building panels 100 of the present invention have airflow properties required for the acoustic building panels 100 to functional as acoustical building panels - as discussed further herein.
  • Exemplary Claim 5 The acoustic panel according to any one of Exemplary Claims 1 to 4, wherein the binder comprises a crosslinker present in an amount ranging from about 0.5 wt% to about 30 wt%, based on the total dry weight of the coating composition.
  • Exemplary Claim 7 The acoustic panel according to any one of Exemplary Claims 1 to 6, wherein the binder is present in an amount from about 5 wt. % to about 70 wt. %, from about 10 wt. % to about 60 wt. %, or from about 30 wt. % to about 50 wt. %, based on the dry weight of the coating composition.
  • Exemplary Claim 8 The acoustic panel according to any one of Exemplary Claims 1 to 7, wherein the pigment comprises titanium dioxide present at a concentration of about 0.1 wt. % to about 35 wt. %, from about 0.5 wt. % to about 25 wt. %, or from about 1 wt. % to about 20 wt. %, based upon the dry weight of the coating composition.
  • Exemplary Claim 12 The acoustic panel according to any one of Exemplary Claims 1 to
  • the coating composition further comprises water.
  • Exemplary Claim 13 The acoustic panel according to Exemplary Claim 12, wherein the water is present in an amount from about 20 wt. % to about 60 wt. %, from about 30 wt. % to about 50 wt. %, or from about 40 wt. % to about 60 wt. %, based upon the wet weight of the coating composition.
  • Exemplary Claim 15 The acoustic panel of Exemplary Claim 14, wherein the hydrophobic polymer emulsion is present in an amount from about 0.1 wt. % to about 10 wt. %, from about 0.5 wt. % to about 5.0 wt. %, or from about 0.75 wt. % to about 3 wt. %, based on the dry weight of the coating composition.
  • Exemplary Claim 16 The acoustic panel according to any one of Exemplary Claims 1 to 15, wherein the coating composition further comprises a wetting and dispersing additive comprising an anionic copolymer.
  • Exemplary Claim 18 The acoustic panel according to any one of Exemplary Claims 1 to
  • wetting and dispersing additive is present in an amount from about 0.1 wt. % to about 5 wt. %, from about 0.1 wt. % to about 2 wt. %, or from about 0.1 wt. % to about 0.5 wt. %, based on the dry weight of the coating composition.
  • Exemplary Claim 19 The acoustic panel according to any one of Exemplary Claims 1 to
  • Exemplary Claim 20 The acoustic panel of Exemplary Claim 19, wherein the clay is present in an amount from about 0.01 wt. % to about 5 wt. %, from about 0.03 wt. % to about 2 wt. %, or from about 0.03 wt. % to about 0.5 wt. %, based on the dry weight of the coating composition.
  • Exemplary Claim 21 The acoustic panel according to any of Exemplary Claims 19 or 20, wherein the clay is a hectorite clay.
  • Exemplary Claim 22 The acoustic panel according to any one of Exemplary Claims 1 to 21, wherein the coating composition further comprises a defoamer.
  • Exemplary Claim 23 The acoustic panel of Exemplary Claim 22, wherein the defoamer comprises wax and mineral oil.
  • Exemplary Claim 24 The acoustic panel according to any one of Exemplary Claims 22 or
  • the defoamer is present in an amount from about 0.01 wt. % to about 2 wt. %, from about 0.01 wt. % to about 1 wt. %, or from about 0.01 wt. % to about 0.1 wt. %, based on the dry weight of the coating composition.
  • Exemplary Claim 25 The acoustic panel according to any one of Exemplary Claims 1 to
  • the coating composition further comprises biocide.
  • Exemplary Claim 26 The acoustic panel according to Exemplary Claim 25, wherein the biocide is present in an amount from about 0.01 wt. % to about 1 wt. %, from about 0.05 wt. % to about 0.8 wt. %, or from about 0.3 wt. % to about 0.7 wt. %, based on the dry weight of the coating composition.
  • Exemplary Claim 27 The acoustic panel according to any of Exemplary Claims 1 to 26, wherein the pigment further comprises precipitated synthetic silicate.
  • Exemplary Claim 28 The acoustic panel of Exemplary Claim 27, wherein the precipitated synthetic silicate is present in an amount from 1 wt. % to about 5 wt. %, from about 1.5 wt. % to about 3.5 wt. %, or from about 2 wt. % to about 3 wt. %%, based on the dry weight of the coating composition.
  • Exemplary Claim 29 The acoustic panel according to any one of Exemplary Claims 1 to 28, wherein the pigment further comprises a calcined extender.
  • Exemplary Claim 30 The acoustic panel of Exemplary Claim 29, wherein the calcined extender is present in an amount from about 1 wt. % to about 25 wt. %, from about 2 wt. % to about 5 wt. %, or from about 3 wt. % to about 4 wt. %, based on the dry weight of the coating composition.
  • Exemplary Claim 31 The acoustic panel according to any one of Exemplary Claims 1 to 30, wherein the acoustic panel is a ceiling or wall panel.
  • Exemplary Claim 32 A method for forming an acoustic building panel, the method comprising: providing a substrate having a first major surface opposite a second major surface and a side surface extending there-between; applying a coating composition over the side surface, the coating composition comprising a crosslinking binder and a pigment; and curing the substrate to yield the acoustic building panel.
  • Exemplary Claim 33 The method according to Exemplary Claim 32, wherein the applying comprises spraying the coating composition at a predetermined application rate.
  • Exemplary Claim 34 The method according to any one of Exemplary Claims 32 or 33, wherein the crosslinking binder comprises a blend of two or more binders, wherein at least one of the two or more binders is a crosslinking binder, and wherein at least one of the two or more binders is not crosslinking.
  • Exemplary Claim 35 The method according to any one of Exemplary Claims 32 to 34, wherein a ratio of pigment-to-binder ranges from about 0.2: 1 to about 20: 1.
  • Exemplary Claim 36 The acoustic panel according to any one of Exemplary Claims 32 to
  • the binder comprises vinyl acetate polymer.
  • Exemplary Claim 37 The acoustic panel according to any one of Exemplary Claims 32 to
  • the binder comprises a crosslinker present in an amount ranging from about 0.5 wt% to about 30 wt%, based on the total dry weight of the coating composition.
  • Exemplary Claim 38 The acoustic panel according to any one of Exemplary Claims 32 to
  • binder is present in an amount from about 5 wt. % to about 70 wt. %, from about 10 wt. % to about 60 wt. %, or from about 30 wt. % to about 50 wt. %, based on the dry weight of the coating composition.
  • Exemplary Claim 39 The method according to any one of Exemplary Claims 32 to 38, wherein curing comprises drying the substrate at a temperature ranging from about 275 °F to about 480 °F.
  • composition of Table 2 is the composition for Example 2 having a crosslinking binder and a filler to binder ratio of 1 : 1 and 55.9% solids.
  • the edge coating composition of Table 4 is the composition for Control 1 using a polyvinyl acetate binder that is not crosslinking.
  • the composition has a filler to binder ratio of 6.03 and
  • the composition has a filler to binder ratio of 6.03 and 60.7% solids.
  • Example 1 and Example 2 with crosslinking binders consistently exhibited higher required indent forces as compared to the control 1 with a binder is not crosslinking. The differences are much bigger at lower filler to binder ratio, which clearly demonstrates that beneficial improvement from the crosslinking binder.
  • Example 4 exhibited a strength about seven times as control sample 2 at 0.20” indent depth.

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  • Physics & Mathematics (AREA)
  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Acoustics & Sound (AREA)
  • Electromagnetism (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Multimedia (AREA)
  • Building Environments (AREA)

Abstract

L'invention concerne un panneau acoustique comprenant un substrat ayant une première surface principale opposée à une seconde surface principale et une surface latérale s'étendant entre celles-ci, et un revêtement sur la face et/ou les surfaces latérales comprenant un pigment et un liant de réticulation. L'invention concerne également des procédés de fabrication de panneaux acoustiques présentant une résistance et une durabilité élevées.
PCT/US2025/022029 2024-03-29 2025-03-28 Revêtements durables pour structures acoustiques et leurs procédés de fabrication Pending WO2025208036A1 (fr)

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US202463571964P 2024-03-29 2024-03-29
US63/571,964 2024-03-29

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Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
KR19990032487A (ko) * 1997-10-18 1999-05-15 김충엽 휨 및 표면충격 강도가 강화된 건축용 패널및 그 제조방법
US20040039098A1 (en) * 2002-08-22 2004-02-26 Hector Belmares Formaldehyde-free coatings and acoustical panel
EP1980540A1 (fr) * 2007-04-05 2008-10-15 Lafarge Plaques de plâtre superhydrophobes et leur procédé de fabrication
US20180345530A1 (en) * 2016-01-08 2018-12-06 Omya International Ag In-line coated wood-based boards
US20190062585A1 (en) * 2017-08-29 2019-02-28 Armstrong World Industries, Inc. High solids coatings for building panels

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
KR19990032487A (ko) * 1997-10-18 1999-05-15 김충엽 휨 및 표면충격 강도가 강화된 건축용 패널및 그 제조방법
US20040039098A1 (en) * 2002-08-22 2004-02-26 Hector Belmares Formaldehyde-free coatings and acoustical panel
EP1980540A1 (fr) * 2007-04-05 2008-10-15 Lafarge Plaques de plâtre superhydrophobes et leur procédé de fabrication
US20180345530A1 (en) * 2016-01-08 2018-12-06 Omya International Ag In-line coated wood-based boards
US20190062585A1 (en) * 2017-08-29 2019-02-28 Armstrong World Industries, Inc. High solids coatings for building panels

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