Acoustic ceiling board with improved aesthetics
View Patent ↗Described herein are acoustical panels, comprising: a substrate; a non-woven veil having an airflow resistance of greater than 45 mks rayls, comprising: from about 20 wt. % to about 60 wt. % glass fibers; from about 40 wt. % to about 80 wt. % of a filler; and from about 110 dry g/m 2 to about 135 dry g/m 2 of a coating. Methods of making and using the panels are also described.
1. An acoustical panel, comprising:
a substrate;
a non-woven veil having an airflow resistance of greater than 45 mks rayls, comprising:
from about 20 wt. % to about 60 wt. % glass fibers; and
from about 40 wt. % to about 80 wt. % of a filler; and
from about 110 dry g/m 2 to about 135 dry g/m 2 of a coating.
2. The panel of claim 1 , wherein the non-woven veil demonstrates a hiding power value of greater than 75%.
3. The panel of claim 1 , wherein the coated non-woven veil has an airflow resistance of about 300 mks rayls or less.
4. The panel of claim 1 , wherein the filler comprises aluminum trihydrate.
5. The panel of claim 1 , comprising about 120 dry g/m 2 of the coating.
6. The panel of claim 1 , wherein the coating is not continuous.
7. The panel of claim 1 , wherein the coating comprises a binder and particles.
8. The panel of claim 7 , wherein the particles have a d 50 of from about 50 microns to about 300 microns.
9. The panel of claim 1 , wherein the non-woven veil is affixed to the substrate using an adhesive.
10. The panel of claim 9 , wherein the adhesive comprises a pressure sensitive adhesive.
11. The panel of claim 1 , wherein the non-woven veil has a thickness of from about 0.2 mm to about 0.5 mm.
12. The panel of claim 1 , wherein the substrate is substantially free of punch holes, wheel abrasions, embossing or erosion.
13. A coated non-woven veil comprising:
a non-woven veil having an airflow resistance of greater than 45 mks rayls, comprising:
from about 20 wt. % to about 60 wt. % glass fibers; and
from about 40 wt. % to about 80 wt. % of a filler; and
a coating comprising:
a binder;
particles; and
a carrier;
wherein the coated non-woven veil has an airflow resistance of about 300 mks rayls or less.
14. The veil of claim 13 , comprising from about 110 dry g/m 2 to about 135 dry g/m 2 of the coating.
15. The veil of claim 13 , wherein the carrier is an aqueous carrier.
16. The veil of claim 13 , wherein the binder is selected from a natural polymer, a modified natural polymer, a synthetic polymer and a combination of two or more thereof.
17. The veil of claim 13 , wherein the particles comprise a material selected from calcium carbonate, dolomite, titanium dioxide, barium sulfate, clay, mica, limestone, silica, talc, perlite, gypsum, wollastonite, calcite, aluminum trihydrate, zinc, a polymer, a pigment and a combination of two or more thereof.
18. The veil of claim 17 , wherein the particles have a d 50 of from about 50 microns to about 300 microns.
19. A method of improving the aesthetics of an acoustical panel, comprising:
affixing to a substrate, a non-woven veil having an airflow resistance of greater than 45 mks rayls comprising:
from about 20 wt. % to about 60 wt. % glass fibers; and
from about 40 wt. % to about 80 wt. % of a filler;
applying to the non-woven veil a coating comprising: a binder; particles having a d 50 of from about 50 microns to about 300 microns; and a carrier, in an amount effective to provide from about 110 dry g/m 2 to about 135 dry g/m 2 of the coating; and
drying the coated non-woven veil.
20. The method of claim 19 , wherein the non-woven veil is affixed to the substrate by lamination using an adhesive.