Humidity and sag resistant building panel
Described herein is an stain and sag resistant acoustic building panel comprising a porous body formed from building material and latex binder, wherein the building material may include fibers and filler and at one of the building materials has been pre-treated with a charge-modifying component, thereby enhancing the sag-resistance of the building panel.
1. A building panel comprising:
a latex binder;
a fibrous material comprising a fiber pre-treated with a charge-modifying component;
wherein the latex is present in a non-zero amount ranging up to about 15 wt. % based on the total dry-weight of the building panel; and
wherein the charge-modifying component is selected from the group consisting of aluminum sulfate, poly(diallyldimethylammonium chloride), and combinations thereof.
2. The building panel according to claim 1 , wherein the charge-modifying component is present in an amount ranging from about 0.1 wt. % to about 2.5 wt. % based on the total weight of the building panel.
3. The building panel according to claim 1 , wherein the fiber is an inorganic fiber selected from the group consisting of mineral wool, fiberglass, and combinations thereof.
4. The building panel according to claim 1 , further comprising a body formed from the latex binder and the fibrous material.
5. The building panel according to claim 4 , wherein latex binder is present in a non-zero amount ranging up to about 10 wt. % based on the total dry-weight of the body.
6. The building panel according to claim 1 , wherein the latex binder has a glass transition temperature ranging from about 60° C. to about 110° C.
7. The building panel according to claim 4 , wherein the body has a density ranging from about 100 kg/m 3 to about 600 kg/m 3 .
8. A method for producing a sag resistant building panel comprising:
a) pre-treating a building material with a charge-modifying component to form a pre-treated building material by mixing the building material and the charge-modifying component in an aqueous slurry;
b) mixing into the aqueous slurry a latex binder; and
c) forming the building panel from the aqueous slurry;
wherein the latex binder is present in a non-zero amount ranging up to about 15 wt. % based on the total dry-weight of the building panel.
9. The method according to claim 8 , wherein the building material has a first ionic charge and the charge-modifying component has a second ionic charge that is opposite the first ionic surface charge.
10. The method according to claim 9 , wherein the latex binder of step b) has a third ionic charge that is the same as the first ionic charge.
11. The method according to claim 9 , wherein the second ionic charge is cationic.
12. The building panel according to claim 8 , wherein the charge-modifying component is selected from the group consisting of aluminum sulfate, poly(diallyldimethylammonium chloride), and combinations thereof.
13. The method according to claim 8 , wherein the building material is selected from the group consisting of perlite particles, clay particles, and combinations thereof.
14. The method according to claim 8 , wherein subsequent to step b) and prior to step c), inorganic fibers are added to the aqueous slurry.
15. The method according to claim 8 , wherein the building material of step a) is inorganic fiber.
16. The method according to claim 15 , wherein the inorganic fiber is selected from the group consisting of mineral wool, fiberglass, and combinations thereof.
17. A building panel comprising:
a latex binder;
a fibrous material comprising a mineral wool pre-treated with a charge-modifying component having a cationic charge;
wherein the latex is present in a non-zero amount ranging up to about 15 wt. % based on the total dry-weight of the building panel; and
wherein the charge-modifying component is selected from the group consisting of aluminum sulfate, poly(diallyldimethylammonium chloride), and combinations thereof.
18. The building panel according to claim 17 , further comprising an inorganic particle.
19. The method according to claim 8 , wherein step a) comprises mixing the building material and the charge-modifying component for about 2.0 minutes to about 60.0 minutes.
20. The method according to claim 8 , wherein step b) comprises mixing the latex binder and the pre-treated building material in the aqueous slurry for about 2.0 minutes to about 60.0 minutes.