Scrim attachment system
The present invention is directed to ceiling panels formed from a porous scrim that is coupled to an acoustical substrate using a scrim attachment system that includes an adhesive.
1. A building panel comprising:
a substrate having a first major substrate surface opposite a second major substrate surface;
a scrim having a first major scrim surface opposite a second major scrim surface;
a dry-state adhesive adhering the first major substrate surface of the substrate to the second major scrim surface of the scrim, the dry-state adhesive comprising a gel-forming film-forming polymer; and
wherein the dry-state adhesive is present in an amount that ranges from 4 g/m 2 to 13 g/m 2 .
2. The building panel according to claim 1 , wherein the substrate has a density ranging from 40 kg/m 3 to 190 kg/m 3 .
3. The building panel according to claim 1 , wherein the substrate comprises a fibrous material.
4. The building panel according to claim 3 , wherein the fibrous material is selected from the group consisting of mineral wool, fiberglass, cellulosic fibers, polymer fibers, protein fibers, and combinations thereof.
5. The building panel according to claim 1 , wherein the gel-forming film-forming polymer comprises at least one of polyvinyl alcohol, starch polymer, polysaccharide polymer, cellulosic polymers, protein solution polymer, an acrylic polymer, polymaleic anhydride, or a combination of two or more thereof.
6. The building panel according to claim 1 , wherein the gel-forming film-forming polymer comprises polyvinyl alcohol that is at least 85% hydrolyzed.
7. The building panel according to claim 1 , wherein the scrim comprises a non-woven structure of fiberglass.
8. The building panel according to claim 1 , wherein the substrate has a porosity ranging from about 75% to about 95%.
9. The building panel according to claim 1 , wherein the gel-forming film-forming polymer comprises polyvinyl alcohol and wherein the gel-forming film-forming polymer is present from about 4.6 g/m 2 to about 7.7 g/m 2 of polymer.
10. The building panel according to claim 9 , wherein the polyvinyl alcohol is at least 85% hydrolyzed.
11. The building panel according to claim 1 , wherein the scrim has an airflow resistance ranging from about 40 MKS rayls to about 200 MKS rayls.
12. The building panel according to claim 1 , wherein the dry-state adhesive provides a pull strength between the substrate and the scrim, the pull strength ranging from about 30 lbs/6 in 2 to 104 lbs/6 in 2 .