Acoustic construction panel, ceiling system and method of forming an acoustic construction panel

Abstract

This document describes an acoustic construction panel comprising a body comprising inorganic fiber in an amount ranging from about 60.0% by weight to about 90.0% by weight based on the total weight of the body; and microfibrillated fiber in an amount ranging from about 0.5% by weight to about 10% by weight based on the total weight of the body.

Description

/ 21 “ACOUSTIC BUILDING PANEL, CEILING SYSTEM AND METHOD OF FORMING AN ACOUSTIC BUILDING PANEL” Cross-Reference to Related Applications

[0001] This application is an International PCT Application of the United States of America Provisional Application No. 62 / 869,310, filed July 1, 2019. The disclosure of the above application is incorporated herein by reference. Fundamentals of the Invention

[0002] Building panels – specifically acoustically permeable ceiling panels – have a tendency to sag when exposed to high humidity environments. These building panels, which are formed from fibrous material, are subjected to additional stresses in high humidity environments because the amount of water absorbed by the building panel increases. Previous attempts to prevent such sagging included adding other non-fibrous components as a way to impart additional strength to the panel. However, such components have a detrimental effect on the acoustic properties of the resulting building panel. Thus, there is a need for a building panel with greater resistance to sagging, without sacrificing the acoustic properties of that panel. Description of the Invention

[0003] According to some embodiments, the present invention is directed to an acoustic construction panel comprising: a body comprising: inorganic fiber in an amount ranging from about 60.0% by weight to about 90.0% by weight based on the total weight of the body; and microfibrillated fiber in an amount ranging from about 0.25% by weight to about 12.5% ​​by weight based on the total weight of the body.

[0004] Other embodiments of the present invention include an acoustic building panel comprising: a body comprising: fiber Petition 870260075053, dated 07 / 28 / 2026, page 37 / 61 / 21 inorganic; microfibrillated fiber; in which the body has an apparent density ranging from about 96 kg / m3 to about 480 kg / m3.

[0005] Other embodiments of the present invention include an acoustic construction panel comprising: a body comprising: inorganic fiber; microfibrillated fiber; wherein the body has a porosity ranging from about 80.0% to about 95.0%.

[0006] Other embodiments of the present invention include a ceiling system comprising: a support structure; and at least one of the acoustic building panels discussed above.

[0007] Other areas of applicability of the present invention will become apparent from the detailed description provided below. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are for illustrative purposes only and are not intended to limit the scope of the invention. Brief Description of the Figures

[0008] The present invention will become more fully understood from the detailed description and accompanying drawings, in which:

[0009] Figure 1 is a top perspective view of a building panel according to the present invention.

[0010] Figure 2 is a cross-sectional view of the construction panel according to the present invention, the cross-sectional view being along line II established in Figure 1.

[0011] Figure 3 is a ceiling system comprising the construction panel of the present invention. Description of Embodiments of the Invention

[0012] The following description of the preferred embodiment(s) is / are merely exemplary in nature and in no way is intended to limit the invention, its application or uses. Petition 870260075053, dated 07 / 28 / 2026, page 38 / 61 / 21

[0013] As used in the whole, ranges are used as an abbreviation to describe each and every value that is within the range. Any value within the range can be selected as the end of the range. In addition, all references cited in this document are incorporated herein by reference in their entirety. In the event of a conflict between a definition in this disclosure and that of a cited reference, this disclosure controls.

[0014] Unless otherwise specified, all percentages and quantities expressed in this document and elsewhere in the descriptive report should be understood as referring to percentages by weight. The quantities provided are based on the active weight of the material.

[0015] The description of the illustrative embodiments according to the principles of the present invention is intended to be read in connection with the accompanying drawings, which should be considered part of the entire written description. In the description of the embodiments of the invention disclosed in this document, any reference to direction or orientation is for the sake of convenience of description only and is in no way intended to limit the scope of the present invention. Relative terms such as lower, upper, horizontal, vertical, above, below, upwards, downwards, top and bottom, as well as their derivatives (e.g., horizontally, descending, ascending, etc.) should be interpreted as referring to the orientation as then described or shown in the drawing under discussion. These relative terms are only for convenience of description and do not require that the apparatus be constructed or operated in a particular orientation unless explicitly indicated as such.

[0016] Terms such as attached, affixed, connected, coupled, interconnected and the like refer to a relationship in which structures are fixed or attached to one another, directly or indirectly by means of Petition 870260075053, dated 07 / 28 / 2026, page 39 / 61 / 21 intermediate structures, as well as movable or rigid links or relationships, unless expressly described otherwise. Furthermore, the features and benefits of the invention are illustrated by reference to the exemplified embodiments. Therefore, the invention should not be expressly limited to such exemplified embodiments which illustrate some possible non-limiting combinations of features that may exist alone or in other combinations of features; the scope of the invention being defined by the appended claims.

[0017] Unless otherwise specified, all percentages and quantities expressed in this document and elsewhere in the descriptive report shall be understood as referring to percentages by weight. The quantities provided are based on the active weight of the material. In accordance with this application, the term “about” means + / - 5% of the reference value. In accordance with this application, the term substantially free is less than about 0.1% by weight based on the total reference value.

[0018] With reference to Figure 1, the construction panel 100 of the present invention may comprise a first main surface 111 opposite a second main surface 112. The ceiling panel 100 may further comprise a side surface 113 extending between the first main surface 111 and the second main surface 112, thus defining a perimeter of the ceiling panel 100.

[0019] With reference to Figure 3, the present invention may further include a ceiling system 1 comprising one or more of the building panels 100 installed in an interior space, wherein the interior space comprises a plenary space 3 and an active room environment 2. The plenary space 3 provides space for mechanical lines 9 within a building (e.g., HVAC, plumbing, etc.). The active space 2 provides space for building occupants during the intended normal use of the building (e.g., Petition 870260075053, dated 07 / 28 / 2026, pp. 40 / 61 / 21 in an office building, the active space would be occupied by offices containing computers, lamps, etc.).

[0020] In the installed state, the building panels 100 may be supported in the interior space by one or more parallel support braces 5. Each of the support braces 5 may comprise an inverted T-bar having a horizontal flange 31 and a vertical web 32. The ceiling system 1 may further comprise a plurality of first braces that are substantially parallel to each other and a plurality of second braces that are substantially perpendicular to the first braces (not shown). In some embodiments, the plurality of second braces intersects the plurality of first braces to create a ceiling support grid 6. The plenary space 3 exists above the ceiling support grid and the active room environment 2 exists below the ceiling support grid 6.

[0021] In the installed state, the first main surface 111 of the building panel 100 faces the active room environment 2 and the second main surface 112 of the building panel 100 faces the plenary space 3. The building panels 100 of the present invention have superior resistance to staining and sagging without sacrificing the desired airflow properties required for the building panels 100 to function as acoustic ceiling panels – as discussed further in this document.

[0022] The ceiling system 1 of the present invention may include the ceiling support grid 6 and at least one construction panel 100 supported by the ceiling support grid, the construction panel 100 having the first main surface 111 opposite the second main surface 112, and the second main surface 112 facing upwards and the first main surface 111 facing downwards.

[0023] With reference now to Figures 1 and 2, the panel of Petition 870260075053, dated 07 / 28 / 2026, p. 41 / 61 / 21 Construction 100 of the present invention may have a panel thickness t0 measured from the first main surface 111 to the second main surface 112. The panel thickness t0 may vary from about 12 mm to about 40 mm - including all values ​​and sub-ranges in between. The construction panel 100 may have a length ranging from about 30 cm to about 310 cm - including all values ​​and sub-ranges in between. The construction panel 100 may have a width ranging from about 10 cm to about 125 cm - including all values ​​and sub-ranges in between.

[0024] The construction panel 100 may comprise a body 120 having an upper surface 122 opposite a lower surface 121 and a body side surface 123 extending between the upper surface 122 and the lower surface 121, thus defining a perimeter of the body 120. The body 120 may have a body thickness t1 extending from the upper surface 122 to the lower surface 121. The body thickness t1 may vary from about 12 mm to about 40 mm – including all values ​​and subranges in between.

[0025] The first main surface 111 of the building panel 100 can comprise the lower surface 121 of the body 120. The second main surface 112 of the building panel 100 can comprise the upper surface 122 of the body 120. When the first main surface 111 of the building panel 100 comprises the lower surface 121 of the body 120 and the second main surface 112 of the building panel 100 comprises the upper surface 122 of the body 120, the thickness of the panel t0 is substantially equal to the thickness of the body t1.

[0026] As discussed in more detail in this document, body 120 may be porous, thus allowing airflow through body 120 between the upper surface 122 and the lower surface 121.

[0027] Body 120 can be made up of fibers 130. The fibers Petition 870260075053, dated 07 / 28 / 2026, page 42 / 61 / 21 130 may comprise a first fibrous component and a second fibrous component. The first fibrous component may comprise organic fiber, inorganic fiber, and combinations thereof. The second fibrous component may comprise microfibrillated cellulose. In some embodiments, the body 120 may further comprise a filler and / or additive. The body 120 may further comprise a binder.

[0028] The first fibrous component of fibers 130 can be organic fibers, inorganic fibers, or a mixture thereof. Non-limiting examples of inorganic fiber mineral wool (also known as slag wool), rock wool, stone wool, and glass fibers. Non-limiting examples of organic fiber include glass fiber, macroscopic cellulosic fibers (e.g., paper fiber - such as newspaper, hemp fiber, jute fiber, flax fiber, wood fiber, or other natural fibers), polymer fibers (including polyester, polyethylene, aramid - i.e., aromatic polyamide and / or polypropylene), protein fibers (e.g., sheep's wool), and combinations thereof. Depending on the specific type of material, the first fibrous component can be hydrophilic (e.g., macroscopic cellulosic fibers) or hydrophobic (e.g., glass fiber, mineral wool, rock wool, stone wool).

[0029] The first fibrous component may be present in an amount ranging from about 60% by weight to about 95% by weight based on total dry body weight 120 - including all values ​​and subranges in between. In some modalities, the first fibrous component may be present in an amount ranging from about 65% by weight to about 90% by weight based on total dry body weight 120 - including all values ​​and subranges in between. In some modalities, the first fibrous component may be present in an amount ranging from about 70% by weight to about 85% by weight based on total dry body weight 120 - including all values ​​and subranges in between. Petition 870260075053, dated 07 / 28 / 2026, p. 43 / 61 / 21

[0030] The term dry weight refers to the weight of a referenced component without the weight of any carrier. Thus, when calculating the weight percentages of components in the dry state, the calculation should be based solely on the solid components (e.g., binder, filler, hydrophobic component, fibers, etc.) and should exclude any amount of residual carrier (e.g., water, VOC solvent) that may still be present from a wet state, which will be discussed further in this document. According to the present invention, the term dry state can also be used to indicate a component that is substantially free of a carrier, in comparison with the term wet state, which refers to that component still containing varying amounts of carrier – as discussed further in this document.

[0031] In a non-limiting example, the first fibrous component may be inorganic fiber, such as mineral wool, wherein the inorganic fiber is present in an amount ranging from about 65% by weight to about 85% by weight – including all weight percentages and subranges in between – based on total body weight 120. In a non-limiting example, the first fibrous component may be inorganic fiber, such as mineral wool, wherein the inorganic fiber is present in an amount ranging from about 70% by weight to about 80% by weight – including all weight percentages and subranges in between – based on total body weight 120.

[0032] In a non-limiting embodiment, the first fibrous component may further comprise macroscopic cellulosic fiber, such as recycled newspaper. In a non-limiting example, the macroscopic cellulosic fiber may be present in an amount ranging from about 0.1% by weight to about 3.0% by weight – including all weight percentages and subranges therebetween – based on total body weight 120. In a non-limiting example, the first fibrous component may further comprise fiber Petition 870260075053, dated 07 / 28 / 2026, p. 44 / 61 / 21 macroscopic cellulosic in an amount ranging from about 0.5% by weight to about 2.0% by weight - based on total body weight 120.

[0033] The diameter of the first fibrous component can vary from about 4 μm to about 10 μm – including all diameters and sub-ranges in between. In some embodiments, the diameter of the first fibrous component can vary from about 4 μm to about 8 μm – including all diameters and sub-ranges in between. The length of the first fibrous component can vary from about 1 mm to about 5 mm – including all lengths and sub-ranges in between.

[0034] The second fibrous component of fibers 130 may be microfibrillated cellulose. Microfibrillated cellulose may be an organic material, but for the purposes of the present invention, microfibrillated cellulose is different from the organic fiber of the first fibrous component.

[0035] Microfibrillated cellulose can be formed from macroscopic cellulosic fibers (e.g., paper fiber - such as newspaper, hemp fiber, jute fiber, flax fiber, wood fiber or other natural fibers), wherein the macroscopic cellulosic fiber is processed so that the outer layer of the macroscopic cellulosic fibers is removed to expose the underlying bundles of fibrils. The outer layer of the macroscopic cellulosic fibers can be removed by a mechanical or chemical process.

[0036] In a preferred embodiment, the outer layer of macroscopic cellulosic fibers is removed by a mechanical process comprising mechanical shearing to expose the bundles of fibrils. The macroscopic cellulosic fibers can be mechanically cut until the outer layer of the macroscopic cellulosic fibers is removed and the inner fibrils are released from each other to form microfibrillated cellulosic fibers. Each of the fibrils that make up the microfibrillated cellulosic fibers has a relatively smaller diameter compared to the Petition 870260075053, dated 07 / 28 / 2026, page 45 / 61 / 21 diameters of macroscopic cellulosic fibers before processing.

[0037] The second fibrous component may be present in an amount ranging from about 0.25% by weight to about 13.0% by weight based on total dry body weight 120 - including all values ​​and subranges in between. In some embodiments, the second fibrous component may be present in an amount ranging from about 0.5% by weight to about 8.0% by weight based on total dry body weight 120 - including all values ​​and subranges in between. In a preferred embodiment, the second fibrous component may be present in an amount ranging from about 1.0% by weight to about 3.0% by weight based on total dry body weight 120 - including all values ​​and subranges in between.

[0038] The fibers 130 of the present invention may comprise the first fibrous component and the second fibrous component in a weight ratio ranging from about 5:1 to about 20:1 – including all ratios and subranges therebetween. In some embodiments, the fibers 130 of the present invention may comprise the first fibrous component and the second fibrous component in a weight ratio ranging from about 5:1 to about 15:1 – including all ratios and subranges therebetween. In some embodiments, the first fibrous component and the second fibrous component may be present in a weight ratio ranging from about 5:1 to about 7.5:1 – including all ratios and subranges therebetween. In some embodiments, the first fibrous component and the second fibrous component may be present in a weight ratio ranging from about 10:1 to about 13.5:1 – including all ratios and subranges therebetween.

[0039] The fibers 130 of the present invention may comprise the inorganic fiber of the first fibrous component and the microfibrillated cellulosic fiber of the second fibrous component in a weight ratio ranging from about Petition 870260075053, dated 07 / 28 / 2026, p. 46 / 61 / 21 15:1 to approximately 40:1 - including all ratios and subranges in between. In some embodiments, the inorganic fiber of the first fibrous component and the macroscopic cellulosic fiber of the first fibrous component may be present in a weight ratio ranging from approximately 40:1 to approximately 80:1 including all ratios and subranges in between.

[0040] Body 120 may further comprise a binder. Non-limiting examples of binders may include a starch-based polymer, polyvinyl alcohol (PVOH), a latex, polysaccharide polymers, cellulosic polymers, protein solution polymers, an acrylic polymer, polymaleic anhydride, epoxy resins, or a combination of two or more thereof.

[0041] The binder may be present in an amount ranging from about 1% by weight to about 20% by weight based on the total dry body weight 120 – including all values ​​and subranges therebetween. In a preferred embodiment, the binder may be present in an amount ranging from about 5% by weight to about 15% by weight based on the total dry body weight 120 – including all values ​​and subranges therebetween. In a non-limiting example, the binder may comprise a starch-based polymer, which is present in an amount ranging from about 6% by weight to about 12% by weight including all weight percentages and subranges therebetween – based on the total body weight 120.

[0042] Body 120 may additionally comprise a filler. Non-limiting examples of filler may include calcium carbonate powder, limestone, titanium dioxide, sand, barium sulfate, clay, mica, dolomite, silica, talc, perlite, polymers, gypsum, wollastonite, expanded perlite, calcite, aluminum trihydrate, pigments, zinc oxide or zinc sulfate. Petition 870260075053, dated 07 / 28 / 2026, page 47 / 61 / 21

[0043] The filler may be present in an amount ranging from about 1.0% by weight to about 30.0% by weight based on the total dry body weight 120 - including all values ​​and subranges in between. In some embodiments, the filler may be present in an amount ranging from about 1.0% by weight to about 20.0% by weight based on the total dry body weight 120 - including all values ​​and subranges in between. In some embodiments, the filler may be present in an amount ranging from about 5.0% by weight to about 18.0% by weight based on the total dry body weight 120 - including all values ​​and subranges in between.

[0044] In a preferred embodiment, the filler may be perlite, which is present in an amount ranging from about 5% by weight to about 17% by weight - based on total body weight 120 - including all amounts and subranges between them.

[0045] In some embodiments, body 120 may additionally comprise a filler that includes calcium carbonate. Calcium carbonate may be present in body 120 in an amount ranging from about 0.25% by weight to 13% by weight – based on the total weight of body 120 including all amounts and subranges therein. In some embodiments, calcium carbonate may be present in an amount ranging from about 0.5% by weight to about 8% by weight based on the total dry weight of body 120 – including all amounts and subranges therein. In some embodiments, calcium carbonate may be present in an amount ranging from about 1.0% by weight to about 3.0% by weight based on the total dry weight of body 120 – including all amounts and subranges therein.

[0046] Non-limiting examples of additives include antifoaming agents, wetting agents, biocides, dispersing agents, Petition 870260075053, dated 07 / 28 / 2026, p. 48 / 61 / 21 flame retardants and similar. The additive may be present in an amount ranging from about 0.01% by weight to about 30% by weight based on the total dry weight of the body 120 - including all values ​​and subranges in between.

[0047] Body 120 may additionally comprise a flocculant. Non-limiting examples of flocculants include ionic flocculants such as cationic polyacrylamide. The flocculant may be present in an amount ranging from about 0.01% by weight to about 1.0% by weight based on the total dry weight of body 120 – including all values ​​and subranges therebetween.

[0048] Body 120 may be porous, thus allowing airflow through body 120 between the upper surface 122 and the lower surface 121 as discussed further in this document. The porosity of body 120 may allow airflow through body 120 under atmospheric conditions so that the building panel 100 may function as an acoustic ceiling panel, which requires properties related to noise reduction and sound attenuation properties - as discussed further in this document.

[0049] Specifically, body 120 of the present invention may have a porosity ranging from about 60% to about 98% – including all values ​​and subranges between them. In a preferred embodiment, body 120 has a porosity ranging from about 75% to 95% – including all values ​​and subranges between them. According to the present invention, porosity refers to the following: % Porosity = [VTotal - (Vbinder + Vf + Filler)] / VTotal where VTotal refers to the total volume of the body 120 defined by the upper surface 122, the lower surface 121 and the lateral surfaces of the body 123. Vbinder refers to the total volume occupied by the binder in the body 120. VF refers to the total volume occupied by the fibers 130 in the body 120. Filler refers to Petition 870260075053, dated 07 / 28 / 2026, p. 49 / 61 / 21 to the total volume occupied by the filling in specimen 120. Vhc refers to the total volume occupied by the hydrophobic component in specimen 120. Thus, the % porosity represents the amount of free volume within specimen 120.

[0050] The construction panel 100 of the present invention comprising the porous body 120 may exhibit sufficient airflow for the construction panel 100 to have the capacity to reduce the amount of sound reflected in a room. The reduction in the amount of sound reflected in a room is expressed by a noise reduction coefficient (NRC) rating, as described in the American Society for Testing and Materials (ASTM) test method C423. This rating is the average of the sound absorption coefficients in four octave bands (250, 500, 1000 and 2000 Hz), where, for example, a system with an NRC of 0.90 has about 90% of the absorption capacity of an ideal absorber. A higher NRC value indicates that the material offers better sound absorption and reduced sound reflection.

[0051] The construction panel 100 of the present invention exhibits an NRC of at least about 0.5. In a preferred embodiment, the construction panel 100 of the present invention may have an NRC ranging from about 0.60 to about 0.99 - including all values ​​and subranges between them.

[0052] Body 100 may also exhibit a measured airflow resistance between the upper surface 122 and the lower surface 121 ranging from about 25 rayl / cm to about 200 rayl / cm – including all airflow resistances and sub-ranges in between. In some embodiments, body 100 may also exhibit a measured airflow resistance between the upper surface 122 and the lower surface 121 ranging from about 115 rayl / cm to about 165 rayl / cm – including all airflow resistances and sub-ranges in between.

[0053] Body 120 may have an airflow resistance that is measured on one or more faces of body 120. The airflow resistance is Petition 870260075053, dated 07 / 28 / 2026, p. 50 / 61 / 21 measured by the following formula: R = (Pa - Patm) / V where R is the airflow resistance (measured in ohms); Pa is the applied air pressure; Patm is the atmospheric air pressure; and V is the volumetric airflow. The airflow resistance of body 120 on the lower face 121 can vary from about 0.5 ohm to about 10 ohms - including all resistances and sub-ranges in between. The airflow resistance of body 120 on the upper face 122 can vary from about 0.5 ohm to about 10 ohms - including all resistances and sub-ranges in between.

[0054] Body 120 in the dry state may have an apparent density ranging from about 96 kg / m3 to about 480 kg / m3 - including all whole numbers and subranges between them. In a preferred embodiment, the body may have an apparent density ranging from about 96 kg / m3 to about 192 kg / m3 - including all values ​​and subranges between them.

[0055] The term apparent density refers to the density measured in relation to the total volume VTotal of the body 120. Therefore, apparent density is a density measurement that includes the total volume VTotal, which includes both the volume occupied by the components that constitute the skeleton of the body 120 (i.e., (Vbinder + Vf + Vhc + Venchement), as well as the voids within the body 120 due to the porous nature of the body 120.

[0056] Body 120 in the dry state may have a skeletal density ranging from about 1,500 kg / m3 to about 2,400 kg / m3—including all whole numbers and subranges in between. In a preferred embodiment, the body may have a skeletal density ranging from about 2,000 kg / m3 to about 2,400 kg / m3—including all values ​​and subranges in between.

[0057] The term skeletal density refers to the density Petition 870260075053, dated 07 / 28 / 2026, p. 51 / 61 / 21 measured only in relation to the volume occupied by the components that constitute the skeleton of body 120 (i.e., (Vagglutinant + Vf + VhC + Venchimento) without taking into account the volume occupied by the empty spaces within body 120 due to the porous nature of body 120.

[0058] According to the present invention, it has been surprisingly found that the addition of the second fibrous component results in a marked improvement in the strength of the resulting body 120 without a decrease in porosity that would result in a detrimental alteration to the airflow characteristics required for the resulting building panel 100 to function as an acoustic building panel 100.

[0059] Specifically, it was found that the addition of the second fibrous component can result in a body 120 with a strength that is at least 125% of the strength of a body without the second fibrous component - as measured by the modulus of body 120 - preferably at least 150% of the strength of a body without the second fibrous component.

[0060] Furthermore, the presence of the second fibrous component can cause less than 3% change in the porosity of body 120 compared to a body without the second fibrous component - preferably less than 2% change in porosity, preferably less than 1% change in porosity. In addition, body 120 of the present invention can exhibit the same or slightly higher densities (i.e., about 100% to about 110%) compared to a body formed without the second fibrous component.

[0061] The combination of substantially increased strength with the same density results in a 100 construction panel that has superior yield strength, as the body strength per unit density has increased, and such 100 construction panels can still Petition 870260075053, dated 07 / 28 / 2026, page 52 / 61 / 21 to operate in acoustic applications, since the resistance to airflow of such bodies 120 also remains substantially the same.

[0062] Although not shown, the construction panel 100 of the present invention may further comprise a screen attached to at least one of the lower surfaces 121 or to the upper surface 122 of the body 120. The screen may be a non-woven screen made of glass fibers. In such embodiments, the first main surface 111 of the construction panel 100 may comprise the screen.

[0063] According to the present invention, the body 120 can be formed according to a standard wet-laying process that uses an aqueous medium (e.g., liquid water) to transport and form the body components into the desired structure. The basic process involves first mixing the various body ingredients (e.g., fibers, binder, filler, etc.) into an aqueous paste (i.e., the wet state), transporting the paste to a forming station, and distributing the paste onto a porous wire mesh that moves into a uniform mat of the desired size and thickness. The water is removed, and the mat is then dried (i.e., in the dry state). The dried mat can be finished into the body by cutting, punching, coating, and / or laminating a tile surface finish.Body 120 in the wet state can be heated to an elevated temperature ranging from about 60°C to about 300°C – including all values ​​and sub-ranges in between – to dry body 120 from the wet state to the dry state.

[0064] The following examples are prepared in accordance with the present invention. The present invention is not limited to the examples described in this document. Examples Experiment 1 Petition 870260075053, dated 07 / 28 / 2026, pp. 53 / 61 / 21

[0065] A first experiment was carried out to test the impact on the strength and porosity of the panels according to the present invention. Each of the panels comprised a body formed by a formulation shown below in Table 1. Table 1 Ex. Comp. 1 Ex. Comp. 2 Ex. 2 Ex. 2 Mineral wool 80.0 77.5 77.6 77.6 MFC fiber - - 0.95 1.9 Newspaper 2.0 2.0 1.0 - CaCO3 5.0 0.95 1.9 Starch 8.0 8.0 12.0 11.1 Perlite 10.0 7.5 7.5 7.5 Total 100.0 100.0 100.0 100.0

[0066] Each panel was then tested for apparent density, skeletal density, porosity, and strength (modulus). The results are presented below in Table 2. Table 2 Ex. Comp. 1 Ex. Comp. 2 Ex. 2 Ex. 2 Apparent density (kg / m3) 129 137 143 145 Skeletal density (kg / m3) 1733 1821 1847 1801 Porosity (%) 92.6 92.4 92.3 91.9 Modulus of rupture (psi) (1 psi = 6.89 kPa) 62 78 111 116

[0067] As demonstrated by Table 2, the addition of fiber MFC resulted in a body exhibiting a marked improvement in strength, evidenced by the increased modulus. Surprisingly, there was no material change in apparent density, skeletal density, or porosity of the body. Therefore, the body of the present invention provides a significant improvement in panel strength without any degradation in airflow characteristics, thus allowing the panel to maintain its acoustic properties. Without a change in density, the increase in strength results in an acoustic panel translating into superior yield strength. Petition 870260075053, dated 07 / 28 / 2026, pages 54 / 61 / 21 Experiment 2

[0068] A second experiment was conducted to further test the strength, porosity, and airflow resistance of the panels according to the present invention. The panels of Ex. Comp. 3 and Ex. 3 were formed with recycled water from the previous plate manufacturing process. The panels of Ex. 4 were formed using standard water supplied by the local municipality. Each of the panels in this experiment comprised a body formed by a formulation presented below in Table 3. Table 3 Ex. Comp. 3 Ex. 3 Ex. 4 Mineral wool 70.5 70.5 70.5 MFC fiber - 2.2 2.2 Newspaper 6.4 2.0 2.0 CaCO3 - 2.2 2.2 Binder 8.0 8.0 8.0 Perlite 15.1 15.1 15.0 Total 100.0 100.0 100.0

[0069] Each panel was then tested for apparent density, skeletal density, porosity and strength (modulus) and airflow resistance. The results are presented below in Table 4. Table 4 Ex. Comp. 3 Ex. 3 Ex. 4 Apparent density (kg / m3) 186 204 202 Skeletal density (kg / m3) 1577 1572 1632 Porosity (%) 88.2 87.0 87.5 Modulus of rupture (psi) (1 psi = 6.89 kPa) 116 178 155 Face Ohms 3.5 3.6 3.8 Back Ohms 3.7 4.2 4.1 Flux resistivity (rayl / cm) 119 158 132

[0070] As demonstrated by Table 4, the addition of fiber MFC resulted in a body exhibiting a marked improvement in strength, evidenced by the increase in modulus. Taking into account the difference in porosity for each example, it was determined that the body in Ex. 3 exhibits a Petition 870260075053, dated 07 / 28 / 2026, page 55 / 61 / 21, shows an increase of approximately 30% in the modulus when adjusting for differences in porosity. In other words, by adjusting the porosity of the Ex. 3 body to be equal to the porosity of the Ex. Comp. 3 body, the resulting modulus of rupture of the Ex. 3 body would be approximately 30% greater than that of the Ex. Comp. 3 body – thus confirming the relative increase in strength. Even more surprising is that this improved body strength is found when the body is formed from a recycled water source – thus providing a cost-effective and environmentally friendly method of forming the building panel according to the present invention.

[0071] The same adjustment was calculated for the face and back ohms of the plates. The resulting calculation determined that the body of Ex. 3 would exhibit an airflow resistance of approximately 2.6 ohms with the same porosity as Ex. Comp. 3 - thus confirming the surprising result that the addition of the second fibrous component does not increase the airflow resistance through the body of the present invention. Experiment 3

[0072] A third experiment was conducted to further test the high-moisture flow resistance of the panels of the present invention. According to this experiment, 3 x 24 (7.62 cm x 60.96 cm) strips of each body from Examples 3 and 4, as well as Comparative Example 3, were subjected to a 90% moisture cycle. A portion of the edge of each panel was supported on a surface, with the remaining portion of each body extending outward from the surface. The total amount of curvature for each body was then measured after completion of the 90% moisture cycle. The results are shown below in Table 5. Table 5 Ex. Comp. 3 Ex. 3 Ex. 4 Total Yield (mm) 7.5 3.9 3.7 Petition 870260075053, dated 07 / 28 / 2026, pp. 56 / 61 / 21

[0073] As demonstrated by Table 5, the addition of the second fibrous component resulted in a significant improvement in yield strength in high-humidity environments compared to bodies formed without the second fibrous component. Petition 870260075053, dated 07 / 28 / 2026, pages 57 / 61

Claims

1 / 3 Claims 1. ACOUSTIC BUILDING PANEL (100), characterized in that it comprises: a body (120) comprising a first main surface (111) opposite a second main surface (112) and a side surface (113) extending between them comprising: starch in an amount ranging from 8.0% by weight to 15.0% by weight based on the total weight of the body (120); inorganic fiber in an amount ranging from 60.0% by weight to 90.0% by weight based on the total weight of the body (120); and microfibrillated fiber in an amount ranging from 0.25% by weight to 12.5% ​​by weight based on the total weight of the body (120); wherein the porous body (120) exhibits greater resistance to yielding under high humidity conditions while maintaining a resistance to airflow ranging from 120 rayl / cm to 170 rayl / cm, measured between the first principal surface (111) and the second principal surface (112).

2. ACOUSTIC BUILDING PANEL (100), according to claim 1, characterized in that the inorganic fiber is present in an amount ranging from 70.0% by weight to 85.0% by weight based on the total body weight.

3. ACOUSTIC BUILDING PANEL (100), according to claim 1 or 2, characterized in that the microfibrillated fiber is present in an amount ranging from 0.5% by weight to 7.5% by weight based on the total body weight.

4. ACOUSTIC BUILDING PANEL (100), according to any one of claims 1 to 3, characterized in that the inorganic fiber comprises mineral wool.

5. ACOUSTIC BUILDING PANEL (100), according to Petition 870260075053, dated 07 / 28 / 2026, page 58 / 61 2 / 3 any of claims 1 to 4, characterized in that the body (120) further comprises a filling selected from the group consisting of perlite, calcium carbonate, limestone, titanium dioxide, sand, barium sulfate, clay, mica, dolomite, silica, talc, wollastonite, calcite, aluminum trihydrate, pigments, zinc oxide, zinc sulfate and combinations thereof.

6. ACOUSTIC BUILDING PANEL (100), according to any one of claims 1 to 5, characterized in that the body (120) has an apparent density ranging from 96 kg / m3 to 480 kg / m3.

7. ACOUSTIC BUILDING PANEL (100), according to claim 1, characterized in that the inorganic fiber and the microfibrillated fiber are present in a weight ratio ranging from 5:1 to 20:

1.

8. ACOUSTIC BUILDING PANEL (100), according to claim 1, characterized in that the inorganic fiber and the microfibrillated fiber are present in a weight ratio ranging from 5:1 to 15:

1.

9. ACOUSTIC CONSTRUCTION PANEL (100), according to any one of claims 7 or 8, characterized in that the skeletal density of the body varies from 1,500 kg / m3 to 2,400 kg / m3.

10. ACOUSTIC BUILDING PANEL (100), according to claim 5, characterized in that perlite is present in an amount ranging from 1.0% by weight to 30.0% by weight based on the total body weight (120).

11. ACOUSTIC BUILDING PANEL (100), according to claim 1, characterized in that the body (120) has a porosity ranging from 80.0% to 95.0%.

12. CEILING SYSTEM (1), characterized in that it comprises: a support structure (5); and Petition 870260075053, dated 07 / 28 / 2026, page 59 / 61 3 / 3 at least one of the acoustic construction panel (100) as defined in any of claims 1 to 12 mounted on the support structure (5).

13. METHOD FOR FORMING AN ACOUSTIC BUILDING PANEL (100), characterized by comprising: forming a porous body (120) by mixing together inorganic, starch and microfibrillated fibers such that the mixture comprises the inorganic fiber in an amount ranging from 60% by weight to 90% by weight, the starch in an amount ranging from 8.0% by weight to 15.0% by weight based on the total weight of the body, and the microfibrillated fiber in an amount ranging from 0.25% by weight to 12.5% ​​by weight based on the total weight of the body (120), wherein the porous body (120) is formed to exhibit greater resistance to yielding under high humidity conditions while maintaining an airflow resistance ranging from 120 rayl / cm to 170 rayl / cm. Petition 870260075053, dated 07 / 28 / 2026, pages 60 / 61

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