Acoustic structure and surface covering system comprising a phase change material and method for its production

Abstract

Disclosed herein are acoustic building panels comprising a porous substrate having a first major surface opposite a second major surface. The substrate comprises one or more of mineral fiber board, glass fiber, jute fiber, wood, or composite material. The substrate is impregnated with a microencapsulated phase change material.

Description

[0001] Cross-references to related applications

[0002] This application is a PCT international application claiming the benefit of U.S. Provisional Application No. 63 / 612250, filed on December 19, 2023. The disclosure of the above application is incorporated herein by reference. Technical Field

[0003] This disclosure relates to acoustic building structures, such as ceiling panels and wall panels, and more particularly to acoustic building structures incorporating phase change materials. Background Technology

[0004] Building materials, such as acoustic structures, wood panels, and veneers used in ceiling and wall systems, are designed to balance benefits related to aesthetics, material costs, structural integrity, acoustics, temperature control, and environmental impact.

[0005] Therefore, those skilled in the art continue to conduct research and development in the field of acoustic building structures. Summary of the Invention

[0006] This invention is intended merely to provide a simplified overview of some aspects of one or more embodiments of the present disclosure. Other applicable areas of the present disclosure will become apparent from the detailed description provided below. This invention is not a broad overview, nor is it intended to identify key elements or essential components of the teachings, nor is it intended to define the scope of the present disclosure. Rather, its purpose is merely to present one or more concepts in a simplified form as a prelude to the following detailed embodiments.

[0007] The applicant has identified acoustic building panels for storing thermal energy.

[0008] In one example, the acoustic architectural panel includes a porous substrate having a first primary surface opposite to the second primary surface. The substrate comprises one or more of mineral fiberboard, glass fiber, jute fiber, wood, or composite materials. The substrate is impregnated with a microencapsulated phase change material.

[0009] In one example, the phase change material is microencapsulated within a polymer material. In one example, the phase change material is an aqueous dispersion microencapsulated within a polymer material. In one example, the phase change material is an organic material. In one example, the phase change material is a powdered material. In one example, the average particle size of the phase change material is in the range of about 10 micrometers to about 50 micrometers, about 10 micrometers to about 30 micrometers, or about 10 micrometers to about 20 micrometers. In one example, the phase change material is enriched adjacent to a first primary surface of the substrate. In one example, the phase change material is enriched adjacent to a second primary surface of the substrate. In one example, the phase change material is uniformly distributed throughout the substrate. In one example, the phase change material is dry-injected into the substrate.

[0010] In one example, the average pore size of the substrate is larger than the average pore size of the phase change material. In one example, the average pore size of the substrate is in the range of about 40 µm to about 100 µm. In one example, the porosity of the substrate is in the range of about 80% to about 95%.

[0011] In one example, the acoustic architectural panel includes a scrim positioned over one of a first or second main surface of a substrate. In another example, the acoustic architectural panel includes an adhesive for adhering the scrim to the substrate.

[0012] In one instance, the acoustic building panel exhibits a nominal thermal resistance of approximately 21.2 mK / watt. In another instance, the acoustic building panel is configured to store thermal energy from approximately 25 BTU / SF to approximately 75 BTU / SF. In yet another instance, the acoustic building panel has an NRC value of at least approximately 0.5.

[0013] A surface covering system for storing thermal energy was also disclosed.

[0014] In one example, the surface covering system includes a plurality of acoustic architectural panels configured to be positioned adjacent to each other to form a plurality of seams between each of the plurality of acoustic architectural panels. Each acoustic architectural panel includes a porous substrate having a first primary surface opposite to a second primary surface, the substrate comprising one or more of mineral fiberboard, glass fiber, jute fiber, wood, or composite materials. The substrate is impregnated with a microencapsulated phase change material.

[0015] In one example, the phase change material is encapsulated in microcapsules. In one example, the phase change material is an aqueous dispersion encapsulated in a polymer material. In one example, the phase change material is an organic material. In one example, the phase change material is a powdered material. In one example, the average particle size of the phase change material is in the range of about 10 micrometers to about 50 micrometers, about 10 micrometers to about 30 micrometers, or about 10 micrometers to about 20 micrometers. In one example, the phase change material is enriched adjacent to a first primary surface of the substrate. In one example, the phase change material is enriched adjacent to a second primary surface of the substrate. In one example, the phase change material is uniformly distributed throughout the substrate. In one example, the phase change material is dry-injected into the substrate.

[0016] In one example, the average pore size of each substrate is larger than the average pore size of the phase change material. In one example, the average pore size of each substrate is in the range of about 40 µm to about 100 µm. In one example, the porosity of each substrate is in the range of about 80% to about 95%.

[0017] In one example, each acoustic architectural panel includes a loosely woven nonwoven fabric positioned above one of a first primary surface or a second primary surface of a respective substrate. In another example, each acoustic architectural panel includes an adhesive for adhering the loosely woven fabric to the substrate.

[0018] In one instance, the individual acoustic architectural panels of the system exhibit a nominal thermal resistance of approximately 21.2 mK / watt. In one instance, the individual acoustic architectural panels of the system are configured to store thermal energy from approximately 25 BTU / SF to approximately 75 BTU / SF. In one instance, the NRC value of the individual acoustic architectural panels of the system is at least approximately 0.5.

[0019] A method for manufacturing acoustic building panels for storing thermal energy was also disclosed.

[0020] In one example, the method includes providing a porous substrate having a first master surface opposite to the second master surface, and injecting microencapsulated phase change material into the pores of the substrate.

[0021] In one instance, the implantation includes dry implantation. In another instance, the implantation includes: applying microencapsulated phase change material to a first primary surface of a substrate, applying an alternating electric field to a second primary surface of the substrate, and drawing the phase change material from the first primary surface into pores of the substrate to produce a substrate impregnated with the phase change material.

[0022] In one example, the phase change material is microencapsulated within a polymer material. In one example, the phase change material is an aqueous dispersion microencapsulated within a polymer material. In one example, the phase change material is an organic material. In one example, the phase change material is a powdered material. In one example, the average particle size of the phase change material is in the range of about 10 micrometers to about 50 micrometers, about 10 micrometers to about 30 micrometers, or about 10 micrometers to about 20 micrometers. In one example, the phase change material is enriched adjacent to a first primary surface of the substrate. In one example, the phase change material is enriched adjacent to a second primary surface of the substrate. In one example, the phase change material is uniformly distributed throughout the substrate.

[0023] In one example, the average pore size of the substrate is larger than the average pore size of the phase change material. In one example, the average pore size of the substrate is in the range of about 40 µm to about 100 µm. In one example, the porosity of the substrate is in the range of about 80% to about 95%.

[0024] In one example, the method includes positioning a loosely woven nonwoven fabric over one of a first primary surface or a second primary surface of a substrate. In another example, the method includes applying an adhesive to the substrate to adhere the loosely woven nonwoven fabric to the substrate.

[0025] In one instance, the acoustic building panel was configured to store approximately 25 BTU / SF to approximately 75 BTU / SF of thermal energy. In another instance, the acoustic building panel exhibited an NRC value of at least approximately 0.5.

[0026] Other applicable areas of this disclosure will become apparent from the detailed description provided below. It should be understood that while the detailed description and specific examples indicate preferred embodiments of this disclosure, they are intended for illustrative purposes only and are not intended to limit the scope of this disclosure. Attached Figure Description

[0027] The detailed description of this disclosure will be better understood when read in conjunction with the accompanying drawings. However, it should be understood that this disclosure is not limited to the precise arrangement and tools of the embodiments shown in the drawings.

[0028] Figure 1 A top perspective view of an acoustic building panel according to one embodiment of the present disclosure;

[0029] Figure 2 A cross-sectional view of the acoustic building panel of this disclosure;

[0030] Figure 3 A cross-sectional view of the acoustic building panel of this disclosure;

[0031] Figure 4 A top perspective view of a surface covering system according to an embodiment of this disclosure; and

[0032] Figure 5 This is a cross-sectional view of the surface covering system of this disclosure. Detailed Implementation

[0033] For illustrative purposes, the principles of this disclosure are described by reference to several embodiments thereof. Although certain embodiments of this disclosure are specifically described herein, those skilled in the art will readily recognize that the same principles apply equally to and can be used in other applications and methods. It should be understood that this disclosure is not limited in its application to the details of any particular embodiment shown. The terminology used herein is for descriptive purposes and is not intended to limit the disclosure, its application, or its uses.

[0034] As used herein and in the appended claims, unless the context otherwise requires, the singular forms “a,” “an,” and “the” include plural references. The singular form of any class of ingredients refers not only to a single chemical substance in that class but also to a mixture of those chemical substances. The terms “a” (or “an”), “one or more,” and “at least one” may be used interchangeably herein. The terms “comprising,” “including,” “containing,” and “having” may be used interchangeably. The term “comprising” should be construed as “including, but not limited to.” The term “comprising” should be construed as “including but not limited to.”

[0035] As used throughout, a range is used as a shorthand to describe the individual values ​​within that range and each value. Any value within the range can be chosen as an endpoint of the range.

[0036] Unless otherwise stated, all percentages and amounts expressed herein and elsewhere in the specification should be understood as weight percentages of the total composition. Unless otherwise stated, reference to a molecule or more in "weight %" means the amount of that molecule or more present in the composition based on the total weight of the composition. Unless otherwise stated, reference to a molecule or more in "based on the dry weight of the composition" means the amount of that molecule or more present in the composition based on the total weight of the composition in a dry state. "Dry state" means that the solvent is present in the composition in an amount less than 5.0% by weight, less than about 3.0% by weight, less than about 1.0% by weight; preferably less than about 0.5% by weight, and more preferably less than about 0.25% by weight. For example, a composition in a dry state can refer to a composition having about 95% solids, about 98% solids, preferably about 99% solids, or more preferably about 100% solids. Conversely, unless otherwise stated, reference to a molecule or more in "based on the wet weight of the composition" means the amount of that molecule or more present in the composition based on the total weight of the composition containing at least 5% by weight of solvent.

[0037] According to this application, the term "about" used in conjunction with a numerical value means a value that can be + / - 5% of that value. As used herein, the term "substantially free of" is intended to mean an amount of the composition of less than about 5.0% by weight, less than 3.0% by weight, less than 1.0% by weight; preferably less than about 0.5% by weight, and more preferably less than about 0.25% by weight.

[0038] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure pertains. All patents, patent applications, publications, and other references cited or referenced herein are incorporated herein in their entirety for all purposes. In the event of any conflict between definitions in this disclosure and definitions in the cited references, the definitions in this disclosure shall prevail.

[0039] In the description of the embodiments disclosed herein, any references to direction or orientation are intended merely for convenience of description and are not intended to limit the scope of this disclosure in any way. Relative terms such as “down,” “up,” “horizontal,” “vertical,” “above,” “below,” “upward,” “downward,” “top,” and “bottom,” and their derivatives (e.g., “horizontally,” “downward,” “upward,” etc.) should be interpreted as referring to the orientation as described therein or as shown in the figures discussed (if applicable). These relative terms are for convenience of description only, and unless otherwise stated, the device need not be constructed or operated in a particular orientation.

[0040] Unless otherwise explicitly described, as used herein, terms such as “attachment,” “attachment to,” “connection,” “coupling,” and “interconnection” refer to relationships in which structures are directly or indirectly fixed or attached to each other, either directly or indirectly through intermediate structures, and both movable or rigid attachments or relationships. Therefore, this disclosure is not limited to illustrating embodiments of certain combinations of features that may exist alone or in combination with other features.

[0041] This disclosure relates to acoustic panels incorporating phase change materials. Phase change materials are substances that release / absorb energy during a phase change to provide useful heating and / or cooling. Therefore, incorporating phase change materials into building panels (which can be used in ceiling systems, wall systems, floor systems, etc.) allows the building panels to assist in heating or cooling interior spaces. In some embodiments, the phase change material can change from a solid to a liquid when it absorbs heat. In some embodiments, the phase change material can change from a liquid to a gas when it absorbs heat. In other embodiments, the phase change can occur between two non-classical states of a substance, such as conformity of a crystal, where the material changes from conforming to one crystal structure to conforming to another crystal structure (which may be in a higher or lower energy state).

[0042] Phase change materials can be organic, such as hydrocarbons like paraffin, as well as lipids and sugar alcohols. Phase change materials can also be inorganic, such as hydrates. In some embodiments, the phase change material may include hydrate materials. One example of a phase change material is a hydrate phase change material comprising water mixed with calcium chloride and a nucleating agent. Non-limiting examples of suitable nucleating agents include silica dust, quartz, or combinations thereof. Other examples of phase change materials are paraffin and other hydrates. However, other types of phase change materials may also be used. The phase change material can be a solid-liquid phase change material or a solid-solid phase change material. Other phase change materials now known or later discovered may be used.

[0043] Reference Figure 1 An acoustic building panel 100 for storing thermal energy is disclosed. The acoustic building panel 100 can be a ceiling panel or a wall panel. The acoustic building panel 100 includes a porous substrate 110 having a first main surface 112 and a second main surface 114 opposite to the first main surface 112.

[0044] The substrate 110 of the acoustic architectural panel 100 may comprise any material having the desired material properties. In one embodiment, the substrate 110 of the acoustic panel 100 is a porous matrix comprising one or more of mineral fiberboard, glass fiber, jute fiber, wood, or composite materials. In another embodiment, the acoustic architectural panel 100 is fire-resistant, such that it is rated ASTM E84 Class A, with a smoke development (SDI) <25 and a flame spread (FSI) <50.

[0045] Still refer to Figure 1 The acoustic architectural panel 100 includes a phase change material. The phase change material is dispersed within the pores of a porous matrix defining a substrate 110. In one embodiment, the phase change material is dispersed within the pores of the substrate 110 such that the substrate 110 is impregnated with the phase change material. In another embodiment, the phase change material is dry-injected into the substrate 110 such that the substrate is wet-formed and dried prior to impregnation with the phase change material encapsulated in powdered microcapsules.

[0046] In one or more embodiments, the phase change material is an organic material. In another embodiment, the phase change material is microencapsulated in a polymer material. In yet another embodiment, the phase change material is an aqueous dispersion microencapsulated in a polymer material. In yet another embodiment, the phase change material is a powder.

[0047] Phase change materials can be characterized by their physical properties. In one embodiment, the average particle size of the phase change material is in the range of about 10 micrometers to about 50 micrometers. In another embodiment, the average particle size of the phase change material is in the range of about 10 micrometers to about 30 micrometers. In yet another embodiment, the average particle size of the phase change material is in the range of about 10 micrometers to about 20 micrometers.

[0048] The phase change material can be positioned within the substrate 110 to optimize thermal storage properties. In one embodiment, the phase change material is enriched adjacent to a first main surface 112 of the substrate 110. In another embodiment, the phase change material is enriched adjacent to a second main surface 114 of the substrate 110. In yet another embodiment, the phase change material is uniformly distributed throughout the thickness of the substrate 110.

[0049] In one or more embodiments, the average pore size of the substrate 110 is larger than the average pore size of the phase change material. In another embodiment, the average pore size of the substrate 110 is in the range of about 40 µm to about 100 µm. In yet another embodiment, the porosity of the substrate 110 is in the range of about 80% to about 95%.

[0050] In one or more embodiments, the acoustic building panel 100 is characterized by its thermal properties. In one embodiment, the acoustic building panel 100 exhibits a nominal thermal resistance of about 21.2 mK / watt. In another embodiment, the acoustic building panel 100 is configured to store thermal energy from about 25 BTU / SF to about 75 BTU / SF.

[0051] In one or more embodiments, the acoustic architectural panel 100 is characterized by its acoustic properties, such as noise reduction coefficient (NRC) and ceiling attenuation class (CAC) rating. An NRC rating of 0 indicates a perfect sound-reflecting material. An NRC rating of 1 indicates a perfect sound-absorbing material. CAC is a measure used to rate the performance of a ceiling material as a barrier to block airborne sound transmission into / out of an enclosed space (plenum) above the ceiling. In one embodiment, the acoustic architectural panel 100 has an NRC value of at least about 0.5. In another embodiment, the acoustic architectural panel 100 has a CAC value of at least about 46.

[0052] Reference Figure 2In one or more embodiments, the acoustic architectural panel 100 further includes a sparse nonwoven fabric 120 having a first primary sparse nonwoven fabric surface 122 opposite to the second primary sparse nonwoven fabric surface 124 and a thickness t2. The sparse nonwoven fabric 120 is positioned above one of the first primary surface 112 or the second primary surface 114 of the substrate 110. In one embodiment, the second primary sparse nonwoven fabric surface 124 of the sparse nonwoven fabric 120 is coupled to the first primary surface 112 of the substrate 110 with an adhesive. In one embodiment, the sparse nonwoven fabric 120 comprises glass fiber.

[0053] Reference Figure 3 In one or more embodiments, the acoustic architectural panel 100 may further include a coating 130 having a thickness t3 over one of the first main surface 112, the second main surface 114, or the loosely woven nonwoven fabric 120. In one embodiment, the coating 130 comprises pigments such as titanium dioxide, diatomaceous earth, calcium carbonate, aluminum hydroxide, or barium sulfate; and binders such as vinyl acrylic polymers. The coating 130 can be selected to balance desired acoustic and aesthetic properties.

[0054] Reference Figure 4 and Figure 5 The paper also discloses a surface covering system 200, such as a ceiling system or a wall system. In one embodiment, the surface covering system 200 includes a plurality of acoustic architectural panels 205 configured to be positioned adjacent to each other to form a plurality of seams 215 between each of the plurality of architectural panels 205.

[0055] In one or more embodiments, each of the plurality of building panels 205' includes a porous substrate 210 having a first main surface 212 opposite to the second main surface 214. The substrate 210 is a porous matrix comprising one or more of mineral fiberboard, glass fiber, jute fiber, wood, or composite materials.

[0056] In one or more embodiments, the substrate 210 is impregnated with a microencapsulated phase change material, such that the microencapsulated phase change material is located within the pores of the substrate 210. In one embodiment, the phase change material is microencapsulated within a polymer material. In another embodiment, the phase change material is an aqueous dispersion microencapsulated within a polymer material. In yet another embodiment, the phase change material is an organic material. In yet another embodiment, the phase change material is a powdered material.

[0057] In one or more embodiments, the average particle size of the phase change material is in the range of about 10 micrometers to about 50 micrometers. In another embodiment, the average particle size of the phase change material is in the range of about 10 micrometers to about 30 micrometers. In yet another embodiment, the average particle size of the phase change material is in the range of about 10 micrometers to about 20 micrometers.

[0058] The phase change material may be enriched adjacent to the first primary surface 212 of each substrate 210 of system 200. In another embodiment, the phase change material is enriched adjacent to each second primary surface 214 of each substrate 210 of system 200. In yet another embodiment, the phase change material is uniformly distributed across each substrate 210 of system 200. In yet another embodiment, at least one of the plurality of building panels 205 includes a substrate having phase change material enriched adjacent to the first primary surface 212, and at least one of the plurality of building panels 205 has a substrate having phase change material enriched adjacent to the second primary surface 214.

[0059] In one or more embodiments, the phase change material of system 200 is dry-injected into each substrate 210 such that it is located within the pores of the substrate 210 matrix. In one embodiment, the average pore size of substrate 210 is larger than the average pore size of the phase change material, such that the powdered microcapsule-encapsulated phase change material is assembled within the pores of the substrate 210 matrix. In one embodiment, the average pore size of substrate 210 is in the range of about 40 µm to about 100 µm. In another embodiment, the porosity of substrate 210 is in the range of about 80% to about 95%.

[0060] Reference Figure 5 In one or more embodiments, each of the plurality of building panels 205' includes a loosely woven nonwoven fabric 220 positioned over one of a first main surface 212 or a second main surface 214 of a respective substrate 210. The loosely woven nonwoven fabric 220 has a first main loosely woven nonwoven surface 222 opposite to the second main loosely woven nonwoven surface 224. In one embodiment, the second main loosely woven nonwoven surface 224 is adhered to the first main surface 212 of the substrate 210 with an adhesive.

[0061] Still refer to Figure 5In one or more embodiments, each of the plurality of building panels 205' includes a coating 230 of thickness t3 over one or more of a first main surface 212, a second main surface 214, a loosely woven fabric 220, or a plurality of seams 215. In one embodiment, the coating 230 comprises pigments such as titanium dioxide, diatomaceous earth, calcium carbonate, aluminum hydroxide, or barium sulfate; and an adhesive such as a vinyl acrylic polymer. The coating 230 can be selected to balance desired acoustic and aesthetic properties.

[0062] Each of the plurality of building panels 205' can be characterized by its thermal control properties. In one embodiment, each of the plurality of building panels 205' exhibits a nominal thermal resistance of about 21.2 mK / watt. In another embodiment, each of the plurality of building panels 205' is configured to store thermal energy from about 25 BTU / SF to about 75 BTU / SF.

[0063] The surface covering system 200 may also be characterized by its acoustic properties, such as noise reduction coefficient (NRC) and ceiling attenuation rating (CAC). An NRC rating of 0 indicates a perfect sound-reflecting material. An NRC rating of 1 indicates a perfect sound-absorbing material. CAC is a measure used to rate the performance of a ceiling material as a barrier to block airborne sound from entering / exiting an enclosed space above the ceiling. In one embodiment, the individual architectural panels 205' of the surface covering system 200 have an NRC value of at least about 0.5.

[0064] A method for manufacturing an acoustic building panel 100 for storing thermal energy is also disclosed. In one or more embodiments, the method includes providing a porous substrate 110 having a first main surface 112 opposite to a second main surface 114, and injecting a phase change material into the pores of the substrate 110.

[0065] In one embodiment, the implantation includes dry implantation. In another embodiment, the implantation includes: applying a phase change material to a first main surface 112 of the substrate 110, applying an alternating electric field to a second main surface 114 of the substrate 110, and drawing the phase change material from the first main surface 112 into a hole in the substrate 110 to produce a substrate 110 impregnated with the phase change material.

[0066] In one or more embodiments, the substrate 110 is a porous structure comprising one or more of mineral fiberboard, glass fiber, jute fiber, wood, or composite materials.

[0067] In one or more embodiments, the phase change material is an organic material. In another embodiment, the phase change material is encapsulated in microcapsules. In yet another embodiment, the phase change material is an aqueous dispersion encapsulated in a polymer material. In yet another embodiment, the phase change material is a powder.

[0068] Phase change materials can be characterized by their physical properties. In one embodiment, the average particle size of the phase change material is in the range of about 10 micrometers to about 50 micrometers. In another embodiment, the average particle size of the phase change material is in the range of about 10 micrometers to about 30 micrometers. In yet another embodiment, the average particle size of the phase change material is in the range of about 10 micrometers to about 20 micrometers.

[0069] The phase change material can be positioned within the substrate 110 to optimize thermal storage properties. In one embodiment, the phase change material is enriched adjacent to a first main surface 112 of the substrate 110. In another embodiment, the phase change material is enriched adjacent to a second main surface 114 of the substrate 110. In yet another embodiment, the phase change material is uniformly distributed throughout the thickness t1 of the substrate 110.

[0070] In one or more embodiments, the average pore size of the substrate 110 is larger than the average pore size of the phase change material. In another embodiment, the average pore size of the substrate 110 is in the range of about 40 µm to about 100 µm. In yet another embodiment, the porosity of the substrate 110 is in the range of about 80% to about 95%.

[0071] In one or more embodiments, the acoustic building panel 100 is characterized by its thermal properties. In one embodiment, the acoustic building panel 100 exhibits a nominal thermal resistance of about 21.2 mK / watt. In another embodiment, the acoustic building panel 100 is configured to store thermal energy from about 25 BTU / SF to about 75 BTU / SF.

[0072] In one or more embodiments, the acoustic architectural panel 100 is characterized by its acoustic properties, such as noise reduction coefficient (NRC) and ceiling attenuation rating (CAC). An NRC rating of 0 indicates a perfect sound-reflecting material. An NRC rating of 1 indicates a perfect sound-absorbing material. CAC is a measure used to rate the performance of a ceiling material as a barrier to block airborne sound transmission into / out of an enclosed space above the ceiling. In one embodiment, the acoustic architectural panel 100 has an NRC value of at least about 0.5. In another embodiment, the acoustic architectural panel 100 has a CAC value of at least about 46.

[0073] In one or more embodiments, the method includes positioning a loosely woven fabric 120, such as a glass fiber loosely woven fabric, over one of a first primary surface 112 and a second primary surface 114 of a substrate 110. In another embodiment, the method includes applying an adhesive to the substrate 110 to adhere the loosely woven fabric 120 to the substrate 110.

[0074] This disclosure may be characterized by the following terms.

[0075] Clause 1: An acoustic building panel comprising: a porous substrate having a first primary surface opposite to a second primary surface, the substrate comprising one or more of mineral fiberboard, glass fiber, jute fiber, wood, or composite material, wherein the substrate is impregnated with a microencapsulated phase change material.

[0076] Clause 2: The acoustic building panel according to Clause 1, wherein the phase change material is microencapsulated in a polymer material.

[0077] Clause 3: Acoustic building panel according to any one of Clauses 1 or 2, wherein the phase change material is an aqueous dispersion encapsulated in a polymer material.

[0078] Clause 4: Acoustic building panels according to any one of Clauses 1 to 3, wherein the phase change material is an organic material.

[0079] Clause 5: Acoustic building panel according to any one of Clauses 1 to 4, wherein the phase change material is a powdered material.

[0080] Clause 6: An acoustic building panel according to any one of Clauses 1 to 5, wherein the average particle size of the phase change material is in the range of about 10 micrometers to about 50 micrometers, about 10 micrometers to about 30 micrometers, or about 10 micrometers to about 20 micrometers.

[0081] Clause 7: An acoustic building panel according to any one of Clauses 1 to 6, wherein the phase change material is enriched adjacent to the first primary surface of the substrate.

[0082] Clause 8: An acoustic building panel according to any one of Clauses 1 to 7, wherein the phase change material is enriched adjacent to the second primary surface of the substrate.

[0083] Clause 9: An acoustic building panel according to any one of Clauses 1 to 8, wherein the phase change material is uniformly distributed throughout the substrate.

[0084] Clause 10: An acoustic building panel according to any one of Clauses 1 to 9, wherein the phase change material is dry-injected into the pores of the substrate.

[0085] Clause 11: An acoustic building panel according to any one of Clauses 1 to 10, wherein the average pore size of the substrate is greater than the average pore size of the phase change material.

[0086] Clause 12: An acoustic building panel according to any one of Clauses 1 to 11, wherein the average pore size of the substrate is in the range of about 40 µm to about 100 µm.

[0087] Clause 13: An acoustic building panel according to any one of Clauses 1 to 12, wherein the porosity of the substrate is in the range of about 80% to about 95%.

[0088] Clause 14: The acoustic building panel according to any one of Clauses 1 to 13 further includes a loosely woven fabric positioned over one of the first primary surface or the second primary surface of the substrate.

[0089] Clause 15: The acoustic building panel as described in Clause 14 further comprises an adhesive for adhering the loosely woven nonwoven fabric to the substrate.

[0090] Clause 16: An acoustic building panel according to any one of Clauses 1 to 15, wherein the acoustic building panel exhibits a nominal thermal resistance of about 21.2 mK / watt.

[0091] Clause 17: An acoustic building panel according to any one of Clauses 1 to 16, wherein the acoustic building panel is configured to store thermal energy of about 25 BTU / SF to about 75 BTU / SF.

[0092] Clause 18: An acoustic building panel pursuant to any one of Clauses 1 to 17, wherein the NRC value of the acoustic building panel is at least about 0.5.

[0093] Clause 19: A surface covering system comprising: a plurality of building panels configured to be positioned adjacent to each other to form a plurality of seams between each of the plurality of building panels, each building panel comprising: a porous substrate having a first primary surface opposite to a second primary surface, the substrate comprising one or more of mineral fiberboard, glass fiber, jute fiber, wood, or composite material, wherein the substrate is impregnated with a microencapsulated phase change material.

[0094] Clause 20: The surface coating system according to Clause 19, wherein the phase change material is microencapsulated in a polymer material.

[0095] Clause 21: A surface coating system according to any one of Clauses 1 or 20, wherein the phase change material is an aqueous dispersion encapsulated in a polymer material.

[0096] Clause 22: A surface covering system according to any one of Clauses 19 to 21, wherein the phase change material is an organic material.

[0097] Clause 23: A surface covering system according to any one of Clauses 19 to 22, wherein the phase change material is a powdered material.

[0098] Clause 24: A surface coating system according to any one of Clauses 19 to 23, wherein the average particle size of the phase change material is in the range of about 10 micrometers to about 50 micrometers, about 10 micrometers to about 30 micrometers, or about 10 micrometers to about 20 micrometers.

[0099] Clause 25: A surface covering system according to any one of Clauses 19 to 24, wherein the phase change material is enriched adjacent to the first primary surface of the substrate.

[0100] Clause 26: A surface covering system according to any one of Clauses 19 to 25, wherein the phase change material is enriched adjacent to the second primary surface of the substrate.

[0101] Clause 27: A surface covering system according to any one of Clauses 19 to 26, wherein the phase change material is uniformly distributed throughout the substrate.

[0102] Clause 28: A surface covering system according to any one of Clauses 19 to 27, wherein the phase change material is dry-injected into the pores of the substrate.

[0103] Clause 29: A surface covering system according to any one of Clauses 19 to 28, wherein the average pore size of the substrate is greater than the average pore size of the phase change material.

[0104] Clause 30: A surface covering system according to any one of Clauses 19 to 29, wherein the average pore size of the substrate is in the range of about 40 µm to about 100 µm.

[0105] Clause 31: A surface covering system according to any one of Clauses 19 to 30, wherein the porosity of the substrate is in the range of about 80% to about 95%.

[0106] Clause 32: The surface covering system according to any one of Clauses 19 to 31 further includes a loosely woven nonwoven fabric positioned over one of the first primary surface or the second primary surface of the substrate.

[0107] Clause 33: The surface covering system according to Clause 32 further includes an adhesive for adhering the loosely woven nonwoven fabric to the substrate.

[0108] Clause 34: A surface covering system pursuant to any one of Clauses 19 to 33, wherein each building panel exhibits a nominal thermal resistance of about 21.2 mK / watt.

[0109] Clause 35: A surface covering system pursuant to any one of Clauses 19 to 34, wherein each building panel is configured to store thermal energy of about 25 BTU / SF to about 75 BTU / SF.

[0110] Clause 36: A surface covering system pursuant to any one of Clauses 19 to 35, wherein the NRC value of each building panel is at least about 0.5.

[0111] Clause 37: A method for manufacturing an acoustic panel, comprising: providing a porous substrate having a first primary surface opposite to a second primary surface; and injecting a capsule-encapsulated phase change material into the pores of the substrate.

[0112] Clause 38: The method described in Clause 37, wherein the injection includes dry injection.

[0113] Clause 39: The method according to any one of Clauses 37 or 38, wherein the implantation comprises: applying microencapsulated phase change material to a first primary surface of the substrate; applying an alternating electric field to a second primary surface of the substrate; and

[0114] The phase change material is drawn from the first main surface into the pores of the substrate to create a substrate impregnated with the phase change material.

[0115] Clause 40: The method according to any one of Clauses 37 to 39, wherein the phase change material is microencapsulated in a polymer material.

[0116] Clause 41: The method according to any one of Clauses 37 to 40, wherein the phase change material is an aqueous dispersion encapsulated in a polymer material.

[0117] Clause 42: The method according to any one of Clauses 37 to 41, wherein the phase change material is an organic material.

[0118] Clause 43: The method according to any one of Clauses 37 to 42, wherein the phase change material is a powdered material.

[0119] Clause 44: The method according to any one of Clauses 37 to 43, wherein the average particle size of the phase change material is in the range of about 10 micrometers to about 50 micrometers, about 10 micrometers to about 30 micrometers, or about 10 micrometers to about 20 micrometers.

[0120] Clause 45: The method according to any one of Clauses 37 to 44, wherein the phase change material is enriched adjacent to the first primary surface of the substrate.

[0121] Clause 46: The method according to any one of Clauses 37 to 45, wherein the phase change material is enriched adjacent to the second primary surface of the substrate.

[0122] Clause 47: The method according to any one of Clauses 37 to 46, wherein the phase change material is uniformly distributed throughout the pores of the substrate.

[0123] Clause 48: The method according to any one of Clauses 37 to 47, wherein the average pore size of the substrate is greater than the average pore size of the phase change material.

[0124] Clause 49: The method according to any one of Clauses 37 to 48, wherein the average pore size of the substrate is in the range of about 40 µm to about 100 µm.

[0125] Clause 50: The method according to any one of Clauses 37 to 49, wherein the porosity of the substrate is in the range of about 80% to about 95%.

[0126] Clause 51: The method according to any one of Clauses 37 to 50 further includes positioning a loosely woven nonwoven fabric above one of the first primary surface or the second primary surface of the substrate.

[0127] Clause 52: The method according to Clause 51 further includes applying an adhesive to the substrate to adhere the loose nonwoven fabric to the substrate.

[0128] Clause 53: The method according to any one of Clauses 37 to 52, wherein the acoustic building panel exhibits a nominal thermal resistance of about 21.2 mK / watt.

[0129] Clause 54: The method according to any one of Clauses 37 to 53, wherein the acoustic building panel is configured to store thermal energy of about 25 BTU / SF to about 75 BTU / SF.

[0130] Clause 55: The method according to any one of Clauses 37 to 54, wherein the acoustic building panel exhibits an NRC value of at least about 0.5.

[0131] Clause 56: The method according to any one of Clauses 37 to 55, wherein the acoustic architectural panel is a ceiling panel.

[0132] Clause 57: The method according to any one of Clauses 37 to 55, wherein the acoustic building panel is a wall panel.

[0133] While this disclosure has been described with reference to several embodiments (which have been set forth in considerable detail for the purpose of fully disclosing this disclosure), such embodiments are merely representative and are not intended to limit or represent an exhaustive enumeration of all aspects of this disclosure. The scope of this disclosure will be determined by the appended claims. Furthermore, it will be apparent to those skilled in the art that many changes may be made to such details without departing from the spirit and principles of this disclosure.

Claims

1. An acoustic architectural panel, comprising: A porous substrate having a first primary surface opposite to a second primary surface, the substrate comprising one or more of mineral fiberboard, glass fiber, jute fiber, wood, or composite materials, wherein the substrate is impregnated with a microencapsulated phase change material.

2. The acoustic building panel of claim 1, wherein the phase change material is microencapsulated in a polymer material.

3. The acoustic building panel according to any one of claims 1 or 2, wherein the phase change material is an aqueous dispersion encapsulated in a polymer material.

4. The acoustic building panel according to any one of claims 1 to 4, wherein the average particle size of the phase change material is in the range of about 10 micrometers to about 50 micrometers, about 10 micrometers to about 30 micrometers, or about 10 micrometers to about 20 micrometers.

5. The acoustic building panel according to any one of claims 1 to 4, wherein the phase change material is enriched adjacent to the first main surface of the substrate.

6. The acoustic building panel according to any one of claims 1 to 4, wherein the phase change material is enriched adjacent to the second primary surface of the substrate.

7. The acoustic building panel according to any one of claims 1 to 4, wherein the phase change material is uniformly distributed throughout the substrate.

8. The acoustic building panel according to any one of claims 1 to 7, wherein the phase change material is dry-injected into the pores of the substrate.

9. A surface coating system, comprising: A plurality of building panels, the plurality of building panels being configured to be positioned adjacent to each other to form a plurality of seams between each of the plurality of building panels, each building panel comprising: A porous substrate having a first primary surface opposite to a second primary surface, the substrate comprising one or more of mineral fiberboard, glass fiber, jute fiber, wood, or composite materials, wherein the substrate is impregnated with a microencapsulated phase change material.

10. The surface coating system of claim 9, wherein the phase change material is microencapsulated in a polymer material.

11. The surface coating system according to any one of claims 9 or 10, wherein the phase change material is an aqueous dispersion encapsulated in a polymer material.

12. The surface coating system according to any one of claims 9 to 11, wherein the average particle size of the phase change material is in the range of about 10 micrometers to about 50 micrometers, about 10 micrometers to about 30 micrometers, or about 10 micrometers to about 20 micrometers.

13. The surface coating system according to any one of claims 9 to 12, wherein the phase change material is enriched adjacent to the first primary surface of the substrate.

14. The surface coating system according to any one of claims 9 to 12, wherein the phase change material is enriched adjacent to the second primary surface of the substrate.

15. The surface covering system according to any one of claims 9 to 12, wherein the phase change material is uniformly distributed throughout the substrate.

16. The surface coating system according to any one of claims 9 to 15, wherein the phase change material is dry-injected into the pores of the substrate.

17. A method for manufacturing an acoustic panel, comprising: A porous substrate is provided having a first main surface opposite to the second main surface; as well as The encapsulated phase change material is injected into the pores of the substrate.

18. The method of claim 17, wherein the injection comprises dry injection.

19. The method according to any one of claims 17 or 18, wherein the injection comprises: The microencapsulated phase change material is applied to the first main surface of the substrate; An alternating electric field is applied to the second main surface on the substrate; as well as The phase change material is drawn from the first main surface into the pores of the substrate to create a substrate impregnated with the phase change material.

20. The method according to any one of claims 17 to 19, wherein the phase change material is microencapsulated in a polymer material.

21. The method according to any one of claims 17 to 20, wherein the phase change material is an aqueous dispersion encapsulated in a polymer material.

22. The method according to any one of claims 17 to 21, wherein the average particle size of the phase change material is in the range of about 10 micrometers to about 50 micrometers, about 10 micrometers to about 30 micrometers, or about 10 micrometers to about 20 micrometers.

23. The method according to any one of claims 17 to 22, wherein the phase change material is enriched adjacent to the first main surface of the substrate.

24. The method according to any one of claims 17 to 22, wherein the phase change material is enriched adjacent to the second primary surface of the substrate.

25. The method according to any one of claims 17 to 22, wherein the phase change material is uniformly distributed throughout the pores of the substrate.

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