Acoustic building panels and surface covering systems

Abstract

Disclosed herein is an acoustic building panel including a substrate having a first major surface opposite a second major surface and a side surface extending therebetween. The substrate includes inorganic material present in an amount ranging from about 20 wt. % to about 80 wt. % based on the total dry-weight of the substrate, organic recycled material present in an amount ranging from about 20 wt. % to about 80 wt. % based on the total dry-weight of the substrate, and a binder present in an amount ranging from about 5 wt. % to about 15 wt. % based on the total dry-weight of the substrate. The organic recycled material includes two or more cellulosic materials.

Description

ACOUSTIC BUILDING PANELS AND SURFACE COVERING SYSTEMSCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application is a PCT International Application claiming priority to United States Provisional Patent Application No. 63 / 546571 filed on October 31, 2023, the disclosure of which is incorporated herein by reference in its entirety.FIELD OF DISCLOSURE

[0002] The present disclosure relates to acoustic building panels and surface covering systems including acoustic building panels.BACKGROUND

[0003] Building materials, such as planks and panels for ceiling and wall systems, may be designed balance interests with respect to aesthetics, material cost, structural integrity, acoustics, and environmental impact.

[0004] Accordingly, those skilled in the art continue research and development in the field of acoustic building panels and surface covering systems.BRIEF SUMMARY

[0005] This summary is intended merely to introduce a simplified summary of some aspects of one or more implementations of the present disclosure. Further areas of applicability of the present disclosure will become apparent from the detailed description provided hereinafter. This summary is not an extensive overview, nor is it intended to identify key or critical elements of the present teachings, nor to delineate the scope of the disclosure. Rather, its purpose is merely to present one or more concepts in simplified form as a prelude to the detailed description below.

[0006] The present disclosure is directed to acoustic building panels.

[0007] In one example, the disclosed acoustic building panel includes a substrate having a first major surface opposite a second major surface and a side surface extending therebetween. The substrate includes inorganic material present in an amount ranging from about 20 wt. % to about 80 wt. % based on the total dry-weight of the substrate, organic recycled material present in an amount ranging from about 20 wt. % to about 80 wt. % based on the total dry-weight of the substrate, and a binder present in an amount ranging from about 5 wt. % to about 15 wt. % based on the total dry-weight of the substrate.

[0008] In certain examples, the inorganic material includes inorganic fiber, such as mineral wool, is present in an amount ranging from about 25.0 wt. % to about 35.0 wt. % based on the total dryweight of the substrate. In certain examples, the inorganic material includes clay present in an amount ranging from about 35 wt. % to about 55 wt. % or from about 40 wt. % to about 50 wt. % based on the total dry-weight of the substrate.

[0009] In certain examples, the organic recycled material includes starch material, cellulosic material, or combinations thereof. In certain examples, the organic recycled material includes newsprint, refined paper, wood fiber, or combinations thereof. In certain examples, the organic recycled material includes newsprint present in an amount ranging from about 10 wt. % to about 20 wt. % based on the total dry-weight of the substrate. In certain examples, the newsprint is present in an amount ranging from about 12 wt. % to about 16 wt. % based on the total dry-weight of the substrate. In certain examples, the organic recycled material includes dry broke present in an amount ranging from about 15 wt. % to about 40 wt. % based on the total dry-weight of the substrate. In certain examples, the dry broke is present in an amount ranging from about 20 wt.% to about 30 wt. % based on the total dry-weight of the substrate.

[0010] In certain examples, the binder includes starch present in an amount ranging from about 5 wt. % to about 15 wt. % based on the total dry- weight of the substrate. In certain examples, the starch is present in an amount ranging from about 6 wt. % to about 10 wt. % based on the total dry-weight of the substrate. In certain examples, the substrate further includes a filler selected from the group consisting of calcium carbonate, limestone, titanium dioxide, sand, barium sulfate, mica, dolomite, silica, talc, wollastonite, calcite, aluminum trihydrate, aluminum silicate, pigments, zinc oxide, zinc sulfate, and combinations thereof.

[0011] In certain examples, the substrate exhibits an airflow resistance from about 30 mks ralys to about 200000 mks ralys. In certain examples, the substrate includes a scrim having a first major scrim surface opposing a second major scrim surface coupled to the first major surface of the substrate. In certain examples, the scrim is a fiberglass scrim. In certain examples, the scrim is a filled scrim includes a filler material selected from calcium carbonate, aluminum trihydrate, and combinations thereof. In certain examples, the scrim has an airflow resistance from about 30 mks ralys to about 200000 mks ralys, preferably from about 30 mks ralys ralys to about 5000 mks ralys.

[0012] In certain examples, the substrate includes an adhesive adhering the first major surface of the substrate to the second major scrim surface of the scrim. In certain examples, the adhesiveincludes polyvinyl acetate emulsion. In certain examples, the substrate has a porosity ranging from about 70.0 % to about 82.0 %. In certain examples, the substrate has a skeletal density ranging from about 1 g / cc to about 2.5 g / cc.

[0013] In certain examples, the substrate includes a coating over the first major surface of the substrate. In certain examples, the coating includes a pigment blend and a binder. In certain examples, a ratio of pigment-to-binder is from about 5 to about 20. In certain examples, the pigment blend includes two or more of calcium carbonate, titanium dioxide, calcined diatomaceous earth, and aluminum hydroxide. In certain examples, the binder includes vinyl acrylic polymer. In certain examples, the coating is applied in an amount ranging from about 40 g / ft2to about 60 g / ft2.

[0014] In certain examples, the acoustic building panel includes a face layer coupled to the first major surface of the substrate. In one example, the face layer has plurality of perforations extending from a first major face surface to a second major face surface. In certain examples, the plurality of perforations have a diameter from about 0.050” to about 0.100”. In certain examples, the plurality of perforations are present in a perforation density ranging from about 20 perforations / ft2to about 15,000 perforations / ft2.

[0015] In certain examples, the acoustic building panel exhibits an NRC value of at least 0.050. In certain examples, the acoustic building panel exhibits an STC value ranging from about 25 to about 35. In certain examples, the acoustic building panel is a wall panel. In certain examples, the acoustic building panel is a wall panel positioned no more than 7ft above ground level.

[0016] In certain examples, the acoustic building panel includes a substrate having a first major surface opposite a second major surface and a side surface extending therebetween. In certain examples, the substrate includes inorganic fiber present in an amount ranging from about 25.0 wt. % to about 35.0 wt. % based on the total dry- weight of the substrate, newsprint present in an amount ranging from about 10 wt. % to about 20 wt. % based on the total dry- weight of the substrate, clay present in an amount ranging from about 35 wt. % to about 55 wt. % based on the total dry-weight of the substrate, starch present in an amount ranging from about 5 wt. % to about 15 wt. % based on the total dry-weight of the substrate, dry broke present in an amount ranging from about 15 wt.% to about 40 wt. % based on the total dry-weight of the substrate, and perlite present in an amount ranging from about 1 wt. % to about 10 wt. % based on the total dry-weight of the substrate. In certain examples, the inorganic fiber includes mineral wool.

[0017] Also disclosed are surface covering systems.

[0018] In one example, the disclosed surface covering system includes a support structure and at least one acoustic building panel mounted to the support structure, wherein the at least one acoustic building panel is positioned no more than 7ft above ground level.

[0019] In another example, the surface covering system includes a plurality of acoustic building panels configured to be positioned adjacent to each other to define a plurality of seams between each acoustic building panel of the plurality of acoustic building panels. Each acoustic building panel of the plurality of acoustic building panels includes a substrate having a first major surface opposite a second major surface. The substrate includes inorganic material present in an amount ranging from about 20 wt. % to about 80 wt. % based on the total dry-weight of the substrate, organic recycled material present in an amount ranging from about 20 wt. % to about 80 wt. % based on the total dry-weight of the substrate, and a binder present in an amount ranging from about 5 wt. % to about 15 wt. % based on the total dry-weight of the substrate. The system further includes a seam- filling material configured to be applied to each seam of the plurality of seams.

[0020] In certain examples, the plurality of acoustic building panels are wall panels. In certain examples, the plurality of acoustic building panels are wall panels positioned no more than 7ft above ground level.

[0021] In certain examples, the inorganic material includes inorganic fiber present in an amount ranging from about 25.0 wt. % to about 35.0 wt. % based on the total dry-weight of each substrate. In certain examples, the inorganic fiber includes mineral wool. In certain examples, the inorganic material includes clay present in an amount ranging from about 35 wt. % to about 55 wt. % based on the total dry-weight of each substrate. In certain examples, the clay is present in an amount ranging from about 40 wt. % to about 50 wt. % based on the total dry-weight of each substrate.

[0022] In certain examples, the organic recycled material includes starch material, cellulosic material, or combinations thereof. In certain examples, the organic recycled material includes newsprint, refined paper, wood fiber, or combinations thereof. In certain examples, the organic recycled material includes newsprint present in an amount ranging from about 10 wt. % to about 20 wt. % based on the total dry-weight of each substrate. In certain examples, the newsprint is present in an amount ranging from about 12 wt. % to about 16 wt. % based on the total dry-weight of each substrate. In certain examples, the organic recycled material includes dry broke present in an amount ranging from about 15 wt.% to about 40 wt. % based on the total dry- weight of eachsubstrate. Tn certain examples, the dry broke is present in an amount ranging from about 20 wt. % to about 30 wt. % based on the total dry-weight of each substrate.

[0023] In certain examples, the binder includes starch present in an amount ranging from about 5 wt. % to about 15 wt. % based on the total dry-weight of each substrate. In certain examples, the starch is present in an amount ranging from about 6 wt. % to about 10 wt. % based on the total dry-weight of each substrate.

[0024] In certain examples, each substrate further includes a filler selected from the group consisting of calcium carbonate, limestone, titanium dioxide, sand, barium sulfate, mica, dolomite, silica, talc, wollastonite, calcite, aluminum trihydrate, aluminum silicate, pigments, zinc oxide, zinc sulfate, and combinations thereof. In certain examples, each substrate exhibits an airflow resistance from about 30 mks ralys to about 200000 mks ralys.

[0025] In certain examples, the system includes a scrim having a first major scrim surface opposing a second major scrim surface coupled to the first major surface of each substrate. In certain examples, the scrim is a fiberglass scrim. In certain examples, the scrim is a filled scrim includes a filler material selected from calcium carbonate, aluminum trihydrate, and combinations thereof. In certain examples, the scrim has an airflow resistance from about 30 mks ralys to about 200000 mks ralys, preferably from about 30 mks ralys ralys to about 5000 mks ralys.

[0026] In certain examples, the system includes an adhesive adhering the first major surface of each substrate to the second major scrim surface of each scrim. In certain examples, the adhesive includes polyvinyl acetate emulsion.

[0027] In certain examples, the substrate has a porosity ranging from about 70.0 % to about 82.0 %. In certain examples, the substrate has a skeletal density ranging from about 1 g / cc to about 2.5 g / cc. In certain examples, the seam-filling material includes gypsum plaster.

[0028] In certain examples, the system includes a coating over the first major surface of each substrate and the seam-filling material. In certain examples, the coating includes a pigment blend and a binder. In certain examples, a ratio of pigment-to-binder is from about 5 to about 20. In certain examples, the pigment blend includes two or more of calcium carbonate, titanium dioxide, calcined diatomaceous earth, and aluminum hydroxide. In certain examples, the binder includes vinyl acrylic polymer. In certain examples, the coating is applied in an amount ranging from about 40 g / ft2to about 60 g / ft2.

[0029] In certain examples, each substrate includes a face layer having a plurality of perforations. In certain examples, the plurality of perforations extend from the first major face surface to the second major face surface. In certain examples, the plurality of perforations have a diameter from about 0.050” to about 0.100”. In certain examples, the plurality of perforations are present in a perforation density ranging from about 20 perforations / ft2to about 15,000 perforations / ft2.

[0030] In certain examples, the plurality of acoustic building panels exhibit an NRC value of at least 0.050. In certain examples, the plurality of acoustic building panels exhibit an STC value ranging from about 25 to about 35.

[0031] In certain examples, the plurality of acoustic building panels includes a first acoustic building panel positioned between ground level and up to 7ft below ground level and a second acoustic building panel positioned adjacent the first acoustic building panel and more than 7ft above ground level, wherein the first acoustic building panel has a first skeletal density and the second acoustic building panel has a second skeletal density, and wherein the first skeletal density is higher than the second skeletal density.

[0032] Also disclosed is a method for forming a surface covering system.

[0033] In one example, the method includes positioning a first acoustic building panel adjacent a second acoustic building panel such that a seam is defined between the fire acoustic building panel and the second acoustic building panel. The method further includes applying a seam-filling material to the seam. The method further includes applying a coating composition over the first acoustic building panel, the second acoustic building panel, and the seam-filling material to yield a coating.BRIEF DESCRIPTION OF THE DRAWINGS

[0034] Figure 1 is a perspective view of an acoustic building panel.

[0035] Figure 2 is a cross-sectional view of an acoustic building panel.

[0036] Figure 3 is a cross-sectional view of an acoustic building panel.

[0037] Figure 4 is a cross-sectional view of an acoustic building panel

[0038] Figure 5 is a prospective view of a surface covering system.

[0039] Figure 6 is a cross-sectional view of a surface covering system.

[0040] Figure 7 is a cross-sectional view of a surface covering system.

[0041] Figure 8 is a building system comprising one or more of the building panels of Figures 1 to 7.

[0042] The detailed description of the disclosure will be better understood when read in conjunction with the appended drawings. It should be understood, however, that the disclosure is not limited to the precise arrangements and instrumentalities of the examples shown in the drawings.DETAILED DESCRIPTION

[0043] For illustrative purposes, the principles of the present disclosure are described by referencing various examples thereof. Although certain examples of the disclosure are specifically described herein, one of ordinary skill in the ail will readily recognize that the same principles are equally applicable to, and can be employed in other applications and methods. It is to be understood that the disclosure is not limited in its application to the details of any particular example shown. The terminology used herein is for the purpose of description and not to limit the disclosure, its application, or uses.

[0044] As used herein and in the appended claims, the singular forms “a”, “an”, and “the” include plural references unless the context dictates otherwise. The singular form of any class of the ingredients refers not only to one chemical species within that class, but also to a mixture of those chemical species. 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 “include” should be interpreted as “include, but are not limited to”. The term “including” should be interpreted as “including, but are not limited to”.

[0045] As used throughout, ranges are used as shorthand for describing each and every value that is within the range. Any value within the range can be selected as the terminus of the range. Thus, any range of values disclosed herein is merely exemplary and includes all values and sub-ranges there-between

[0046] Unless otherwise specified, all percentages and amounts expressed herein and elsewhere in the specification should be understood to refer to percentages by weight of the total composition. Unless otherwise specified, reference to a molecule, or to molecules, being present at a “wt. %” refers to the amount of that molecule, or molecules, present in the composition based on the total dry-weight of the composition. Unless otherwise specified, reference to a molecule, or to molecules, being present “based on the dry weight of the composition” refers to that molecule, or molecules, being present in the composition based on the total dry-weight of the composition in adry state. The “dry state” refers to solvent being present in the composition at an amount less than 5.0 wt. %, less than about 3.0 wt. %, less than about 1.0 wt. %; preferably less than about 0.5 wt. %, and more preferably less than about 0.25 wt. % of the composition. For example, a composition in the dry state may refer to a composition having about 95% solids, about 98% solids, preferably about 99% solids, or more preferably about 100% solids. By contrast, unless otherwise specified, reference to a molecule, or to molecules, being present “based on the wet weight of the composition” refers to that molecule, or molecules, being present in the composition based on the total dry-weight of the composition which includes at least 5 wt. % of solvent.

[0047] According to the present application, use of the term “about” in conjunction with a numeral value refers to a value that may be + / - 5% of that numeral. As used herein, the term “substantially free” is intended to mean an amount less than about 5.0 wt. %, less than 3.0 wt. %, less than 1.0 wt. %; preferably less than about 0.5 wt. %, and more preferably less than about 0.25 wt. % of the composition.

[0048] Unless defined otherwise, all technical and scientific terms used herein have the same meanings as commonly understood by one of ordinary skill in the art to which this disclosure belongs. All patents, patent applications, publications, and other references cited or referred to herein are incorporated by reference in their entireties for all purposes. In the event of a conflict in a definition in the present disclosure and that of a cited reference, the present disclosure Comparatives.

[0049] In the description of examples disclosed herein, any reference to direction or orientation is merely intended for convenience of description and is not intended in any way to limit the scope of the present disclosure. Relative terms such as "lower," "upper," “horizontal,” “vertical,”, “above,” “below,” “up,” “down,” “top” and “bottom” as well as derivatives thereof (e.g., “horizontally,” “downwardly,” “upwardly,” etc.) should be construed to refer to the orientation as then described or as shown in the drawing (if applicable) under discussion. These relative terms are for convenience of description only and, unless specified otherwise, do not require that the apparatus be constructed or operated in a particular orientation.

[0050] As used herein, terms such as “attached,” “affixed,” “connected,” “coupled,” “interconnected,” and the like refer to a relationship wherein structures are secured or attached to one another either directly or indirectly through intervening structures, as well as both movable or rigid attachments or relationships, unless expressly described otherwise. Accordingly, thedisclosure is not limited to such examples illustrating certain combinations of features that may exist alone or in combination with other features.

[0051] In one aspect, the disclosure provides a single-layer acoustic building panel and system that yields desired acoustic properties, including a lower Sound Transmission Coefficient (STC) and higher Noise Reduction Coefficient (NRC), while achieving desired mechanical properties, including impact resistance. It has been discovered that simultaneously achieving desired acoustic and mechanical properties is possible via the combination of materials disclosed herein exhibiting high skeletal density to provide desirable porosity, impact resistance, and acoustics.

[0052] Referring to Figure 1, disclosed is an acoustic building panel 100. The acoustic building panel 100 may be a wall panel, a ceiling panel, or a furniture panel. In one example, the acoustic building panel 100 is a wall panel positioned such that extends anywhere from the ground level to no more than 7ft above the ground level. In another example, the acoustic building panel 100 is a ceiling panel. In yet another example, the acoustic building panel 100 is a furniture panel, such as for ready-to-assemble furniture. In one example, the acoustic building panel 100 may be used for laminated structures, such as laminated product manufacturing. The acoustic building panel 100 may be characterized by its bulk density, skeletal density, and porosity.

[0053] The acoustic building panel 100 may have a panel thickness ti as measured from the first major surface 112 to the second major surface 114. The panel thickness ti may range from about 12 mm to about 40 mm - including all values and sub-ranges there-between. The acoustic building panel 100 may have a length Lp ranging from about 30 cm to about 310 cm - including all values and sub-ranges there-between. The acoustic building panel 100 may have a width Wp ranging from about 10 cm to about 125 cm - including all values and sub-ranges there-between.

[0054] The acoustic building panel 100 includes a substrate 110 having a first major surface 112 opposite a second major surface 114 and a side surface 113 extending therebetween. The substrate 110 includes a combination of inorganic and organic materials, some recycled, with a binder to yield desirable acoustic and mechanical properties.

[0055] In one or more examples, the substrate 110 includes inorganic material present in an amount ranging from about 20 wt. % to about 80 wt. % based on the total dry-weight of the substrate 110. In one example, the inorganic material comprises inorganic fiber present in an amount ranging from about 25.0 wt. % to about 35.0 wt. % based on the total dry- weight of the substrate 110- including all values and sub-ranges there-between. In another example, theinorganic material is mineral wool present in an amount of about 28 wt. % based on the total dryweight of the substrate.

[0056] In one or more examples, the inorganic material includes clay. The clay may be present in an amount ranging from about 35 wt. % to about 55 wt. % based on the total dry-weight of the substrate. In another example, the clay is present in an amount ranging from about 40 wt. % to about 50 wt. % based on the total dry-weight of the substrate- including all values and sub-ranges there-between. In another example, the clay is present an amount of about 45 wt. % based on the total dry-weight of the substrate.

[0057] In one example, the inorganic material includes perlite. In another example, the inorganic material includes expanded perlite. The perlite may be present in an amount ranging from about 1 wt. % to about 10 wt. % based on the total dry-weight of the substrate - including all values and sub-ranges there-between. In another example, the perlite is present in an amount ranging from about 3 wt. % to about 8 wt. % - including all values and sub-ranges there-between. In yet another example, the perlite is present in an amount of about 5 wt. % based on the total dry-weight of the substrate.

[0058] The substrate 110 also includes organic material, such as organic recycled material. The organic material may be present in an amount ranging from about 20 wt. % to about 80 wt. % based on the total dry-weight of the substrate 110. In one example, the organic recycled material comprises starch material, cellulosic material, or combinations thereof. In one or more examples, the organic recycled material of the substrate 110 includes newsprint, refined paper, wood fiber, dry broke, or combinations thereof.

[0059] In one or more examples, the organic recycled material of the substrate 110 includes newsprint present in an amount ranging from about 10 wt. % to about 20 wt. % based on the total dry-weight of the substrate. In another example, the newsprint is present in an amount ranging from about 12 wt. % to about 16 wt. % based on the total dry-weight of the substrate- including all values and sub-ranges there-between. In another example, the newsprint is present in an amount of about 14 wt. % based on the total dry-weight of the substrate.

[0060] In one or more examples, the organic recycled material of the substrate 110 includes dry broke present in an amount ranging from about 15 wt. % to about 40 wt. % based on the total dryweight of the substrate. In another example, the dry broke is present in an amount ranging from about 20 wt.% to about 30 wt. % based on the total dry-weight of the substrate- including allvalues and sub-ranges there-between. In yet another example, the dry broke is present in an amount of about 25 wt. % based on the total dry-weight of the substrate.

[0061] In one or more examples, the substrate 110 includes a binder present in an amount ranging from about 5 wt. % to about 15 wt. % - including all values and sub-ranges there-between -based on the total dry-weight of the substrate. In one example, the binder includes starch. In another example, the binder comprises starch present in an amount ranging from about 5 wt. % to about 15 wt. % based on the total dry- weight of the substrate. In yet another example, the starch is present in an amount ranging from about 6 wt. % to about 10 wt. % based on the total dry-weight of the substrate. In another example, the binder includes latex. In a further example, the binder is free from formaldehyde.

[0062] In one or more examples, the substrate 110 of the acoustic building panel 100 further includes one or more filler selected from the group consisting of calcium carbonate, limestone, titanium dioxide, sand, barium sulfate, mica, dolomite, silica, talc, wollastonite, calcite, aluminum trihydrate, aluminum silicate, pigments, zinc oxide, zinc sulfate, and combinations thereof.

[0063] The substrate 110 may be characterized by its physical properties, including airflow resistance, porosity, and skeletal density. The unit of measure MKS rayls (Pa-s / m) is measured according to the methodology set forth in ASTM C522 “Standard Test Method for Airflow Resistance of Acoustical Materials. In one example, the substrate is comprised of a material that is non-acoustic, meaning its airflow resistance is beyond the airflow resistance required to be an acoustic material. Examples of materials that are non-acoustic include metals, ceramics, composites, granite, wood, and other materials have non-acoustic properties. In one example, the substrate 110 exhibits an airflow resistance from about 30 mks ralys to about 200000 mks ralys inch - including all values and sub-ranges there-between.

[0064] In one or more examples, the substrate 110 has a porosity ranging from about 70.0 % to about 82.0 %- including all values and sub-ranges there-between. In another example, the substrate 110 has a porosity ranging from about 72.0 % to about 80.0 %- including all values and sub-ranges there-between. In another example, the substrate 110 has a porosity ranging from about 72.0 % to about 78.0 %- including all values and sub-ranges there-between. In yet another example, the substrate 110 has a porosity ranging from about 74.0 % to about 78.0 %- including all values and sub-ranges there-between. In a further example, the substrate 110 has a porosity ranging from about 75.0 % to about 77.0 %- including all values and sub-ranges there-between.

[0065] In one or more examples, the substrate 1 10 has a skeletal density ranging from about 1 g / cc to about 2.5 g / cc inch - including all values and sub-ranges there -between. In another example, the substrate 110 has a skeletal density ranging from about 1.2 g / cc to about 2.4 g / cc inch - including all values and sub-ranges there -between. In another example, the substrate 110 has a skeletal density ranging from about 1.6 g / cc to about 2.2 g / cc inch - including all values and subranges there-between.

[0066] The skeletal density and porosity, along with the disclosed composition, advantageously yield an acoustic building panel 100 having high impact resistance. In one example, the acoustic building panel 100 exhibits an impact resistance of about 0.040” to about 0.025” - including all values and sub-ranges there-between - when tested via ball impact testing to determine durability per ASTM D1037-99 Standard Test Methods for Evaluating Properties of Wood-Base Fiber and Particle Panel Materials and ASTM C 367-99 Standard Test Methods for Strength Properties of Prefabricated Architectural Acoustical Tile or Lay-In Ceiling Panels.

[0067] Referring to Figure 2, in one or more examples, the acoustic building panel 100 further includes a scrim 120 having a first major scrim surface 122 opposing a second major scrim surface 124 coupled to the first major surface 112 of the substrate 110. The scrim 120 has a thickness t2 defined as the distance between the first major scrim surface 122 and the second major scrim surface 124. In one or more examples, the scrim 120 has a thickness t2 from about 0.5 mm to about 0.8 mm.

[0068] In one example, the scrim 120 is a fiberglass scrim. The scrim 120 may be an unfilled scrim or a filled scrim. In one example, the scrim 120 is a filled scrim comprising a filler material selected from calcium carbonate, aluminum trihydrate, and combinations thereof. The scrim 120 may be further characterize by its airflow resistance. In one example, the scrim 120 has an airflow resistance from about 30 mks ralys to about 200000 mks ralys, preferably from about 30 mks ralys ralys to about 5000 mks ralys- including all values and sub-ranges there-between.

[0069] The acoustic building panel 100 may further include an adhesive adhering the first major surface 112 of the substrate 110 to the second major scrim surface 124 of the scrim 120. In one example, the adhesive comprises polyvinyl acetate emulsion.

[0070] Referring to Figure 4, the acoustic building panel 100 may further include a coating 130 over the first major surface 112 and / or the scrim 120 of the substrate 110 present at a thickness t3. In one example, the coating 130 thickness t3 in an amount ranging from about 40 g / ft2to about 60g / ft2. In another example, the acoustic building panel 100 includes more than one coating 130. The acoustic building panel 100 may be characterized by its total thickness to as measured from the first major exposed surface 116 to the second major exposed surface 118, including the thickness of the substrate 110 ti, the thickness of the scrim 120 t2, and the thickness of the coating 130 ta. The first major exposed surface 116 may be the same surface as the first major surface 112 or may be defined by a scrim 120 or coating 140 as described herein.

[0071] In one example, the coating 130 includes a pigment blend and a binder. In one example, the binder comprises vinyl acrylic polymer. The pigment blend and binder may be present a ratio of pigment-to-binder from about 5 to about 20- including all values and sub-ranges there-bet ween.

[0072] In one or more examples, the pigment blend comprises two or more of calcium carbonate, titanium dioxide, barium sulfate, calcined diatomaceous earth, and aluminum hydroxide. In one example, pigment blend includes calcined diatomaceous earth present in an amount from about 3 wt. % to about 20 wt. %, from about 5 wt. % to about 17.5 wt. %, or from about 7.5 wt. % to about 15 wt. %, based on the dry weight of the coating composition.

[0073] In one or more examples, the pigment blend comprises titanium dioxide present at a concentration of about 0.1 wt. % to about 15 wt. %, from about 0.5 wt. % to about 10 wt. %, or from about 1 wt. % to about 8 wt. %, based upon the dry weight of the coating composition.

[0074] In one or more examples, the pigment blend comprises barium sulfate present at a concentration of about 0.1 wt. % to about 15 wt. %, from about 0.5 wt. % to about 10 wt. %, or from about 1 wt. % to about 8 wt. %, based upon the dry weight of the coating composition.

[0075] In one or more examples, the pigment blend includes aluminum hydroxide present in an amount from about 3 wt. % to about 20 wt. %, from about 5 wt. % to about 18 wt. %, or from about 10 wt. % to about 15 wt. %, based on the dry weight of the coating composition.

[0076] In one or more examples, the pigment blend includes calcium carbonate present in an amount from about 20 wt. % to about 60 wt. %, from about 25 wt. % to about 35 wt. %, or from about 27.0 wt. % to about 32.5 wt. %, based on the dry weight of the coating composition.

[0077] In one or more examples, the coating 130 includes one or more additives, including one or more of a defoamer, humectant, clay, wetting and dispersing additive, calcined extender, hydrophobic polymer emulsion, biocide, or precipitated synthetic silicate.

[0078] The coating 130 may be applied in any amount needed to sufficiently achieve desired aesthetic and acoustic properties. In one example, the coating 130 is applied in an amount ranging from about 40 g / ft2to about 60 g / ft2- including all values and sub-ranges there-bet ween.

[0079] Referring to Figure 3, the acoustic building panel 100 may further include a face layer 150 having a first major face surface 152 and a second major face surface 154 coupled to the first major surface 112 of the substrate 110. In one example, the face layer 150 includes a plurality of perforations 140. The plurality of perforations 140 may extend the entirety of the face layer 150 from the first major face surface 152 to the second major face surface 154. In one example, the plurality of perforation 140 may extend the entirety of the face layer 150, or may be located within predefined areas so as to define a perimeter on the face layer 150 free from the plurality of perforations 140. In one example, each perforation 140' of the plurality of perforations 140 has a diameter Di from about 0.050” to about 0.100”. The plurality of perforations 140 may be present in a perforation density ranging from about 20 perforations / ft2to about 15,000 perforations / ft2. In another example, the plurality of perforations 140 may be present in a perforation density ranging from about 1,000 perforations / ft2to about 3,000 perforations / ft2. In one aspect, the plurality of perforations 140 beneficially improve acoustic properties of the acoustic building panel 100.

[0080] The acoustic building panel 100 and substrate 110 are further characterized by their acoustic properties. NRC is a measure of sound energy absorption of a material. An NRC rating of 0 is a perfect sound reflection material. An NRC rating of 1 is a perfect sound absorption material. CAC is a measure for rating the performance of a ceiling material as a barrier to block airborne sound transmission through the material to / from the plenum above the ceiling. In one example, the acoustic building panel 100 exhibits an NRC value of at least 0.050.

[0081] The acoustic building panel 100 may be further characterized by its Sound Transmission Coefficient (STC). In one example, the acoustic building panel 100 exhibits an STC value ranging from about 25 to about 35.

[0082] In one or more examples, the disclosed building panel 100 includes a substrate 110 having a first major surface 112 opposite a second major surface 114 and a side surface 113 extending therebetween. The substrate 110 is comprised of a mixture of inorganic and organic materials.

[0083] In one example, the substrate 110 includes inorganic fiber, such as mineral wool, present in an amount ranging from about 25.0 wt. % to about 35.0 wt. % based on the total dry- weight of the substrate 110. The substrate 110 further includes newsprint present in an amount ranging fromabout 10 wt. % to about 20 wt. % based on the total dry- weight of the substrate 1 10. The substrate 110 further includes clay present in an amount ranging from about 35 wt. % to about 55 wt. % based on the total dry-weight of the substrate 110. The substrate 110 further includes starch present in an amount ranging from about 5 wt. % to about 15 wt. % based on the total dry-weight of the substrate 110. The substrate 110 further includes dry broke present in an amount ranging from about 15 wt.% to about 40 wt. % based on the total dry-weight of the substrate 110. The substrate 110 further includes perlite present in an amount ranging from about 1 wt. % to about 10 wt. % based on the total dry-weight of the substrate 110.

[0084] Referring to Figures 5 to 7, also disclosed is a surface covering system 200, such as a wall system, ceiling system, or furniture system. In one example, the surface covering system 200 is a wall system including a support structure and at least one acoustic building panel 100 mounted to the support structure, wherein the at least one acoustic building panel 100 is positioned between ground level to no more than 7ft above ground level, see Figure 11.

[0085] In one or more examples, the surface covering system 200 includes a plurality of acoustic building panels 202 as disclosed herein. The plurality of acoustic building panels 202 are configured to be positioned adjacent each other so as to define a plurality of seams 215 between each acoustic building panel 202' of the plurality of acoustic building panels 202.

[0086] Referring to Figure 5, each acoustic building panel 202' of the plurality of acoustic building panels 202 includes a substrate 210 having a first major surface 212 opposite a second major surface 214. Each substrate 210 is comprised of a blend of inorganic material and organic material, such as recycled organic material, with a binding material.

[0087] In one or more examples, the substrate 210 includes inorganic material present in an amount ranging from about 20 wt. % to about 80 wt. % based on the total dry-weight of the substrate 210. In one example, the inorganic material comprises inorganic fiber present in an amount ranging from about 25.0 wt. % to about 35.0 wt. % based on the total dry- weight of the substrate 210- including all values and sub-ranges there-bet ween. The inorganic material may include wool, such mineral wool.

[0088] In one or more examples, the inorganic material includes clay. The clay may be present in an amount ranging from about 35 wt. % to about 55 wt. % based on the total dry-weight of the substrate. In another example, the clay is present in an amount ranging from about 40 wt. % toabout 50 wt. % based on the total dry-weight of the substrate- including all values and sub-ranges thcrc-bctwccn.

[0089] In one example, the inorganic material includes perlite. In another example, the inorganic material includes expanded perlite. The perlite may be present in an amount ranging from about 1 wt. % to about 10 wt. % based on the total dry-weight of the substrate - including all values and sub-ranges there-between. In another example, the perlite is present in an amount ranging from about 3 wt. % to about 8 wt. % - including all values and sub-ranges there-between. In yet another example, the perlite is present in an amount of about 5 wt. % based on the total dry-weight of the substrate.

[0090] The substrate 210 also includes organic material, such as organic recycled material. The organic material may be present in an amount ranging from about 20 wt. % to about 80 wt. % based on the total dry-weight of the substrate 210. In one example, the organic recycled material comprises starch material, cellulosic material, or combinations thereof. In one or more examples, the organic recycled material of the substrate 210 includes newsprint, refined paper, wood fiber, dry broke, or combinations thereof.

[0091] In one or more examples, the organic recycled material of the substrate 210 includes newsprint present in an amount ranging from about 10 wt. % to about 20 wt. % based on the total dry-weight of the substrate. In another example, the newsprint is present in an amount ranging from about 12 wt. % to about 16 wt. % based on the total dry-weight of the substrate- including all values and sub-ranges there-between.

[0092] In one or more examples, the organic recycled material of the substrate 210 includes dry broke present in an amount ranging from about 15 wt.% to about 40 wt. % based on the total dryweight of the substrate. In another example, the dry broke is present in an amount ranging from about 20 wt.% to about 30 wt. % based on the total dry-weight of the substrate- including all values and sub-ranges there-between.

[0093] In one or more examples, the substrate 210 includes a binder present in an amount ranging from about 5 wt. % to about 15 wt. % inch - including all values and sub-ranges there-between - based on the total dry-weight of the substrate. In one example, the binder includes starch. In another example, the binder comprises starch present in an amount ranging from about 5 wt. % to about 15 wt. % based on the total dry- weight of the substrate. In yet another example, the starch ispresent in an amount ranging from about 6 wt. % to about 10 wt. % based on the total dry-weight of the substrate. In a further example, the binder is free from formaldehyde.

[0094] In one or more examples, each substrate 210 of the surface covering system 200 further includes one or more filler selected from the group consisting of calcium carbonate, limestone, titanium dioxide, sand, barium sulfate, mica, dolomite, silica, talc, wollastonite, calcite, aluminum trihydrate, aluminum silicate, pigments, zinc oxide, zinc sulfate, and combinations thereof.

[0095] The surface covering system 200 further includes a seam-filling material. The seam-filling material, or joint compound, is configured to be applied to each seam 215' of the plurality of seams 215. The seam-filling material is configured to couple or join two acoustic building panels 202' to each other. In one example, the seam-filling material includes gypsum plaster.

[0096] In one or more examples, the plurality of acoustic building panels 202 are wall panels, ceiling panels, or furniture panels. In another example, the plurality of acoustic building panels 202 are wall panels positioned between ground level to no more than 7ft above ground level.

[0097] Each substrate 210 of the plurality of acoustic building panels 202 may be characterized by its physical properties, including airflow resistance, porosity, and skeletal density. The unit of measure MKS rayls (Pa- s / m) is measured according to the methodology set forth in ASTM C522 “Standard Test Method for Airflow Resistance of Acoustical Materials. In one example, the substrate is comprised of a material that is non-acoustic, meaning its airflow resistance is beyond the airflow resistance required to be an acoustic material. Examples of materials that are nonacoustic include metals, ceramics, composites, granite, wood, and other materials have nonacoustic properties. In one example, each substrate 210 exhibits an airflow resistance from about 30 mks ralys to about 200000 mks ralys inch - including all values and sub-ranges there-bet ween.

[0098] In one or more examples, the substrate 210 has a porosity ranging from about 70.0 % to about 82.0 %- including all values and sub-ranges there-between. In another example, the substrate 210 has a porosity ranging from about 72.0 % to about 80.0 %- including all values and sub-ranges there-between. In another example, the substrate 210 has a porosity ranging from about 72.0 % to about 78.0 %- including all values and sub-ranges there-between. In yet another example, the substrate 210 has a porosity ranging from about 74.0 % to about 78.0 %- including all values and sub-ranges there-between. In a further example, the substrate 210 has a porosity ranging from about 75.0 % to about 77.0 %- including all values and sub-ranges there-between.

[0099] In one or more examples, the substrate 210 has a skeletal density ranging from about 1 g / cc to about 2.5 g / cc inch - including all values and sub-ranges there -between. In another example, the substrate 210 has a skeletal density ranging from about 1.2 g / cc to about 2.4 g / cc inch - including all values and sub-ranges there -between. In another example, the substrate 210 has a skeletal density ranging from about 1.6 g / cc to about 2.2 g / cc inch - including all values and subranges there-between.

[0100] The skeletal density and porosity, along with the disclosed composition, advantageously yield an acoustic building panel 202' having high impact resistance. In one example, the acoustic building panel 202' exhibits an impact resistance of about 0.040” to about 0.025” - including all values and sub-ranges there-between - when tested via ball impact testing to determine durability per ASTM D1037-99 Standard Test Methods for Evaluating Properties of Wood-Base Fiber and Particle Panel Materials and ASTM C 367-99 Standard Test Methods for Strength Properties of Prefabricated Architectural Acoustical Tile or Lay-In Ceiling Panels.

[0101] In one or more examples, each acoustic building panel 202' of the plurality of acoustic building panels 202 may have a panel thickness U as measured from the first major exposed surface 216 to the second major exposed surface 218. The panel thickness U may range from about 0.25 inch to about 1.0 inch - including all values and sub-ranges there-between. The first major exposed surface 216 may be the same surface as the first major surface 212 or may be defined by a scrim 220 or coating 230 as described below.

[0102] Each substrate 210 of the plurality of acoustic building panels 200 may have a body thickness ts that extends from the first major surface 212 to the second major surface 214. The body thickness ts may range from about 0.25 inch to about 1 inch - including all values and subranges there-between.

[0103] Referring to Figure 6, in one or more examples, each substrate 210 of the plurality of acoustic building panels 202 further includes a scrim 220 having a first major scrim surface 222 opposing a second major scrim surface 224 coupled to the first major surface 212 of the substrate 210. In one example, the scrim 220 is a fiberglass scrim. The scrim 220 may be an unfilled scrim or a filled scrim. In one example, the scrim 220 is a filled scrim comprising a filler material selected from calcium carbonate, aluminum trihydrate, and combinations thereof. The scrim 220 may be further characterize by its airflow resistance. In one example, the scrim 220 has an airflowresistance from about 30 mks ralys to about 200000 mks ralys, preferably from about 30 mks ralys ralys to about 5000 mks ralys- including all values and sub-ranges thcrc-bctwccn.

[0104] The surface covering system 200 may further include an adhesive adhering the first major surface 212 of the substrate 210 to the second major scrim surface 224 of the scrim 220. In one example, the adhesive comprises polyvinyl acetate emulsion.

[0105] Still referring to Figure 6, the surface covering system 200 may further include a coating 230 over the first major surface 212 and / or the scrim 220 of the substrate 210. In one example, the coating 230 includes a pigment blend and a binder. In one example, the binder comprises vinyl acrylic polymer. The pigment blend and binder may be present a ratio of pigment-to-binder from about 5 to about 20- including all values and sub-ranges there-between.

[0106] In one or more examples, the pigment blend comprises two or more of calcium carbonate, titanium dioxide, barium sulfate, calcined diatomaceous earth, and aluminum hydroxide. In one example, pigment blend includes calcined diatomaceous earth present in an amount from about 3 wt. % to about 20 wt. %, from about 5 wt. % to about 17.5 wt. %, or from about 7.5 wt. % to about 15 wt. %, based on the dry weight of the coating composition.

[0107] In one or more examples, the pigment blend comprises titanium dioxide present at a concentration of about 0.1 wt. % to about 15 wt. %, from about 0.5 wt. % to about 10 wt. %, or from about 1 wt. % to about 8 wt. %, based upon the dry weight of the coating composition.

[0108] In one or more examples, the pigment blend comprises barium sulfate present at a concentration of about 0.1 wt. % to about 15 wt. %, from about 0.5 wt. % to about 10 wt. %, or from about 1 wt. % to about 8 wt. %, based upon the dry weight of the coating composition.

[0109] In one or more examples, the pigment blend includes aluminum hydroxide present in an amount from about 3 wt. % to about 20 wt. %, from about 5 wt. % to about 18 wt. %, or from about 10 wt. % to about 15 wt. %, based on the dry weight of the coating composition.

[0110] In one or more examples, the pigment blend includes calcium carbonate present in an amount from about 20 wt. % to about 60 wt. %, from about 25 wt. % to about 35 wt. %, or from about 27.0 wt. % to about 32.5 wt. %, based on the dry weight of the coating composition.

[0111] In one or more examples, the coating 230 includes one or more additives, including one or more of a defoamer, humectant, clay, wetting and dispersing additive, calcined extender, hydrophobic polymer emulsion, biocide, or precipitated synthetic silicate.

[0112] The coating 230 may be applied in any amount needed to sufficiently achieve desired aesthetic and acoustic properties. In one example, the coating 230 is applied in an amount ranging from about 40 g / ft2to about 60 g / ft2- including all values and sub-ranges there-bet ween.

[0113] Referring to Figure 7, the each acoustic building panel 202' of the plurality of acoustic building panels 202 may further include further include a face layer 250 having a first major face surface 252 and a second major face surface 254 coupled to the first major surface 212 of the substrate 210. In one example, the face layer 250 includes a plurality of perforations 240. The plurality of perforations 240 may extend the entirety of the face layer 250 from the first major face surface 252 to the second major face surface 254. In one example, the plurality of perforations 240 may extend the entirety of the face layer 250 or may be located within predefined areas so as to define a perimeter on the face layer 250 free from the plurality of perforations 240. In one example, each perforation 240' of the plurality of perforations 240 has a diameter Di from about 0.050” to about 0.100”. The plurality of perforations 240 may be present in a perforation density ranging from about 20 perforations / ft2to about 15,000 perforations / ft2. In another example, the plurality of perforations 240 may be present in a perforation density ranging from about 1,000 perforations / ft2to about 3,000 perforations / ft2. In one aspect, the plurality of perforations 240 beneficially improve acoustic properties of the acoustic building panel 200.

[0114] The plurality of acoustic building panels 202 and substrate 210 are further characterized by their acoustic properties. NRC is a measure of sound energy absorption of a material. An NRC rating of 0 is a perfect sound reflection material. An NRC rating of 1 is a perfect sound absorption material. CAC is a measure for rating the performance of a ceiling material as a barrier to block airborne sound transmission through the material to / from the plenum above the ceiling. In one example, the disclosed plurality of acoustic building panels 202 and substrate 210 exhibit an NRC value of at least 0.050 in an installed state.

[0115] The plurality of acoustic building panels 202 and substrate 210 may be further characterized by its Sound Transmission Coefficient (STC). In one example, the plurality of acoustic building panels 202 and substrate 210 exhibit an STC value ranging from about 25 to about 35.

[0116] Referring to Figure 8, in one or more examples, the present disclosure may be implemented in a building system 1. In one example, the present disclosure includes a building system 1 comprising one or more of the acoustic building panels 100 or plurality of acoustic building panels202 installed in an interior space 8. Figure 8 shows the acoustic building panel 100 and system 200 installed, however, the following discussion applies to any configuration disclosed herein.

[0117] The interior space 8 may comprise a floor surface 4, equivalent to ground level as disclosed herein, that is opposite a ceiling surface 5. The interior space 8 may further comprise a cavity space 3 and an active room environment 2. The cavity space 3 may provide a free volume for joists and / or wall stud 9 to be located within the acoustic building system 1. The active room environment 2 provides room for the acoustic building occupants during normal intended use of the acoustic building (e.g., in an office building, the active space would be occupied by offices containing computers, lamps, etc.). The floor surface 4 provides for building occupants to walk on within the room environment 2. The floor surface 4 may extend into the cavity space 3. The floor surface 4 may be formed a building material (e.g., wood flooring, concrete flooring, metal grate, etc.).

[0118] In the installed state, the acoustic building panels 100, plurality of acoustic building panels 202, and / or surface covering system 200 may be supported in the interior space 8 by one or more of the wall studs 9 (for acoustic building panels 100 that function as wall panels) and / or one or more of the ceiling joists (for acoustic building panels 100 that function as ceiling panels - not pictured). In the installed state, the plurality of acoustic building panels 100 supported by the wall studs 9 may form a wall surface 50. In the installed state, the plurality of building panels 100 supported by the ceiling joists may form a ceiling surface 5.

[0119] The plurality of wall studs 9 may be arranged substantially parallel to each other. The plurality of wall studs 9 may be offset from each other by a distance Dws of about 16 inches - as measured on center from each adjacent wall stud 9. The distance Dws between wall studs 9 may provide for an open cavity volume 11. The open cavity volume 11 may be an unoccupied space within the acoustic building system 1. In other embodiments, insulation may be installed into the open cavity volume 11 - non-limiting examples of insulation include sound insulation, thermal insulation, and combinations thereto.

[0120] The wall studs 9 may be an elongated body having a substantially vertical orientation - extending in a direction that spans between the floor surface 4 and the ceiling surface 5. Depending on the room layout design, the wall studs 9 may be oriented orthogonal to the floor surface 4 - i.e., resulting in a wall surface 50 that is completely vertical (also referred to as a “vertical wall surface” 50). In other embodiments, the wall studs 9 may be oriented at an angle between about 46° to about89° relative to the floor surface 4 - i.e., resulting in a wall surface 50 that is slanted (also referred to as a “slanted wall surface” 50).

[0121] Depending on the room layout design, the ceiling surface 5 may be substantially parallel to the floor surface 4 - i.e., resulting in a ceiling surface 5 that is completely horizontal (also referred to as a “horizontal ceiling surface” 5). In other embodiments, the ceiling surface 5 may be oriented at an angle between about 1° to about 44° relative to the floor surface 4 - i.e., resulting in a ceiling surface 5 that is slanted (also referred to as a “slanted ceiling surface” 5).

[0122] The cavity space 3 may exist behind each one of the plurality of acoustic building panels 202. The active room environment 2 may exists in front of each one of the plurality of acoustic building panels 202. The first exposed major surface 116 of each acoustic building panel 100 may face the active room environment 2. The second exposed major surface 118 of each acoustic building panel 100 may face the cavity space 3. As discussed further herein, the acoustic building panels 100 of the present invention have airflow properties required for the acoustic building panels 100 to functional as acoustical building panels - as discussed further herein.

[0123] In a non-limiting embodiment, the acoustic building panels 100 may be supported by the one or more of the wall studs 9 using a mechanical fastener (e.g., screw), adhesive, or combinations thereto. In a non-limiting embodiment, the acoustic building panels 100 may be support by the one or more ceiling joists using a mechanical fastener (e.g., screw), adhesive, or combinations thereof.

[0124] Each of the acoustic building panels 100 may be positioned within building system 1 such that at least one of the side exposed surfaces 113 is located adjacent to the floor surface 4. Specifically, the first side surface 113a (or second side surface 113b) may be located adjacent to the floor surface 4 - whereby in such arrangement, the wall acoustic building panel 100 is vertically oriented in a sideways manner (not pictured). The wall acoustic building panel 100 vertically oriented in the sideways manner may comprise the third side surface 113c and the fourth side surface 113d being substantially parallel to the elongated body of the wall studs 9 - whereby each one of the third side surface 113c and / or fourth side surface 113d may overlap with a single wall stud 9. The wall acoustic building panel 100 vertically oriented in the sideways manner may comprise the first side surface 113a and the second side surface 113b being substantially orthogonal to the elongated body of the wall studs 9 - whereby each one of the first side surface 113a and / or second side surface 113b may overlap with a plurality of wall studs 9.- l-

[0125] In other embodiments, each of the acoustic building panels 100 may be positioned within building system 1 such that at least one of the side surfaces 113 is located adjacent to the floor surface 4 such that the third side surface 113c (or fourth side surface 113d) may be located adjacent to the floor surface 4 - whereby in such arrangement, the wall acoustic building panel 100 is vertically oriented in an upstanding manner. The wall acoustic building panel 100 vertically oriented in the upstanding manner may comprise the first side surface 113a and the second side surface 113b being substantially parallel to the elongated body of the wall studs 9 - whereby each one of the first side surface 113a and / or second side surface 113b may overlap with a single wall stud 9. The wall panel 100 vertically oriented in the upstanding manner may comprise the third side surface 113c and the fourth side surface 113d being substantially orthogonal to the elongated body of the wall studs 9 - whereby each one of the third side surface 113c and / or fourth side surface 113d may overlap with a plurality of wall studs 9.

[0126] In the installed state, the acoustic building panel 100 may be secured to one or more of the wall studs 9 such that the acoustic building panel 100 is located from the floor surface 4 by a panelfloor distance DPF. The panel-floor distance DPF may be determined by the vertical distance spanning between the floor surface 4 and the most-proximate point on the acoustic building panel 100 from the floor surface 4. The panel-floor distance DPF may range from zero to about 7 feet - including all distances and sub-ranges there-between. The panel-floor distance DPF may range from zero to about 6 feet - including all distances and sub-ranges there-between. When the panelfloor distance DPF is zero, the acoustic building panel 100 may be in direct contact with the floor surface 4. In some embodiments, the panel-floor distance DPF is less than about 6 feet.

[0127] In another aspect, Figure 8 demonstrates that a first acoustic building panel 100a and a second acoustic building panel 100b may be positioned adjacent to each other, whereby a panel seam 215' is located where the first side surface 113a of the first building panel 100a is located adjacent to the second side surface 113b of the second building panel 100b.

[0128] In other embodiments, the acoustic building panel 100 may also be installed such that it forms a ceiling surface (not pictured) and / or be position above the panel-floor distance DPF.

[0129] Furthermore, the disclosed plurality of acoustic building panels 202 of the surface covering system 200 includes a first acoustic building panel positioned between ground level and up to 7ft above ground level. The plurality of acoustic building panels 202 further includes a second acoustic building panel positioned adjacent the first acoustic building panel and more than 7ftabove ground level (not shown). The panels are defined such that the first acoustic building panel has a first skeletal density and the second acoustic building panel has a second skeletal density, and the first skeletal density is higher than the second skeletal density. Furthermore, the first building panel has a higher impact resistance than the second building panel.

[0130] Also disclosed is a method for forming a surface covering system 200. The method includes implementing any of the acoustic building panels 100 and systems 200 as disclose herein. In one example, the method includes positioning a first acoustic building panel 100a adjacent a second acoustic building panel 100b such that a seam 215' is defined between the fire acoustic building panel 100a and the second acoustic building panel 100b. The method further includes applying a seam- filling material to the seam215'. The method further includes applying a coating composition over the first acoustic building panel, the second acoustic building panel, and the seam-filling material to yield a coating 230.

[0131] In one or more examples, the method further includes affixing the first acoustic building panel 100a and the second acoustic building panel 100b to a frame structure 9. In one or more examples, the method further includes applying tape to the seam 215'. The method may yield an impact resistant surface covering system 200, such as a ceiling system, wall system, or furniture system. In one example, the surface covering system 200 manufactured by the method is a wall system including wall panels located no more than 7ft above ground level.

[0132] Also disclosed is a method of manufacture for a building panel 100. In one example, the method includes forming a blend by combining together a binder composition, an inorganic material, a recycled organic material, and water.

[0133] The method further includes flowing the blend into a mold having a geometry. In one example, the geometry of the mold is such that the resulting building panel comprises a first major surface opposite a second major surface.

[0134] In one or more examples, the method includes hardening the blend in the mold such that the binder composition and recycled material conform to the geometry of the mold, resulting in a building panel body. In one example, the building panel has a length and a width, the length ranging from about 1 ft. to about 8ft and the width ranging from about 1 ft. to about 4 ft.

[0135] In one or more examples, the method further includes coupling one or more of a scrim 120 and face layer 150 to the first major surface 112 of the body.

[0136] In one or more examples, the inorganic material is present in an amount ranging from about 20 wt. % to about 80 wt. % based on the total dry-weight of the substrate, the organic recycled material is present in an amount ranging from about 20 wt. % to about 80 wt. % based on the total dry-weight of the substrate, and the binder is present in an amount ranging from about 5 wt. % to about 15 wt. % based on the total dry- weight of the substrateEXAMPLES

[0137] The examples and other implementations described herein are exemplary and not intended to be limiting in describing the full scope of compositions and methods of this disclosure. Equivalent changes, modifications and variations of specific implementations, materials, compositions, and methods may be made within the scope of the present disclosure, with substantially similar results.

[0138] The examples below were tested for various material and mechanical properties, including porosity, skeletal density, impact resistance, modulus of elasticity, modulus of resistance, and acoustics (face ohms). For impact resistance, the examples were tested via ball impact testing, Instron Ball Indent, to determine durability per ASTM D1037-99 Standard Test Methods for Evaluating Properties of Wood-Base Fiber and Particle Panel Materials and ASTM C 367-99 Standard Test Methods for Strength Properties of Prefabricated Architectural Acoustical Tile or Lay-In Ceiling Panels. The indentor used was a threaded stem with 1” diameter steel ball. The examples included specimens of 4" x 4" pieces exposed for at least 24 hours to conditions including 73.4°F and 50% RH. The ball was positioned toward the specimens at 0.5" / minute to a load of 35 lb.TALBE 1

[0139] Table 1 discloses the dry-weight composition for an exemplary acoustic building panel for the examples tested of the present disclosure.TABLE 2TABLE 2 CONTINUED

[0140] Table 2 illustrates data collected for Examples 1 and 2 for, among other things, modulus of elasticity (MOE), modulus of rupture (MOR), density, basis weight, porosity, skeletal density, and indent depth. As shown above, the Examples exhibited indent depths of about 0.033” and 0.037” pursuant the testing conditions as described above.TABLE 3

[0141] Table 3 illustrates acoustic data collected for Examples 1 and 2. Acoustic fata was collected at raised temperatures and at room temperature. As shown above, raised temperatures did not impact acoustics of the Examples.

[0142] While the present disclosure has been described with reference to several examples, which examples have been set forth in considerable detail for the purposes of making a complete disclosure of the disclosure, such examples are merely representative and are not intended to be limiting or represent an exhaustive enumeration of all aspects of the disclosure. The scope of the disclosure is to be determined from the claims appended hereto. Further, it will be apparent to-26-SUBSTITUTE SHEET (RULE 26)

Claims

WHAT IS CLAIMED IS:

1. An acoustic building panel comprising: a substrate having a first major surface opposite a second major surface and a side surface extending therebetween, the substrate comprising: inorganic material present in an amount ranging from about 20 wt. % to about 80 wt. % based on the total dry-weight of the substrate; organic recycled material present in an amount ranging from about 20 wt. % to about 80 wt. % based on the total dry-weight of the substrate; and a binder present in an amount ranging from about 5 wt. % to about 15 wt. % based on the total dry-weight of the substrate, wherein the organic recycled material comprises a blend of two or more cellulosic materials.

2. The acoustic building panel according to claim 1, wherein the inorganic material comprises inorganic fiber present in an amount ranging from about 25.0 wt. % to about 35.0 wt. % based on the total dry-weight of the substrate.

3. The acoustic building panel according to claim 2, wherein the inorganic fiber comprises mineral wool.

4. The acoustic building panel according to any one of claims 1 to 3, wherein the inorganic material comprises clay present in an amount ranging from about 35 wt. % to about 55 wt. % based on the total dry-weight of the substrate.

5. The acoustic building panel according to claim 4, wherein the clay is present in an amount ranging from about 40 wt. % to about 50 wt. % based on the total dry-weight of the substrate.

6. The acoustic building panel according to any one of claims 1 to 5, wherein the organic recycled material comprises starch material, cellulosic material, or combinations thereof.

7. The acoustic building panel according to any one of claims 1 to 6, wherein the organic recycled material comprises newsprint, refined paper, wood fiber, or combinations thereof.

8. The acoustic building panel according to any one of claims 1 to 7, wherein the organic recycled material comprises newsprint present in an amount ranging from about 10 wt. % to about 20 wt. % based on the total dry-weight of the substrate.

9. The acoustic building panel according to claim 8, wherein the newsprint is present in an amount ranging from about 12 wt. % to about 16 wt. % based on the total dry-weight of the substrate.

10. The acoustic building panel according to any one of claims 1 to 9, wherein the organic recycled material comprises dry broke present in an amount ranging from about 15 wt. % to about 40 wt. % based on the total dry-weight of the substrate.

11. The acoustic building panel according to claim 10, wherein the dry broke is present in an amount ranging from about 20 wt. % to about 30 wt. % based on the total dry-weight of the substrate.

12. The acoustic building panel according to any one of claims 1 to 11, wherein the binder comprises starch present in an amount ranging from about 5 wt. % to about 15 wt. % based on the total dry-weight of the substrate.

13. The acoustic building panel according to claim 12, wherein the starch is present in an amount ranging from about 6 wt. % to about 10 wt. % based on the total dry-weight of the substrate.

14. The acoustic building panel according to any one of claims 1 to 13, wherein the substrate further comprises a filler selected from the group consisting of calcium carbonate, limestone, titanium dioxide, sand, barium sulfate, mica, dolomite, silica, talc, wollastonite, calcite, aluminum trihydrate, aluminum silicate, pigments, zinc oxide, zinc sulfate, and combinations thereof.

15. The acoustic building panel according to any one of claims 1 to 14, wherein the substrate exhibits an airflow resistance from about 30 mks ralys to about 200000 mks ralys.

16. The acoustic building panel according to any one of claims 1 to 14, further comprising a face layer having a first major face surface opposite a second major face surface coupled to the first major surface of the substrate.

17. The acoustic building panel according to claim 16, wherein the face layer comprises a plurality of perforations extending from the first major face surface to the second major face surface.

18. The acoustic building panel according to claim 16 or 17, wherein the plurality of perforations are present in a perforation density ranging from about 20 perforation / ft2to about 15,000 perforation / ft2.

19. The acoustic building panel according to any one of claims 16 to 18, wherein the plurality of perforations have an average diameter ranging from about 0.050” to about 0.100”.

20. The acoustic building panel according to any one of claims 16 to 19, further comprising an adhesive adhering the first major surface of the substrate to the second major face surface of the face layer.

21. The acoustic building panel according to claim 20, wherein the adhesive comprises polyvinyl acetate emulsion.

22. The acoustic building panel according to any one of claims 1 to 21, wherein the substrate has a porosity ranging from about 70.0 % to about 82.0 %.

23. The acoustic building panel according to any one of claims 1 to 22, wherein the substrate has a skeletal density ranging from about 1 g / cc to about 2.5 g / cc.

24. The acoustic building panel according to any one of claims 1 to 23, further comprising a coating over the first major face surface of the face layer.

25. The acoustic building panel according to claim 24, wherein the coating comprises: a pigment blend; and a binder.

26. The acoustic building panel according to any one of claims 24 to 25, wherein a ratio of pigment- to-binder is from about 5 to about 20.

27. The acoustic building panel according to any one of claims 24 to 26, wherein the pigment blend comprises two or more of calcium carbonate, titanium dioxide, calcined diatomaceous earth, and aluminum hydroxide.

28. The acoustic building panel according to any one of claims 24 to 27, wherein the binder comprises vinyl acrylic polymer.

29. The acoustic building panel according to any one of claims 24 to 28, wherein the coating is applied in an amount ranging from about 40 g / ft2to about 60 g / ft2.

30. The acoustic building panel according to any one of claims 1 to 29, exhibiting an NRC value of at least 0.050.

31. The acoustic building panel according to any one of claims 1 to 30, exhibiting an impact depth from about 0.040” to about 0.025” when subjected to impact testing per ASTM C 367-99.

32. The acoustic building panel according to any one of claims 1 to 31, wherein the acoustic building panel is a wall panel or a ceiling panel.

33. The acoustic building panel according to any one of claims 1 to 32, wherein the acoustic building panel is a wall panel positioned no more than 7ft above ground level.-SO-34. An acoustic building panel comprising: a substrate having a first major surface opposite a second major surface and a side surface extending therebetween, the substrate comprising: inorganic fiber present in an amount ranging from about 25.0 wt. % to about 35.0 wt. % based on the total dry-weight of the substrate; newsprint present in an amount ranging from about 10 wt. % to about 20 wt. % based on the total dry-weight of the substrate; clay present in an amount ranging from about 35 wt. % to about 55 wt. % based on the total dry-weight of the substrate; starch present in an amount ranging from about 5 wt. % to about 15 wt. % based on the total dry-weight of the substrate; dry broke present in an amount ranging from about 15 wt.% to about 40 wt. % based on the total dry-weight of the substrate; and perlite present in an amount ranging from about 1 wt. % to about 10 wt. % based on the total dry-weight of the substrate.

35. The acoustic building panel according to claim 34, wherein the inorganic fiber comprises mineral wool.

36. A surface covering system comprising: a plurality of acoustic building panels configured to be positioned adjacent to each other to define a plurality of seams between each acoustic building panel of the plurality of acoustic building panels, each acoustic building panel of the plurality of acoustic building panels comprising: a substrate having a first major surface opposite a second major surface, the substrate comprising: inorganic material present in an amount ranging from about 20 wt. % to about 80 wt. % based on the total dry-weight of the substrate; organic recycled material present in an amount ranging from about 20 wt.% to about 80 wt. % based on the total dry-weight of the substrate; anda binder present in an amount ranging from about 5 wt. % to about 15 wt. % based on the total dry-weight of the substrate; and a seam-filling material configured to be applied to each seam of the plurality of seams, wherein the organic recycled material comprises a blend of two or more cellulosic materials.

37. The surface covering system according to claim 36, wherein the plurality of acoustic building panels are wall panels or ceiling panels.

38. The surface covering system according to claim 36 or 37, wherein the plurality of acoustic building panels are wall panels positioned no more than 7ft above ground level.

39. The surface covering system according to any one of claims 36 to 38, wherein the inorganic material comprises inorganic fiber present in an amount ranging from about 25.0 wt. % to about 35.0 wt. % based on the total dry- weight of each substrate.

40. The surface covering system according to claim 39, wherein the inorganic fiber comprises mineral wool.

41. The surface covering system according to any one of claims 36 to 40, wherein the inorganic material comprises clay present in an amount ranging from about 35 wt. % to about 55 wt. % based on the total dry-weight of each substrate.

42. The surface covering system according to claim 41, wherein the clay is present in an amount ranging from about 40 wt. % to about 50 wt. % based on the total dry-weight of each substrate.

43. The surface covering system according to any one of claims 36 to 42, wherein the organic recycled material comprises starch material, cellulosic material, or combinations thereof.

44. The surface covering system according to any one of claims 36 to 43, wherein the organic recycled material comprises newsprint, refined paper, wood fiber, or combinations thereof.

45. The surface covering system according to any one of claims 36 to 44, wherein the organic recycled material comprises newsprint present in an amount ranging from about 10 wt. % to about 20 wt. % based on the total dry-weight of each substrate.

46. The surface covering system according to claim 45, wherein the newsprint is present in an amount ranging from about 12 wt. % to about 16 wt. % based on the total dry-weight of each substrate.

47. The surface covering system according to any one of claims 36 to 46, wherein the organic recycled material comprises dry broke present in an amount ranging from about 15 wt. % to about 40 wt. % based on the total dry-weight of each substrate.

48. The surface covering system according to claim 47, wherein the dry broke is present in an amount ranging from about 20 wt. % to about 30 wt. % based on the total dry-weight of each substrate.

49. The surface covering system according to any one of claims 36 to 48, wherein the binder comprises starch present in an amount ranging from about 5 wt. % to about 15 wt. % based on the total dry-weight of each substrate.

50. The surface covering system according to claim 49, wherein the starch is present in an amount ranging from about 6 wt. % to about 10 wt. % based on the total dry-weight of each substrate.

51. The surface covering system according to any one of claims 36 to 50, wherein each substrate further comprises a filler selected from the group consisting of calcium carbonate, limestone, titanium dioxide, sand, barium sulfate, mica, dolomite, silica, talc, wollastonite, calcite, aluminum trihydrate, aluminum silicate, pigments, zinc oxide, zinc sulfate, and combinations thereof.

52. The surface covering system according to any one of claims 36 to 51, wherein each substrate exhibits an airflow resistance from about 30 mks ralys to about 200000 mks ralys.

53. The surface covering system according to any one of claims 36 to 52 , further comprising a scrim having a first major scrim surface opposing a second major scrim surface coupled to the first major surface of each substrate.

54. The surface covering system according to claim 53, wherein each scrim is a fiberglass scrim.

55. The surface covering system according to any one of claims 53 to 54, wherein each scrim is a filled scrim comprising a filler material selected from calcium carbonate, aluminum trihydrate, and combinations thereof.

56. The surface covering system according to any one of claims 53 to 55, wherein each scrim has an airflow resistance from about 30 mks ralys to about 200000 mks ralys, preferably from about 30 mks ralys ralys to about 5000 mks ralys.

57. The surface covering system according to any one of claims 53 to 56, further comprising an adhesive adhering the first major surface of each substrate to the second major scrim surface of each scrim.

58. The surface covering system according to claim 57, wherein the adhesive comprises polyvinyl acetate emulsion.

59. The surface covering system according to any one of claims 36 to 58, further comprising a face layer having a first major face surface and a second major face surface coupled to the first major surface of each substrate.

60. The surface covering system according to claim 59, wherein the face layer comprises a plurality of perforations extending from the first major face surface to the second major face surface.

61. The surface covering system according to claim 60, wherein the plurality of perforations are present in a perforation density ranging from about 20 perforation / ft2to about 15,000 perforation / ft2.

62. The surface covering system according to claim 60 or 61, wherein the plurality of perforations have an average diameter ranging from about 0.050” to about 0.100”.

63. The surface covering system according to any one of claims 53 to 56, further comprising an adhesive adhering the first major surface of the substrate to the second major face surface of the face layer.

64. The surface covering system according to claim 57, wherein the adhesive comprises polyvinyl acetate emulsion.

65. The surface covering system according to any one of claims 36 to 63, wherein each substrate has a porosity ranging from about 70.0 % to about 82.0 %.

66. The surface covering system according to any one of claims 36 to 64, wherein each substrate has a skeletal density ranging from about 1 g / cc to about 2.5 g / cc.

67. The surface covering system according to any one of claims 36 to 65, wherein the seam-filling material comprises gypsum plaster.

68. The surface covering system according to any one of claims 36 to 66, further comprising a coating over the first major surface of each substrate and the seam-filling material.

69. The surface covering system according to claim 67, wherein the coating comprises: a pigment blend; and a binder.

70. The surface covering system according to any one of claims 68 to 69, wherein a ratio of pigment-to-binder is from about 5 to about 20.

71. The surface covering system according to any one of claims 68 to 70, wherein the pigment blend comprises two or more of calcium carbonate, titanium dioxide, calcined diatomaceous earth, and aluminum hydroxide.

72. The surface covering system according to any one of claims 68 to 71, wherein the binder comprises vinyl acrylic polymer.

73. The surface covering system according to any one of claims 68 to 72, wherein the coating is applied in an amount ranging from about 40 g / ft2to about 60 g / ft2.

74. The surface covering system according to any one of claims 36 to 73, wherein the plurality of acoustic building panels exhibit an NRC value of at least 0.050.

75. The surface covering system according to any one of claims 36 to 74, the plurality of acoustic building panels exhibiting an impact depth from about 0.040” to about 0.025” when subjected to impact testing per ASTM C 367-99.

76. The surface covering system according to any one of claims 36 to 75, wherein the plurality of acoustic building panels comprises: a first acoustic building panel positioned between ground level and up to 7ft below ground level; and a second acoustic building panel positioned adjacent the first acoustic building panel and more than 7ft above ground level, wherein the first acoustic building panel has a first skeletal density and the second acoustic building panel has a second skeletal density, and wherein the first skeletal density is higher than the second skeletal density.

77. A wall system comprising: a support structure; and at least one acoustic building panel according to any one of claims 1 to 76 mounted to the support structure, wherein the at least one acoustic building panel is positioned no more than 7ft above ground level.

78. A method for forming a surface covering system comprising: positioning a first acoustic building panel adjacent a second acoustic building panel such that a seam is defined between the fire acoustic building panel and the second acoustic building panel; applying a seam-filling material to the seam; and applying a coating composition over the first acoustic building panel, the second acoustic building panel, and the seam-filling material, wherein at least one of the first acoustic building panel and the second acoustic building panel comprises: a substrate having a first major surface opposite a second major surface, the substrate comprising: inorganic material present in an amount ranging from about 20 wt. % to about 80 wt. % based on the total dry-weight of the substrate; organic recycled material present in an amount ranging from about 20 wt.% to about 80 wt. % based on the total dry-weight of the substrate; and a binder present in an amount ranging from about 5 wt. % to about 15 wt. % based on the total dry-weight of the substrate.

79. The method according to claim 78, further comprising affixing the first acoustic building panel and the second acoustic building panel to a frame structure.

80. The method according to claim 78 or claim 79, further comprising applying tape to the seam.

81. A method of manufacture of a building panel comprising: a) forming a blend by combining together a binder composition, an inorganic material, a recycled organic material, and water; b) flowing the blend into a mold having a geometry; c) hardening the blend in the mold such that the binder composition and recycled material conform to the geometry of the mold, resulting in a building panel body; wherein the inorganic material is present in an amount ranging from about 20 wt. % to about 80 wt. % based on the total dry-weight of the substrate, wherein the organic recycled material is present in an amount rangingfrom about 20 wt. % to about 80 wt. % based on the total dry- weight of the substrate, and wherein the binder is present in an amount ranging from about 5 wt. % to about 15 wt. % based on the total dry-weight of the substrate82. The method according to claim 81, wherein the geometry of the mold is such that the resulting building panel comprises a first major surface opposite a second major surface.

83. The method according to any one of claims 81 to 82, wherein the building panel has a length and a width, the length ranging from about 1 ft. to about 8ft and the width ranging from about 1 ft. to about 4 ft.

84. The method according to any one of claims 81 to 82, wherein subsequent to c), the method further comprises d) coupling one or more of a scrim and face layer to the first major surface of the body.

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