Acoustic panels, surface covering systems, and methods for making the same

Abstract

Disclosed is an acoustic panel. The acoustic panel includes a substrate having a first major surface opposite a second major surface, the substrate having an airflow resistance from about 300 mks rayls to about 700 mks rayls. The acoustic panel further includes a scrim having a first major scrim surface and a second major scrim surface coupled to the first major surface of the substrate, the scrim having a fiber mesh and a filler. The scrim has an airflow resistance from about 300 mks rayls to about 700 mks rayls. Also disclosed are surface covering systems and methods for their formation.

Description

ACOUSTIC PANELS, SURFACE COVERING SYSTEMS, AND METHODS FOR MAKING THE SAMECROSS-REFERENCE TO RELATED APPLICATION

[0001] This application is a PCT International Application that claims the benefit of U.S. Provisional Application No. 63 / 540537 filed on September 26, 2023. The disclosure of the above application is incorporated herein by reference.FIELD OF THE DISCLOSURE

[0002] The present disclosure relates to acoustic panels, such as ceiling and wall panels, and more particularly to acoustic panels having filled scrims.BACKGROUND

[0003] Building materials, such as planks and panels of ceiling and wall systems, are commonly coated with coating compositions, such as paints, for aesthetic purposes. Acoustic substrates typically do not have filled scrims or veils because using a denser, filled scrim or veil may be detrimental to the performance of the panels, particularly to the acoustic properties. Using a filled scrim, however, advantageously offers desirable hiding and light-reflectance properties for aesthetic purposes.

[0004] Accordingly, there is a need for improved acoustic panels having sufficient aesthetic properties while maintaining desired acoustic properties.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] Applicants have discovered combining filled scrims with acoustic substrates to yield acoustic panels.

[0007] In one example, the disclosed acoustic panel includes a substrate having a first major surface opposite a second major surface, the substrate having an airflow resistance from at leastabout 300 mks rayls to about 700 mks rayls. The acoustic panel further includes a scrim having a first major scrim surface and a second major scrim surface coupled to the first major surface of the substrate, the scrim including a fiber mesh and a filler. The scrim has an airflow resistance from about 300 mks rayls to about 700 mks rayls.

[0008] In certain examples, the substrate includes mineral fiber board, fiberglass, jute fiber, wood, or a composite material. In certain examples, the scrim has a thickness from about 0.5 mm to about 0.8 mm. In certain examples, the filler includes calcium carbonate. In certain examples, the filler includes aluminum trihydrate. In certain examples, the acoustic panel further includes an adhesive adhering the first major surface of the substrate to the second major scrim surface of the scrim. In certain examples, the adhesive includes polyvinyl acetate emulsion.

[0009] In certain examples, the acoustic panel further includes a coating over the first major scrim surface. In certain examples, the coating includes a pigment blend comprising calcium carbonate, titanium dioxide, calcined diatomaceous earth, and aluminum hydroxide. The coating further includes a binder. In certain examples, the titanium dioxide is 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 composition. In certain examples, wherein the calcined diatomaceous earth is 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 composition. In certain examples, the aluminum hydroxide is 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 composition. In certain examples, the calcium carbonate is 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 composition. In certain examples, a ratio of pigment-to-binder is from about 5 to about 20. In certain examples, the binder is present in an amount from about 2 wt. % to about 20 wt. %, from about 2 wt. % to about 18 wt. %, or from about 3 wt. % to about 16 wt. %, based on the dry weight of the composition. In certain examples, the binder includes vinyl acrylic polymer. In certain examples, the coating further includes one or more of a defoamer, humectant, clay, wetting and dispersing additive, calcined extender, hydrophobic polymer emulsion, biocide, or precipitated synthetic silicate. In certain examples, the coating is applied in an amount ranging from about 40 g / ft2 to about 60 g / ft2. In certain examples, the acoustic panel includes at least twocoatings applied to the acoustic panel, at least three coatings applied to the acoustic panel, or at least four coatings applied to the acoustic panel.

[0010] In certain examples, the acoustic panel has an NRC value of at least about 0.8. In certain examples, the acoustic panel has a CAC value of at least about 46. In certain examples, the acoustic panel has a light reflectance from about 0.05 to about 0.87. In certain examples, the acoustic panel has a hiding power of about 0.99.

[0011] Also disclosed are surface covering systems.

[0012] In one example, the surface covering system includes a plurality of acoustic panels positioned adjacent to each other and defining a plurality of seams between each acoustic panel of the plurality of acoustic panels, each acoustic panel including a substrate having a first major surface opposite a second major surface, the substrate having an airflow resistance from at least about 300 mks rayls to about 700 mks rayls, or from about 300 mks rayls to about 600 mks rayls. The surface covering system further includes a scrim having a first major scrim surface and a second major scrim surface coupled to the first major surface of the substrate. The scrim includes a fiber mesh and a filler. The scrim has an airflow resistance from about 300 mks rayls to about 700 mks rayls. The surface covering system further includes a seam-filling material applied to each seam of the plurality of seams and a coating applied to the plurality of acoustic panels and the seam-filling material.

[0013] In certain examples, the substrate includes mineral fiber board, fiberglass, jute fiber, wood, or a composite material. In certain examples, the substrate has an airflow resistance from at least about 300 mks rayls to about 700 mks rayls. In certain examples, the filler includes calcium carbonate. In certain examples, the filler includes aluminum trihydrate. In certain examples, the surface covering system further includes an adhesive adhering the first major surface of the substrate to the second major scrim surface of the scrim. In certain examples, the adhesive includes polyvinyl acetate emulsion. In certain examples, the seam-filling material includes gypsum plaster.

[0014] In certain examples, the coating is applied in an amount ranging from about 40 g / ft2 to about 60 g / ft2. In certain examples, the coating includes: a pigment blend including two or more of calcium carbonate, titanium dioxide, calcined diatomaceous earth, and aluminum hydroxide, and a binder. In certain examples, the titanium dioxide is 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 about8 wt. %, based upon the dry weight of the composition. In certain examples, the calcined diatomaceous earth is 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 composition. In certain examples, the aluminum hydroxide is 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 composition. In certain examples, the calcium carbonate is 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 composition. In certain examples, a ratio of pigment-to-binder is from about 5 to about 20. In certain examples, the binder is present in an amount from about 2 wt. % to about 20 wt. %, from about 2 wt. % to about 18 wt. %, or from about 3 wt. % to about 16 wt. %, based on the dry weight of the composition. In certain examples, the binder includes vinyl acrylic polymer. In certain examples, the coating further includes one or more of a defoamer, humectant, clay, wetting and dispersing additive, calcined extender, hydrophobic polymer emulsion, biocide, or precipitated synthetic silicate. In certain examples, the coating is applied in an amount ranging from about 40 g / ft2 to about 60 g / ft2. In certain examples, the surface covering system includes at least two coatings applied to the plurality of acoustic panels and the seam-filling material, at least three coatings applied to the plurality of acoustic panels and the seam-filling material, or at least four coatings applied to the plurality of acoustic panels and the seam-filling material.

[0015] In certain examples, a color difference in L* between the plurality of acoustic panels and the seam-filling material is from about 1 to about 6. In certain examples, the plurality of acoustic panels has an average NRC value of at least about 0.8. In certain examples, the plurality of acoustic panels has an average CAC value of at least about 46. In certain examples, the plurality of acoustic panels has an average light reflectance from about 0.05 to about 0.87.

[0016] Also disclosed are methods for forming acoustic panels.

[0017] In one example, the method includes affixing to a substrate having a first major surface opposite a second major surface, a scrim having a first major scrim surface and a second major scrim surface coupled to the first major surface of the substrate. The scrim includes a fiber meshand a filler. The scrim has an airflow resistance from about 300 mks rayls to about 700 mks rayls. The method further includes applying a coating to the scrim.

[0018] In certain examples, the substrate has an airflow resistance from about 300 mks rayls to about 700 mks rayls. In certain examples, the substrate includes mineral fiber board, fiberglass, jute fiber, wood, or a composite material. In certain examples, the scrim has a thickness from about 0.5 mm to about 0.8 mm. In certain examples, the filler includes calcium carbonate. In certain examples, the filler includes aluminum trihydrate. In certain examples, the affixing includes laminating the scrim to the substrate using an adhesive. In certain examples, the adhesive includes polyvinyl acetate emulsion.

[0019] In certain examples, the coating includes a pigment blend having two or more of: calcium carbonate, titanium dioxide, calcined diatomaceous earth, and aluminum hydroxide. The coating further includes a binder. In certain examples, the titanium dioxide is 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 composition. In certain examples, the calcined diatomaceous earth is 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 composition. In certain examples, the aluminum hydroxide is 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 composition. In certain examples, the calcium carbonate is 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 composition. In certain examples, a ratio of pigment-to-binder is from about 5 to about 20.

[0020] In certain examples, the binder is present in an amount from about 2 wt. % to about 20 wt. %, from about 2 wt. % to about 18 wt. %, or from about 3 wt. % to about 16 wt. %, based on the dry weight of the composition. In certain examples, the binder includes vinyl acrylic polymer. In certain examples, the coating further includes one or more of a defoamer, humectant, clay, wetting and dispersing additive, calcined extender, hydrophobic polymer emulsion, biocide, or precipitated synthetic silicate. In certain examples, the coating is applied in an amount rangingfrom about 40 g / ft2 to about 60 g / ft2. In certain examples, the method includes applying a second coating to the scrim.

[0021] In certain examples, the method includes drying the coated scrim. In certain examples, the drying is performed at a temperature from about 60 °F to about 90 °F. In certain examples, the method includes coupling the acoustic panel to a second acoustic panel with a seam-filling material. In certain examples, the seam-filling material includes gypsum plaster. In certain examples, a color difference in L* between the acoustic panel and the seam-filling material is from about 1 to about 6. In certain examples, the acoustic panel has an average NRC value of at least about 0.8.

[0022] In certain examples, the acoustic panel has an average CAC value of at least about 46. In certain examples, the acoustic panel has an average light reflectance from about 0.05 to about 0.87.DESCRIPTION OF THE DRAWINGS

[0023] Figure 1 is a top perspective view of an acoustic panel according to an example of the present disclosure;

[0024] Figure 2 is a cross-sectional view of an acoustic panel of the present disclosure;

[0025] Figure 3 is a cross-sectional view of an acoustic panel of the present disclosure;

[0026] Figure 4 is a top perspective view of a surface covering system according to an example of the present disclosure;

[0027] Figure 5 is a cross-sectional view of a surface covering system of the present disclosure;

[0028] Figure 6 is a graph illustrating titanium dioxide content impact on opacity; and

[0029] Figure 7 is a graph illustrating burnish testing results.

[0030] 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

[0031] 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 art will readily recognize that the sameprinciples 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.

[0032] 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”.

[0033] 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.

[0034] 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 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 weight of the composition in a dry 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 weight of the composition which includes at least 5 wt. % of solvent.

[0035] 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.

[0036] 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 controls.

[0037] 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.

[0038] 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, the disclosure is not limited to such examples illustrating certain combinations of features that may exist alone or in combination with other features.

[0039] The present disclosure relates to acoustic panels, such as ceiling and wall panels, having filled scrims, or veils. It is understood that the terms scrim and veil may be used interchangeably throughout the disclosure.

[0040] Using filled scrims with acoustic substrate advantageously reduces the color and texture differences between the joint compound, or seam- filling material, and the scrim of the acoustic panel. The disclosure improves the color and texture uniformity over the scrim and jointcompound after finishing, and reduces the total amount of paint needed to hide the joint compound, while maintaining desired acoustic properties.

[0041] Acoustic panels using unfilled scrims exhibit much lower whiteness values (L*~77) than the joint compound (L*~92). Additionally, many coatings, such as finish paint, react differently with unfilled scrim and joint compound, resulting in different texture after paint application. During the spraying process, for example, fiberglass of the unfilled scrim may raise up, requiring additional work to the panel to be squeezed after each coat.

[0042] For example, coupling a filled scrim filled with calcium carbonate, alumina trihydrate, or other additives deposited on the fiber glass of the scrim with an acoustic substrate yields a much higher whiteness than one coupled with unfilled scrim. The filled scrim has fewer open areas and a texture more similar to the joint compound, resulting in a more uniform texture after finishing. There is also less fiber rising up during spraying process with filled scrim.

[0043] Referring to Figure 1 and Figure 2, disclosed is an acoustic panel 100. The acoustic panel 100 includes a substrate 110 having a first major surface 112 opposite a second major surface 114. The substrate 110 may further have a side surface 116 that extends between the first major surface 112 and the second major surface 114. In one example, the substrate has an airflow resistance from about 300 mks rayls to about 700 mks rayls. The substrate 110 is comprised of any material having requisite acoustic properties, such as mineral fiber board, fiberglass, jute fiber, wood, or a composite material.

[0044] The acoustic panel 100 may have a panel thickness tO as measured from the first major surface 112 to the second major surface 114. The panel thickness tO may range from about 12 mm to about 40 mm - including all values and sub-ranges there-bet ween. The acoustic panel 100 may have a length LP ranging from about 30 cm to about 310 cm - including all values and subranges there-the acoustic panel 100 may have a width WP ranging from about 10 cm to about 125 cm - including all values and sub-ranges there-between. The density of the acoustic panel 100 may vary. In certain examples, the density of the acoustic panel 100 is from about 0.3 g / cm3 to about 1.5 g / cm3. In certain examples, the building panel density is from about 0.4 g / cm3 to about 0.9 g / cm3. In further examples, the acoustic panel density is from about 0.5 g / cm3 to about 0.7 g / cm3.

[0045] Still referring to Figure 2, the acoustic panel 100 includes a scrim 120 having a first major scrim surface 122 and a second major scrim surface 124 coupled to the first major surface 112 ofthe substrate 110. Tn one example, the scrim 120 is adhered to the first major surface 112 of the substrate 110 with an adhesive. In one example, the adhesive includes polyvinyl acetate emulsion.

[0046] In one example the scrim 120 is a filled scrim, such as a fiberglass scrim, comprised of a fibrous material or fiber mesh, such as glass fibers, and a filler. It is understood that an unfilled scrim is a scrim comprised of a fibrous, mesh material having a network of fibers that may be unevenly or evenly distributed with spaces defined between the fibers, and that a filled scrim is comprised of a fibrous mesh with a filler material dispersed between the fibers of the fibrous mesh. In one example, the scrim 120 includes from about 20 wt.% to about 60 wt.% glass fibers and from about 40 wt.% to about 80 wt.% of a filler. The filler may be any material dispersed throughout the scrim 120 having a particle size to yield desired color aesthetics and hiding values. In one example, the filler is calcium carbonate. In another example, the filler is aluminum trihydrate. In yet another example, the filler includes both calcium carbonate and aluminum trihydrate.

[0047] In one example, the scrim 120 has an airflow resistance from about 300 mks rayls to about 700 mks rayls. 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.

[0048] Referring to Figure 3, the acoustic panel 110 includes a coating 130 over the first major scrim surface 122. In one example, the coating 130 includes a pigment blend. The pigment blend includes a blend of two or more pigments to yield desired coloring and coating properties. In one example, the pigment blend is selected to yield a deep base coating, having a light reflectance from about 40 to about 70. In another example, the pigment blend is selected to yield an ultradeep base coating, having a light reflectance of about 40.

[0049] In one or more examples, the pigment blend includes calcium carbonate. In one example, the calcium carbonate is present in an amount from about 20 wt. % to about 60 wt. %, based on the dry weight of the composition of the coating. In another example, the calcium carbonate is present in an amount from about 25 wt. % to about 35 wt. %, based on the dry weight of the composition of the coating. In yet another example, the calcium carbonate is present in an amountfrom about 27.0 wt. % to about 32.5 wt. %, based on the dry weight of the composition of the coating.

[0050] In one or more examples, the pigment blend includes titanium dioxide. In one example, the titanium dioxide is 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 composition.

[0051] In one or more examples, the pigment blend includes calcined diatomaceous earth. The calcined diatomaceous earth is 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 composition.

[0052] In one or more examples, the pigment blend includes aluminum hydroxide. The aluminum hydroxide is 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 composition.

[0053] The coating 130 further includes a binder. In one example, a ratio of pigment-to-binder is from about 5 to about 20. In another example, the binder is present in an amount from about 2 wt. % to about 20 wt. %, from about 2 wt. % to about 18 wt. %, or from about 3 wt. % to about 16 wt. %, based on the dry weight of the composition of the coating. In another example, the binder comprises vinyl acrylic polymer.

[0054] In one example, the coating is applied in an amount ranging from about 40 g / ft2 to about 60 g / ft2. In another example, at least two coatings 130 are applied to the acoustic panel 102. In another example, at least three coatings 130 are applied to the acoustic panel 100. In yet another example, at least four coatings are 130 applied to the acoustic panel 100.

[0055] In one or more examples, the coating 130 includes other additives. For example, the coating 130 includes one or more of a defoamer, humectant, clay, wetting and dispersing additive, calcined extender, hydrophobic polymer emulsion, biocide, and / or precipitated synthetic silicate.

[0056] The amount of filler added to the scrim 120 and coating 130 over the scrim 120 is selected to yield desired acoustic properties and aesthetic properties of the acoustic panel 100. In one example, the acoustic panels have appropriate acoustical characteristics for the specified application. Some non-limiting examples of panel materials that may be used include, without limitation, mineral fiber board, fiberglass, metals, polymers, wood, composites, combinationsthereof, or other. Examples of panels have a sufficiently high noise reduction coefficient (NRC) and ceiling attenuation class (CAC) rating to be characterized as an acoustical substrate in contrast to gypsum-based drywall having substantially lower NRCs (e.g. 0.05) characteristic of sound reflecting, not absorbing materials. 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 panel 100 has an NRC value of at least about 0.8. In another example, the acoustic panel 100 has a CAC value of at least about 46. In another example, the acoustic panel 100 has a light reflectance from about 0.05 to about 0.87.

[0057] In certain examples, the disclosed acoustic panel 100 may include one or more fire retardants. In certain examples, the fire retardant is selected from magnesium oxide, sodium silicate, magnesium sulfate, calcium carbonate, ammonium polyphosphate, or a combination thereof. The one or more fire retardants may be present at various amounts or concentrations. In certain examples, the one or more fire retardants are present in an amount from about 50 wt. % to about 70 wt. %. In certain embodiments, magnesium oxide may be present in an amount from about 10 to about 25 wt. %. In another example, sodium silicate may be present in an amount from about 10 to about 25 wt. %. In yet another example, magnesium sulfate may be present in an amount from about 5 to about 10 wt. %. In a further example, calcium carbonate may be present in an amount from about 5 to about 10 wt. %.

[0058] An important characteristic for building materials is the burning performance. ASTM E84-20 provides methods to determine the relative burning behavior of the material. In particular, ASTM E84-20 provides methods for determining the Flame Spread Index (FSI) which characterizes how far flames generated on the test material spread. The FSI is measured from 0 (indicating no flames) to 200 (which indicates spreading flames). ASTM E84-20 also provides methods for determining the Smoke Developed Index (SDI) which states how much smoke is generated. SDI is measured on a scale of 0 to 450, which correlates to no smoke generated (value of 0) to thick, heavy smoke (value of 450). Obtained FSI and SDI values are then compiled and applied to a three-tiered class system: Class A, Class B, and Class C, with Class A rated materials producing minimal to no flames or smoke, while Class C materials producing the most flames or smoke. In order to qualify as an E84 Class A fire rating, a flame spread index (FSI) of 25 or lessand smoke developed index (SDI) at 450 or less must be exhibited. In certain examples, the building panel has a flame spread index (FSI) of about 0 to about 10, as determined by ASTM E84-20. In certain examples, the disclosed acoustic panel has a flame spread index (FSI) of about 10 as determined by ASTM E84-20. In certain examples, the disclosed acoustic panel has a flame spread index (FSI) of about 0 as determined by ASTM E84-20. In certain examples, the disclosed acoustic panel has a smoke developed index (SDI) of about 450, or less, as determined by ASTM E84-20. In certain examples, the disclosed acoustic panel has a smoke developed index (SDI) of about 350, or less, as determined by ASTM E84-20.

[0059] Referring to Figure 4 and Figure 5, disclosed is a surface covering system 200. The surface covering system 200 utilizes a plurality of acoustic panels 205, such as acoustic panel 100, as shown and described herein. In one example, the plurality of acoustic panels 205 are positioned adjacent to each other, defining a plurality of seams 215, such that two panels positioned adjacent to each other define a seam 215' between each other.

[0060] Each acoustic panel 205' of the plurality of acoustic panels 205 includes a substrate 210 having a first major surface 212 opposite a second major surface 214. The substrate 210 has an airflow resistance from about 300 mks rayls to about 700 mks rayls. In one example, substrate 210 comprises mineral fiber board, fiberglass, jute fiber, wood, or a composite material. In another example, the substrate 210 has an airflow resistance from about 300 mks rayls to about 700 mks rayls.

[0061] Still referring to Figure 4 and Figure 5, each acoustic panel 205' of the plurality of acoustic panels 205 includes a scrim 220 having a first major scrim surface 222 and a second major scrim surface 224 coupled to the first major surface 212 of the substrate 210. In one or more examples, the scrim 220 has an airflow resistance from about 300 mks rayls to about 700 mks rayls. The scrim 220 is comprised of a fiber mesh and a filler. In one example, the filler includes calcium carbonate. In another example, the filler includes aluminum trihydrate.

[0062] Still referring to Figure 4 and Figure 5, the surface covering system 200 includes a seamfilling 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 jointwo acoustic panels 205' to each other. In one example, the seam-filling material includes gypsum plaster.

[0063] Still referring to Figure 4 and Figure 5, in one or more examples, the surface covering system 200 includes a coating 230 applied to the plurality of acoustic panels 205 and the seamfilling material over the plurality of seams 215. In one example, the coating is applied in an amount ranging from about 40 g / ft2 to about 60 g / ft2. The coating 230 may be a deep base coating having a light reflectance from about 40 to about 70, or an ultra-deep base coating having a light reflectance of about 40. The coating 230 may be characterized by its hiding power, wherein a perfect hiding power value is 1. In one example, the coating 230 applied demonstrates a hiding power of about 0.99.

[0064] The coating 230 includes a pigment blend and a binder. In one example, the pigment blend includes two or more of calcium carbonate, titanium dioxide, calcined diatomaceous earth, and aluminum hydroxide.

[0065] In one or more examples, the pigment blend includes calcium carbonate. In one example, the calcium carbonate is present in an amount from about 20 wt. % to about 60 wt. %, based on the dry weight of the composition of the coating. In another example, the calcium carbonate is present in an amount from about 25 wt. % to about 35 wt. %, based on the dry weight of the composition of the coating. In yet another example, the calcium carbonate is present in an amount from about 27.0 wt. % to about 32.5 wt. %, based on the dry weight of the composition of the coating.

[0066] In one or more examples, the pigment blend includes titanium dioxide. In one example, the titanium dioxide is 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 composition.

[0067] In one or more examples, the pigment blend includes calcined diatomaceous earth. The calcined diatomaceous earth is 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 composition.

[0068] In one or more examples, the pigment blend includes aluminum hydroxide. The aluminum hydroxide is present in an amount from about 3 wt. % to about 20 wt. %, from about 5 wt. % toabout 18 wt. %, or from about 10 wt. % to about 15 wt. %, based on the dry weight of the composition.

[0069] The coating 230 further includes a binder. In one example, a ratio of pigment-to-binder is from about 5 to about 20. In another example, the binder is present in an amount from about 2 wt. % to about 20 wt. %, from about 2 wt. % to about 18 wt. %, or from about 3 wt. % to about 16 wt. %, based on the dry weight of the composition of the coating. In another example, the binder comprises vinyl acrylic polymer.

[0070] In one or more examples, the coating 230 includes other additives. For example, the coating 230 includes one or more of a defoamer, humectant, clay, wetting and dispersing additive, calcined extender, hydrophobic polymer emulsion, biocide, and / or precipitated synthetic silicate.

[0071] In one example, the coating 230 is applied in an amount ranging from about 40 g / ft2 to about 60 g / ft2. In another example, at least two coatings 230 are applied to the plurality of acoustic panels 205 and the seam-filling material of the surface covering system 200. In another example, at least three coatings 230 are applied to the plurality of acoustic panels 205 and the seam-filling material of the surface covering system 200. In yet another example, at least four coatings 230 are applied to the plurality of acoustic panels 205 and the seam-filling material if the surface covering system 200.

[0072] In one or more examples, the surface covering system 200 includes an adhesive for 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 includes polyvinyl acetate emulsion.

[0073] The surface covering system 200 may be further characterized by a color difference between the seam- filling mater, or joint compound, and the plurality of acoustic panels 205. In one example, a color difference in whiteness, L*, between the plurality of acoustic panels and the seam- filling material is from about 1 to about 6. In another example, the plurality of acoustic panels 205 has an average light reflectance from about 0.05 to about 0.87.

[0074] The surface covering system 200 may be further characterized by the acoustic properties of the plurality of acoustic panels 205. In one example, the plurality of acoustic panels 205 hasan average NRC value of at least about 0.8. In another example, the plurality of acoustic panels 205 has an average CAC value of at least about 46.

[0075] Also disclosed is a method for forming an acoustic panel 100, 205'. The method may be implemented to form acoustic panel 100 as disclosed above and each acoustic panel 205' of the plurality of acoustic panels 205 of the disclosed surface covering system 200.

[0076] In one or more examples, the method includes affixing to a substrate 110 having a first major surface 112 opposite a second major surface 114, a scrim 120 having a first major scrim surface 122 and a second major scrim surface 124 coupled to the first major surface 112 of the substrate 110. In one example, the affixing includes laminating the scrim 120 to the substrate 110 using an adhesive, such as a polyvinyl acetate emulsion adhesive.

[0077] The substrate 110 is characterized by its acoustic properties and airflow. In one example, the substrate 110 has an airflow resistance from about 300 mks rayls to about 700 mks rayls. The substrate 110 is comprised of a material including one or more of mineral fiber board, fiberglass, jute fiber, wood, or a composite material.

[0078] In one example, the scrim 120 includes a fiber mesh and a filler. In one example, the filler includes calcium carbonate. In another example, the filler includes aluminum trihydrate. In yet another example, the filler includes both calcium carbonate and aluminum trihydrate.

[0079] The scrim 120 is characterized by its airflow properties and porosity. In one example, the scrim 120 has an airflow resistance from about 300 mks rayls to about 700 mks rayls. The scrim 120 is further characterized by its dimensions. In one example, the scrim 120 has a thickness t2 from about 0.5 mm to about 0.8 mm.

[0080] The method further includes applying a coating 130 to the scrim 120. The coating may be a deep base paint or an ultra-deep base paint. In one example, the coating includes a pigment blend. The pigment blend includes two or more of calcium carbonate, titanium dioxide, calcined diatomaceous earth, and aluminum hydroxide.

[0081] In one or more examples, the pigment blend includes calcium carbonate. In one example, the calcium carbonate is present in an amount from about 20 wt. % to about 60 wt. %, based on the dry weight of the composition of the coating. In another example, the calcium carbonate is present in an amount from about 25 wt. % to about 35 wt. %, based on the dry weight of the composition of the coating. In yet another example, the calcium carbonate is present in an amountfrom about 27.0 wt. % to about 32.5 wt. %, based on the dry weight of the composition of the coating.

[0082] In one or more examples, the pigment blend includes titanium dioxide. In one example, the titanium dioxide is 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 composition.

[0083] In one or more examples, the pigment blend includes calcined diatomaceous earth. The calcined diatomaceous earth is 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 composition.

[0084] In one or more examples, the pigment blend includes aluminum hydroxide. The aluminum hydroxide is 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 composition.

[0085] The coating 130 further includes a binder. In one example, a ratio of pigment-to-binder is from about 5 to about 20. In another example, the binder is present in an amount from about 2 wt. % to about 20 wt. %, from about 2 wt. % to about 18 wt. %, or from about 3 wt. % to about 16 wt. %, based on the dry weight of the composition of the coating. In another example, the binder comprises vinyl acrylic polymer.

[0086] In one or more examples, the coating 130 includes other additives. For example, the coating 230 includes one or more of a defoamer, humectant, clay, wetting and dispersing additive, calcined extender, hydrophobic polymer emulsion, biocide, and / or precipitated synthetic silicate.

[0087] The coating 130 is applied in an amount ranging from about 40 g / ft2 to about 60 g / ft2. In one example, the method includes applying a second coating 130 to the scrim 120, a third coating 130 to the scrim 120, and / or a fourth coating 130 to the scrim 120.

[0088] The method further includes drying the coating 130 applied to the scrim 120. In one example, the drying is performed at room temperature for a predetermined time period from about 10 minutes to about 24 hours. In another example, the drying is performed for a time period from about 20 minutes to about 60 minutes. In another example, the drying is performed at an elevated temperature for a predetermined time period from about 10 minutes to about 24 hours. In yetanother example, the drying is performed at a temperature from about 60 °F to about 90 °F for a predetermined time period from about 10 minutes to about 24 hours.

[0089] In one or more examples, the method further includes coupling the acoustic panel 100 to a second acoustic panel 100 along a defined seam 215' with a seam-filling material to yield a surface covering system 200. In one example, the seam-filling material comprises gypsum plaster.

[0090] The surface covering system 200 may be characterized by its aesthetic properties, such as color difference between the acoustic panel 100 and the seam-filling material, or joint compound. In one example, a color difference in L* between the acoustic panel and the seam-filling material is from about 1 to about 6. In another example, the acoustic panel 100 has an average light reflectance from about 0.05 to about 0.87.

[0091] The surface covering system 200 may be further characterized by its acoustic properties. In one example, the acoustic panel has an average NRC value of at least about 0.8. In another example, the acoustic panel has an average CAC value of at least about 46.EXAMPLES

[0092] 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. Unless otherwise indicated, all viscosity values are as measured by Brookfield LVT #2 at 10 rpm and 20 °C.

[0093] Experiment 1: Formation of the coating and testing of opacity and burnish testing. Coating compositions were prepared in approximate amounts as described in Table 1.Table 1: Base coating composition.panels with scrim, both filled and unfilled, and over joint compound for testing. Color andlightness were tested on the above-mentioned samples, under conditions as outlined in Table 2 below.Table 2: Color and Gloss Data

[0095] Figures 6 and 7 are graphical representations of the impact of the example composition’s pigment-to-binder ratio and variations of titanium dioxide content. As shown in Figure 6, samples 54A and 57C with the 5:1 and 3:1 pigment-to-binder ratios, respectively, exhibited the lowest Delta 85 gloss and Delta E, showing least color, whiteness, and gloss changes over the coated surfaces having filled scrim. Further, as shown in Figure 7, increasing titanium dioxide yielded increase in amount of colorants needed for achieving desirable opacity of the coatings. A composition having about 1% titanium dioxide was selected for the formulation to provide both good hiding power and tinting ability. Acoustical testing was further conducted and the samples advantageously exhibited an NRC rating of 0.8.

[0096] While the foregoing description and drawings represent exemplary embodiments of the present disclosure, it will be understood that various additions, modifications and substitutions may be made therein without departing from the spirit and scope and range of equivalents of theaccompanying claims. In particular, it will be clear to those skilled in the art that the present invention may be embodied in other forms, structures, arrangements, proportions, sizes, and with other elements, materials, and components, without departing from the spirit or essential characteristics thereof. In addition, numerous variations in the methods / processes described herein may be made within the scope of the present disclosure. One skilled in the art will further appreciate that the embodiments may be used with many modifications of structure, arrangement, proportions, sizes, materials, and components and otherwise, used in the practice of the disclosure, which are particularly adapted to specific environments and operative requirements without departing from the principles described herein. The presently disclosed embodiments are therefore to be considered in all respects as illustrative and not restrictive. The appended claims should be construed broadly, to include other variants and embodiments of the disclosure, which may be made by those skilled in the art without departing from the scope and range of equivalents. In addition, all combinations of any and all of the features described in the disclosure, in any combination, are part of the invention.

Claims

CL IMSWhat Is Claimed Is:

1. An acoustic panel comprising: a substrate having a first major surface opposite a second major surface, the substrate having an airflow resistance from about 300 mks rayls to about 700 mks rayls; a scrim having a first major scrim surface and a second major scrim surface coupled to the first major surface of the substrate, the scrim comprising: a fiber mesh; and a filler; wherein the scrim has an airflow resistance from about 300 mks rayls to about 700 mks rayls.

2. The acoustic panel of claim 1, wherein the substrate comprises mineral fiber board, fiberglass, jute fiber, wood, or a composite material.

3. The acoustic panel of any one of claims 1 or 2, wherein the scrim has a thickness from about 0.5 mm to about 0.8 mm.

4. The acoustic panel of any one of claims 1 to 3, wherein the filler comprises calcium carbonate.

5. The acoustic panel of any one of claims 1 to 4, wherein the filler comprises aluminum trihydrate.

6. The acoustic panel of any one of claims 1 to 5, further comprising an adhesive adhering the first major surface of the substrate to the second major scrim surface of the scrim.

7. The acoustic panel of claim 6, wherein the adhesive comprises polyvinyl acetate emulsion.

8. The acoustic panel of any one of claims 1 to 7, further comprising a coating over the first major scrim surface.

9. The acoustic panel of claim 8, wherein the coating comprises: a pigment blend comprising two or more of: calcium carbonate; titanium dioxide; calcined diatomaceous earth; and aluminum hydroxide; and a binder.

10. The acoustic panel of any one of claims 8 or 9, wherein the titanium dioxide is 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 composition.

11. The acoustic panel of any one of claims 8 to 10, wherein the calcined diatomaceous earth is 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 composition.

12. The acoustic panel of any one of claims 8 to 11 , wherein the aluminum hydroxide is 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 composition.

13. The acoustic panel of any one of claims 8 to 12, wherein the calcium carbonate is 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 composition.

14. The acoustic panel of any one of claims 8 to 13, wherein a ratio of pigment-to-binder is from about 5 to about 20.

15. The acoustic panel of any one of claims 8 to 1 , wherein the binder is present in an amount from about 2 wt. % to about 20 wt. %, from about 2 wt. % to about 18 wt. %, or from about 3 wt. % to about 16 wt. %, based on the dry weight of the composition.

16. The acoustic panel of any one of claims 8 to 15, wherein the binder comprises vinyl acrylic polymer.

17. The acoustic panel of any one of claims 8 to 16, wherein the coating further comprises one or more of a defoamer, humectant, clay, wetting and dispersing additive, calcined extender, hydrophobic polymer emulsion, biocide, or precipitated synthetic silicate.

18. The acoustic panel of any one of claims 8 to 17, wherein the coating is applied in an amount ranging from about 40 g / ft2to about 60 g / ft2.

19. The acoustic panel of any one of claims 8 to 18, comprising at least two coatings applied to the acoustic panel, at least three coatings applied to the acoustic panel, or at least four coatings applied to the acoustic panel.

20. The acoustic panel of any one of claims 1 to 19 having an NRC value of at least about 0.8.

21. The acoustic panel of any one of claims 1 to 20 having a CAC value of at least about 46.

22. The acoustic panel any one of claims 1 to 21 having a light reflectance from about 0.05 to about 0.87.

23. The acoustic panel of any one of claims 8 to 22, wherein the coating demonstrates a hiding power of about 0.99.

24. A surface covering system comprising: a plurality of acoustic panels positioned adjacent to each other and defining a plurality of seams between each acoustic panel of the plurality of acoustic panels, each acoustic panel comprising: a substrate having a first major surface opposite a second major surface, the substrate having an airflow resistance from about 300 mks rayls to about 700 mks rayls; a filled scrim having a first major scrim surface and a second major scrim surface coupled to the first major surface of the substrate; a seam-filling material applied to each seam of the plurality of seams; and a coating applied to the plurality of acoustic panels and the seam-filling material.

25. The surface covering system of claim 24, wherein the substrate comprises mineral fiber board, fiberglass, jute fiber, wood, or a composite material, and wherein the substrate has an airflow resistance from about 300 mks rayls to about 700 mks rayls..

26. The surface covering system of any one of claims 24 or 25, wherein the scrim comprises: a fiber mesh; and a filler, and wherein the scrim has an airflow resistance from about 300 mks rayls to about 700 mks rayls;27. The surface covering system of any one of claims 24 to 26, wherein the filler comprises calcium carbonate.

28. The surface covering system of any one of claims 24 to 27, wherein the filler comprises aluminum trihydrate.

29. The surface covering system of any one of claims 24 to 28, further comprising an adhesive adhering the first major surface of the substrate to the second major scrim surface of the scrim.

30. The surface covering system of claim 29, wherein the adhesive comprises polyvinyl acetate emulsion.

31. The surface covering system of any one of claims 24 to 30, wherein the seam-filling material comprises gypsum plaster.

32. The surface covering system of any one of claims 24 to 31 , wherein the coating is applied in an amount ranging from about 40 g / ft2to about 60 g / ft2.

33. The surface covering system of any one of claims 24 to 32, wherein the coating comprises: a pigment blend comprising two or more of: calcium carbonate; titanium dioxide; calcined diatomaceous earth; and aluminum hydroxide; and a binder.

34. The surface covering system of claim 33, wherein the titanium dioxide is 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 composition.

35. The surface covering system of any one of claims 33 or 34, wherein the calcined diatomaceous earth is 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 composition.

36. The surface covering system of any one of claims 33 to 35, wherein the aluminum hydroxide is 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 composition.

37. The surface covering system of any one of claims 33 to 36, wherein the calcium carbonate is present in an amount from about 20 wt. % to about 60 wt. %, from about 25 wt. % toabout 35 wt. %, or from about 27.0 wt. % to about 32.5 wt. %, based on the dry weight of the composition.

38. The surface covering system of any one of claims 33 to 37, wherein a ratio of pigment-to- binder is from about 5 to about 20.

39. The surface covering system of any one of claims 33 to 38, wherein the binder is present in an amount from about 2 wt. % to about 20 wt. %, from about 2 wt. % to about 18 wt. %, or from about 3 wt. % to about 16 wt. %, based on the dry weight of the composition.

40. The surface covering system of any one of claims 33 to 39, wherein the binder comprises vinyl acrylic polymer.

41. The surface covering system of any one of claims 33 to 40, wherein the coating further comprises one or more of a defoamer, humectant, clay, wetting and dispersing additive, calcined extender, hydrophobic polymer emulsion, biocide, or precipitated synthetic silicate.

42. The surface covering system of any one of claims 24 to 41, wherein the coating is applied in an amount ranging from about 40 g / ft2to about 60 g / ft2.

43. The surface covering system of any one of claims 24 to 42, comprising at least two coatings applied to the plurality of acoustic panels and the seam-filling material, at least three coatings applied to the plurality of acoustic panels and the seam-filling material, or at least four coatings applied to the plurality of acoustic panels and the seam-filling material.

44. The surface covering system of any one of claims 24 to 43, wherein a color difference in L* between the plurality of acoustic panels and the scam- filling material is from about 1 to about 6.

45. The surface covering system of any one of claims 24 to 44, wherein the plurality of acoustic panels has an average NRC value of at least about 0.8.

46. The surface covering system of any one of claims 24 to 45, wherein the plurality of acoustic panels has an average CAC value of at least about 46.

47. The surface covering system of any one of claims 24 to 46, wherein the plurality of acoustic panels has an average light reflectance from about 0.05 to about 0.87.

48. A method for forming an acoustic panel comprising: affixing to a substrate having a first major surface opposite a second major surface, a scrim having a first major scrim surface and a second major scrim surface coupled to the first major surface of the substrate, the scrim comprising: a fiber mesh; and a filler; wherein the scrim has an airflow resistance from about 300 mks rayls to about 700 mks rayls; and applying a coating to the scrim.

49. The method of claim 48, wherein the substrate has an airflow resistance from about 300 mks rayls to about 700 mks rayls.-SO-50. The method of any one of claims 48 or 49, wherein the substrate comprises mineral fiber board, fiberglass, jute fiber, wood, or a composite material.

51. The method of any one of claims 48 to 50, wherein the scrim has a thickness from about 0.5 mm to about 0.8 mm.

52. The method of any one of claims 48 to 51, wherein the filler comprises calcium carbonate.

53. The method of any one of claims 48 to 52, wherein the filler comprises aluminum trihydrate.

54. The method of any one of claims 48 to 53, wherein the affixing comprises laminating the scrim to the substrate using an adhesive.

55. The method of any one of claims 48 to 54, wherein the adhesive comprises polyvinyl acetate emulsion.

56. The method of any one of claims 48 to 55, wherein the coating comprises: a pigment blend comprising two or more of: calcium carbonate; titanium dioxide; calcined diatomaceous earth; and aluminum hydroxide; and a binder.

57. The method of claim 56, wherein the titanium dioxide is 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 composition.

58. The method of any one of claims 56 or 57, wherein the calcined diatomaceous earth is 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 composition.

59. The method of any one of claims 56 to 58, wherein the aluminum hydroxide is 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 composition.

60. The method of any one of claims 56 to 59, wherein the calcium carbonate is 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 composition.

61. The method of any one of claims 56 to 60, wherein a ratio of pigment-to-binder is from about 5 to about 20.

62. The method of any one of claims 56 to 61, wherein the binder is present in an amount from about 2 wt. % to about 20 wt. %, from about 2 wt. % to about 18 wt. %, or from about 3 wt. % to about 16 wt. %, based on the dry weight of the composition.

63. The method of any one of claims 56 to 62, wherein the binder comprises vinyl acrylic polymer.

64. The method of any one of claims 56 to 63, wherein the coating further comprises one or more of a defoamer, humectant, clay, wetting and dispersing additive, calcined extender, hydrophobic polymer emulsion, biocide, or precipitated synthetic silicate.

65. The method of any one of claims 48 to 64, wherein the coating is applied in an amount ranging from about 40 g / ft2to about 60 g / ft2.

66. The method of any one of claims 48 to 65, further comprising applying a second coating to the scrim.

67. The method of any one of claims 48 to 66, further comprising drying the coated scrim.

68. The method of claim 67, wherein the drying is performed at a temperature from about 60 °F to about 90 °F.

69. The method of any one of claims 48 to 68, further comprising coupling the acoustic panel to a second acoustic panel with a seam-filling material.

70. The method of claim 69, wherein the seam-filling material comprises gypsum plaster.

71. The method of any one of claims 69 or 70, wherein a color difference in L* between the acoustic panel and the seam-filling material is from about 1 to about 6.

72. The method of any one of claims 48 to 71, wherein the acoustic panel has an average NRC value of at least about 0.8 and wherein the acoustic panel has an average CAC value of at least about 46.

73. The method of any one of claims 48 to 72, wherein the acoustic panel has an average light reflectance from about 0.05 to about 0.87.

74. The method of any one of claims 48 to 73, wherein the acoustic panel is a ceiling panel or a wall panel.

75. A method for installing a surface covering system comprising: a) securing a first building panel and a second building panel to a support structure, whereby a seam is formed between the first building panel and the second building panel; b) applying a seam-filling material to the seam; c) applying a coating to the first building panel, the second building panel, and the seamfilling material; wherein each of the first building panel and the second building panel comprise a substrate and a filled scrim attached to the substrate.

76. The method according to claim 75, wherein each of the first building panel and the second building panel the comprise a first exposed major surface opposite a second exposed major surface, and the first exposed major surface of the building panel comprises the filled scrim.

77. The method according to claim 76, wherein during step b), the seam-filling material contacts at least a portion of the first major exposed surface of each of the first building panel and the second building panel.

78. The method according to any one of claims 76 to 77, wherein during step c), the coating contacts at least a portion of the first major exposed surface of each of the first building panel and the second building panel.

79. The method according to any one of claims 76 to 78, wherein the filled scrim comprises a fiber mesh; anda filler; wherein the filled scrim has an airflow resistance from about 300 mks rayls to about 700 mks rayls.

80. The method according to claim 79, wherein the filler comprises at least one of calcium carbonate, aluminum trihydrate, and combinations thereof.

81. The method according to any one of claims 76 to 80, wherein the coating comprises: a pigment blend comprising two or more of: calcium carbonate; titanium dioxide; calcined diatomaceous earth; and aluminum hydroxide; and a binder.

82. A surface covering system comprising: a plurality of acoustic panels configured to be positioned adjacent to each other to form a plurality of seams between each of the plurality of acoustic panels, each acoustic panel comprising: a substrate having a first major surface opposite a second major surface, the substrate having an airflow resistance from about 300 mks rayls to about 700 mks rayls; a scrim having a first major scrim surface and a second major scrim surface coupled to the first major surface of the substrate, the scrim comprising: a fiber mesh; and a filler;wherein the scrim has an airflow resistance from about 300 mks rayls to about 700 mks rayls; a seam-filling material configured to be applied to each of the plurality of seams; and a coating configured to be applied to the plurality of acoustic panels and the seam-filling material.

83. The surface covering system of claim 82, wherein the substrate comprises mineral fiber board, fiberglass, jute fiber, wood, or a composite material.

84. The surface covering system of any one of claims 82 or 83, wherein the substrate has an airflow resistance from about 300 mks rayls to about 700 mks rayls.

85. The surface covering system of any one of claims 82 to 84, wherein the filler comprises calcium carbonate.

86. The surface covering system of any one of claims 82 to 85, wherein the filler comprises aluminum trihydrate.

87. The surface covering system of any one of claims 82 to 86, further comprising an adhesive adhering the first major surface of the substrate to the second major scrim surface of the scrim.

88. The surface covering system of claim 87, wherein the adhesive comprises polyvinyl acetate emulsion.

89. The surface covering system of any one of claims 82 to 88, wherein the seam-filling material comprises gypsum plaster.

90. The surface covering system of any one of claims 82 to 89, wherein the coating comprises: a pigment blend comprising two or more of: calcium carbonate; titanium dioxide; calcined diatomaceous earth; and aluminum hydroxide; and a binder.

91. The surface covering system of claim 90, wherein the titanium dioxide is 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.

92. The surface covering system of any one of claims 90 or 91, wherein the calcined diatomaceous earth is 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.

93. The surface covering system of any one of claims 90 to 92, wherein the aluminum hydroxide is 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.

94. The surface covering system of any one of claims 90 to 93, wherein the calcium carbonate is present in an amount from about 20 wt. % to about 60 wt. %, from about 25 wt. % toabout 35 wt. %, or from about 27.0 wt. % to about 32.5 wt. %, based on the dry weight of the coating.

95. The surface covering system of any one of claims 90 to 94, wherein a ratio of pigment-to- binder is from about 5 to about 20.

96. The surface covering system of any one of claims 90 to 95, wherein the binder is present in an amount from about 2 wt. % to about 20 wt. %, from about 2 wt. % to about 18 wt. %, or from about 3 wt. % to about 16 wt. %, based on the dry weight of the coating.

97. The surface covering system of any one of claims 90 to 96, wherein the binder comprises vinyl acrylic polymer.

98. The surface covering system of any one of claims 90 to 97, wherein the coating further comprises one or more of a defoamer, humectant, clay, wetting and dispersing additive, calcined extender, hydrophobic polymer emulsion, biocide, or precipitated synthetic silicate.

99. The surface covering system of any one of claims 82 to 98, wherein the plurality of acoustic panels has an average NRC value of at least about 0.8.

100. The surface covering system of any one of claims 82 to 99, wherein the plurality of acoustic panels has an average CAC value of at least about 46.

101. The surface covering system of any one of claims 82 to 100, wherein the plurality of acoustic panels has an average light reflectance from about 0.05 to about 0.87.

102. The surface covering system of any one of claims 82 to 101 , wherein the plurality of acoustic panels arc ceiling panels or wall panels.

Images