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 and a plurality of perforations extending from the first major surface to the second major surface of the substrate. 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 substrate includes a material having an airflow resistance of about 300 mks rayls to about 2000 mks rayls. The acoustic panel has an airflow resistance of less than about 300 mks rayls. Also disclosed are surface covering systems and methods for making the same.

Description

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

[0001] This application is a PCT International Application claiming priority to United States Provisional Patent Application No. 63 / 540,517, filed on September 26, 2023, the disclosure of which is incorporated herein by reference in its entirety.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 a plurality of perforations.BACKGROUND

[0003] Building materials, such as planks and panels of surface covering systems, particularly ceiling and wall systems, are designed to optimize acoustic and aesthetic properties while maintaining structural integrity.

[0004] Accordingly, those skilled in the art continue research and development in the field of acoustic panels.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 perforating 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 and a plurality of perforations extending from the first major surface to the second major surface of the substrate, and a scrim having a first major scrim surface and a second major scrim surface coupled to the first major surface of the substrate. The substrate is comprised of a material having an airflow resistance of less than about 300 mks rayls and the acoustic panel has an airflow resistance from at least about 300 mks rayls to about 2000 mks rayls.

[0008] In certain examples, the plurality of perforations are present in a perforation density ranging from about 20 pcrforation / ft2to about 15,000 perforation / ft2. In certain examples, the plurality of perforations have an average diameter ranging from about 50 mils to about 500 mils. In certain examples, the substrate exhibits an NRC value ranging from about 40 to about 95, selectively controlled by the number and size of the perforations. In certain examples, the substrate comprises a metallic, ceramic, or composite material.

[0009] In certain examples, the scrim is comprised of a fibrous material selected from one or more of fiberglass, mineral wool, 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 to about 5000 mks ralys. In certain examples, the scrim comprises a filler material selected from calcium carbonate, aluminum trihydrate, and combinations thereof.

[0010] In certain examples, the acoustic panel 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 comprises polyvinyl acetate emulsion.

[0011] In certain examples, the acoustic panel includes a coating over the first major scrim surface of the scrim. In certain examples, the coating includes a pigment blend a binder present at 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 coating 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 composition. In certain examples, the coating comprises 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 composition. In certain examples, the coating comprises the 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 composition. In certain examples, the coating comprises 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 composition. 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 comprises vinyl acrylic polymer. Tn certain examples, the coating is applied in an amount ranging from about 40 g / ft2to about 60 g / ft2. 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.

[0012] In certain examples, the acoustic panel includes a central portion comprising the plurality of perforations, a beveled portion defined around a perimeter of the central portion, and an edge portion defined around a perimeter of the beveled portion. In certain examples, the edge portion is free from perforations.

[0013] Also disclosed are surface covering systems.

[0014] In one example, the surface covering system includes a plurality of acoustic panels configured to be positioned adjacent to each other to define a plurality of seams between each acoustic panel of the plurality of acoustic panels. Each acoustic panel of the plurality of acoustic panels includes a substrate having a first major surface opposite a second major surface and a plurality of perforations extending from the first major surface to the second major surface of the substrate, the substrate having an airflow resistance of less than about 300 mks rayls. The 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 system further includes a seam-filling material configured to be applied to each seam of the plurality of seams.

[0015] In certain examples, the plurality of perforations are present in a perforation density ranging from about 20 perforation / ft2to about 15,000 perforation / ft2. In certain examples, the plurality of perforations have an average diameter ranging from about 50 mils to about 500 mils. In certain examples, the substrate exhibits an NRC value ranging from about 40 to about 95, selectively controlled by the number and size of the perforations. In certain examples, the substrate includes a metallic, ceramic, or composite material.

[0016] In certain examples, the scrim is comprised of a fibrous material selected from one or more of fiberglass, mineral wool, 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 to about 5000 mks ralys. In certain examples, the scrim includes a filler material selected from calcium carbonate, aluminum trihydrate, and combinations thereof.

[0017] In certain examples, the 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.

[0018] In certain examples, the system further includes a coating configured to be applied to the plurality of acoustic panels and the seam-filling material. In certain examples, the coating includes a pigment blend and a binder present at 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 coating includes 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 composition. In certain examples, the coating 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 composition. In certain examples, the coating includes the 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 composition. In certain examples, the coating 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 composition. 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 is applied in an amount ranging from about 40 g / ft2to about 60 g / ft2. 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.

[0019] In certain examples, each acoustic panel of the plurality of acoustic panels includes a central portion comprising the plurality of perforations, a beveled portion defined around a perimeter of the central portion, and an edge portion defined around a perimeter of the beveled portion. In certain examples, the edge portion is free from perforations.

[0020] In certain examples, the plurality of acoustic panels are ceiling panels or wall panels.

[0021] Also disclosed is a method for manufacturing an acoustic panel.

[0022] In one example, the method includes affixing to a substrate having a first major surface opposite a second major surface and a plurality of perforations extending from the first major surface to the second major surface of the substrate, a scrim having a first major scrim surface and a second major scrim surface coupled to the first major surface of the substrate. The method further includes applying a coating to the first major scrim surface of the scrim.

[0023] In certain examples, the plurality of perforations are present in a perforation density ranging from about 20 perforation / ft2to about 15,000 perforation / ft2. In certain examples, the plurality of perforations have an average diameter ranging from about 50 mils to about 500 mils. In certain examples, the substrate has an airflow resistance of less than about 300 mks rayls. In certain examples, the substrate exhibits an NRC value ranging from about 40 to about 95, selectively controlled by the number and size of the perforations. In certain examples, the substrate includes a metallic, ceramic, or composite material, based upon on the number and size of the perforations.

[0024] In certain examples, the scrim is comprised of a fibrous material selected from one or more of fiberglass, mineral wool, and combinations thereof. In certain examples, scrim has an airflow resistance from about 30 mks ralys to about 200000 mks ralys, preferably from about 30 mks ralys to about 5000 mks ralys. In certain examples, the scrim includes a filler material selected from calcium carbonate, aluminum trihydrate, and combinations thereof.

[0025] In certain examples, the affixing includes laminating the scrim to the substrate using an adhesive. In certain examples, the adhesive includes polyvinyl acetate emulsion.

[0026] In certain examples, the coating includes a pigment blend and a binder present at 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 coating includes 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 composition. In certain examples, the coating 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 composition. In certain examples, the coating includes the 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 composition. Incertain examples, the coating 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 composition.

[0027] 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 is applied in an amount ranging from about 40 g / ft2to about 40 g / ft2. 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

[0028] In certain examples, the method further includes perforating the substrate prior to affixing. In certain examples, the perforating includes drilling, punching, molding, or a combination thereof. In certain examples, the method further includes forming a beveled portion on the substrate to define an edge portion and a central portion of the substrate. In certain examples, the edge portion is free from perforations. In certain examples, the beveled portion is at least about 1 / 16”.

[0029] In certain examples, the method further includes mounting the acoustic panel to a building structure. In certain examples, the method further includes spackling at least a portion of the acoustic panel.DESCRIPTION OF THE DRAWINGS

[0030] Figure 1 is a top perspective view of an acoustic panel according to an example of the present disclosure;

[0031] Figure 2 is a side cross-sectional view of the acoustic panel of Figure 1;

[0032] Figure 3 is a top perspective view of an acoustic panel according to an example of the present disclosure;

[0033] Figure 4 is a side cross-sectional view an acoustic panel;

[0034] Figure 5 is a top perspective view of a surface covering system;

[0035] Figure 6 is a side cross-sectional view of a portion of a surface covering system;

[0036] Figure 7 is a top view of an acoustic panel;

[0037] Figure 8 is a side cross-sectional view of an acoustic panel;

[0038] Figure 9 is a side-cross sectional view of a portion of an acoustic panel;

[0039] Figure 10 is a side cross-sectional view of a portion of an acoustic panel;

[0040] Figure 11 is a top perspective view of a surface covering system; and

[0041] Figure 12 is a side cross- sectional view of a portion of a surface covering system.DETAILED DESCRIPTION

[0042] 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 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.

[0043] 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”.

[0044] 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 - including all values and sub-ranges there-between.

[0045] 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.

[0046] 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.

[0047] 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.

[0048] 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.

[0049] 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.

[0050] The present disclosure relates to acoustic panels, such as ceiling or wall panels. In one aspect, the disclosure utilizes acoustic panels including a substrate having a plurality of perforations. The plurality of perforations are selectively designed to achieve desired acousticproperties. The number and dimensions of the plurality of perforations is adjustable to meet the acoustic, durability, and strength requirements for different substrate materials and sizes. The plurality of perforations allows for the use of non-acoustic materials, meaning those having an airflow resistance of less than about 300 mks rayls, for acoustic panels by creating an acoustic airflow resistance via the plurality of perforations. The plurality of perforations further allows for the use of materials having higher strength as compared to materials typically used for acoustic panels

[0051] Referring to Figure 1, 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 is defined by its airflow resistance. 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 is comprised of a material having an airflow resistance of less than about 300 mks rayls. A substrate 110 exhibiting an airflow resistance of about 100 mks rayls to about 200000 mks ralys, preferably from about 100 mks rayls to about 2000 mks ralys, is characterized as acoustic without departing from the scope of the disclosure.

[0052] The substrate 110 of the acoustic panel 100 includes a side exposed surface. 113 that extends between the first major surface 112 and the second major surface 114. The side exposed surface 113 includes a first side surface 113a opposite a second side surface 113b and a third side surface 113c opposite a fourth side surface 113d. The first and second side surfaces 113a, 113b may be substantially parallel. The third and fourth side surfaces 113c, 113d may be substantially parallel. The first and second side surfaces 113a, 113b may be substantially orthogonal to the third and fourth side surface 113c, 113d. The first side surface 113a may intersect the third side surface 113c and the fourth side surface 113d. The second side surface 113b may intersect the third side surface 113c and the fourth side surface 113d.

[0053] The acoustic panel 100 may have a panel width WP as measured by the distance between the first side surface 113a and the second side surface 113b. The panel width WP may range from about 12 inches to about 48 inches - including all widths and sub-ranges there-between. Thebuilding panel 100 may have a panel length LP as measured by the distance between the third side surface 113c and the fourth side surface 113d. The panel length LP may range from about 12 inches to about 96 inches - including all widths and sub-ranges there-between.

[0054] Referring now to FIGS. 1 and 2, the acoustic panel 100 of the present disclosure may have a panel thickness tO as measured from the first major exposed surface 116 to the second major exposed surface 118. The panel thickness tO 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 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 below.

[0055] The substrate 110 may have a body thickness ti that extends from the first major surface 112 to the second major surface 114. The body thickness ti may range from about 0.25 inch to about 1 inch - including all values and sub-ranges there-between.

[0056] In one or more examples, the substrate 110 includes a plurality of perforations 130. The plurality of perforations 130 extend from the first major surface 112 to the second major surface 114 such that they extend through an entirety of the thickness of the substrate 110. The number of perforations of the plurality of perforations 130 is selectively designed to yield desired material properties. To convert air flow to air flow resistivity, the formulation r=A / Pd is utilized, where a is the area, p is the permeability, and d is the thickness of the substrate. In one example, the acoustic properties of a perforated substrate are characterized by the Transparency Index, as defined by Schultz’s guideline. As outlined, the transparency index, TI, is defined by the following: TI=nd2 / ta2, where n is the number of holes per square inch, d is the perforation diameter (in inches), t is the sheet thickness (in inches), a is the distance between the holes, where a is represented as a=b-d, where b is the on-center hole spacing (in inches).

[0057] For example, the plurality of perforations 130 is determined by the overall surface area and dimensions of the substrate 110, including length, width, and thickness of the substrate 110. In another aspect, the plurality of perforations 130 is determined by the material properties of the substrate 110. For example, a substrate 110 material having lower porosity and less airflow resistance will require less perforations than a material having higher porosity and more airflow.

[0058] In one example, the plurality of perforations 130 are present in a perforation density ranging from about 20 perforation / ft2to about 15,000 perforation / ft2. In another example, theplurality of perforations 130 are present in a perforation density ranging from about 50 perforation / ft2to about 1,000 perforation / ft2.

[0059] The plurality of perforations 130 have predetermined dimensions, such as diameter and shape, needed for the desired material properties. In one example, each perforation 132 of the plurality of perforations 130 has the same dimensions. In another example, the plurality of perforations 130 includes perforations of various dimensions. In one example, the plurality of perforations 130 have an average diameter ranging from about 50 mils to about 500 mils.

[0060] The acoustic 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 surface panel material, such as a wall or ceiling material as a barrier to block airborne sound transmission through the material to / from the plenum above the ceiling. In one example, the substrate 110 exhibits an NRC value ranging from about 40 to about 95, selectively controlled by the number and size of the perforations. In another example, the substrate 110 exhibits a CAC value above 20.

[0061] Referring to Figure 2, the acoustic panel 100 includes a scrim 120 having a first major scrim surface 122 opposite a second major scrim surface 124. In one example, the scrim 120 is coupled to the substrate 110 such that the second major scrim surface 124 is adhered to the first major surface 112 of the substrate 110. The scrim 120 is adhered to the substrate 110 with an adhesive. In one example, the adhesive includes polyvinyl acetate emulsion. The scrim 120 is further characterized by its dimensions, see Figure 4. In one example, the scrim 120 has a thickness t2 from about 0.5 mm to about 0.8 mm.

[0062] The scrim 120 of the acoustic panel 100 is comprised of a fibrous material selected from one or more of fiberglass, mineral wool, and combinations thereof. In one example, the scrim 120 has an airflow resistance from about 300 mks rayls to about 2000 mks rayls. The acoustic panel 100 may include an unfilled scrim or a filled scrim based upon the desired application. In one example, the scrim 120 is a filled scrim having a filler material selected from calcium carbonate, aluminum trihydrate, and combinations thereof. In another example, the scrim 120 is an unfilled scrim.

[0063] Referring to Figure 4, in one or more examples, the acoustic panel 100 includes a coating 140. The coating 140 may be a paint having a pigment blend and a binder. In one example, thecoating has a pigment-to-binder is from about 5 to about 20. In one example, the binder includes vinyl acrylic polymer. In another example, the pigment blend includes two or more of calcium carbonate, titanium dioxide, calcined diatomaceous earth, and aluminum hydroxide.

[0064] In one or more examples, the coating 140 includes 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 composition.

[0065] In one or more examples, the coating 140 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 composition.

[0066] In one or more examples, the coating 140 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 composition.

[0067] In one or more examples, the coating 140 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 composition.

[0068] In one or more examples, the coating 140 includes one or more of a defoamer, humectant, clay, wetting and dispersing additive, calcined extender, hydrophobic polymer emulsion, biocide, or precipitated synthetic silicate.

[0069] Referring to Figure 4, the coating 140 is present at a thickness t3. In one example, the coating 140 thickness h in an amount ranging from about 40 g / ft2to about 60 g / ft2. In another example, the acoustic panel 100 includes more than one coating 140.

[0070] Referring to Figures 7 to 10, disclosed is an acoustic panel 1100. The acoustic panel 1100 includes a substrate 1110 having a first major surface 1112 opposite a second major surface 1114. The substrate 1110 is defined by its airflow resistance. 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 1110 is comprised of a material having an airflow resistance of less than about 300 mks rayls.

[0071] Referring to Figure 7, the acoustic panel 1 100 defines a central portion 1 102, a beveled portion 1104, and an edge portion 1106. The central portion 1102 is substantially centered within the acoustic panel 1100 with the beveled portion 1104 defining a perimeter about the central portion 1102, and the edge portion 1106 defines a perimeter about the beveled portion 1104, also defining a width and length of the acoustic panel 1100 as described below.

[0072] The central portion 1102 has a length Lcas measured by the distance between a first central edge 1102a and a second central edge 1102b. In one example, the length Lcis about 0.10 inches to about 12 inches. The central portion 1102 has a width Wcas measured by the distance between a third central edge 1102c and a fourth central edge 1102d. In one example, the width Wcis about 0.1 inches to about 12 inches. In one non-limiting example, the length Lcis substantially equal to the width Wc.

[0073] The beveled portion 1104 defines a perimeter about the central portion 1102. In one example, the bevel of the beveled portion 1104 is about 1 / 16”. The beveled portion 1104 has a length Lb as measured by the distance between a first beveled edge 1104a and a second beveled edge 1104b. In one example, the length Lb is about 12 inches to about 48 inches. The beveled portion 1104 has a width Wb as measured by the distance between a third beveled edge 1104c and a fourth beveled edge 1104d. In one example, the width Wb is about 12 inches to about 48 inches. In one non-limiting example, the length Lb is substantially equal to the width Wb.

[0074] The edge portion 1106 defines a perimeter about the beveled portion 1104. The edge portion 1106 has a length Le as measured by the distance between a first side 1106a and a second side 1106b. In one example, the length Le is about 12 inches to about 48 inches. The edge portion 1106 has a width Weas measured by the distance between a third side 1106c and a fourth side 1106d. In one example, the width Weis about 0.1 inches to about 3 inches. In one non-limiting example, the length Le is substantially equal to the width We.

[0075] In one or more examples, the substrate 1110 includes a plurality of perforations 1130. In one example, the plurality of perforations 1130 are defined within the central portion 1102 of the acoustic panel 1100. The plurality of perforations 1130 extend from the first major surface 1112 to the second major surface 1114 such that they extend through an entirety of the thickness of the substrate 1110. The number of perforations of the plurality of perforations 1130 is selectively designed to yield desired material properties. For example, the plurality of perforations 1130 is determined by the overall surface area and dimensions of the substrate 1110, including length,width, and thickness of the substrate 1 110. In another aspect, the plurality of perforations 1 130 is determined by the material properties of the substrate 1110. For example, a substrate 1110 material having lower porosity and less airflow resistance will require less perforations than a material having higher porosity and more airflow.

[0076] In one example, the plurality of perforations 1130 are present in a perforation density ranging from about 20 perforation / ft2to about 15,000 perforation / ft2. In another example, the plurality of perforations 1130 are present in a perforation density ranging from about 50 perforation / ft2to about 1,000 perforation / ft2.

[0077] The plurality of perforations 1130 have predetermined dimensions, such as diameter and shape, needed for the desired material properties. In one example, each perforation 1132 of the plurality of perforations 1130 has the same dimensions. In another example, the plurality of perforations 1130 includes perforations of various dimensions. In one example, the plurality of perforations 1130 have an average diameter ranging from about 50 mils to about 500 mils.

[0078] The acoustic panel 1100 and substrate 1110 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 substrate 1110 exhibits an NRC value ranging from about 45 to about 95, selectively controlled by the number and size of the perforations. In another example, the substrate 210 exhibits a CAC value above 20.

[0079] Referring to Figure 10, the acoustic panel 1100 includes a scrim 1120 having a first major scrim surface 1122 opposite a second major scrim surface 1124. In one example, the scrim 1120 is coupled to the substrate 1110 such that the second major scrim surface 1124 is adhered to the first major surface 1112 of the substrate 1110. The scrim 1120 is adhered to the substrate 1110 with an adhesive. In one example, the adhesive includes polyvinyl acetate emulsion.

[0080] The scrim 1120 of the acoustic panel 1100 is comprised of a fibrous material selected from one or more of fiberglass, mineral wool, and combinations thereof. In one example, the scrim 1120 has an airflow resistance from about 300 inks rayls to about 2000 mks rayls. The acoustic panel 1100 may include an unfilled scrim or a filled scrim based upon the desired application. In one example, the scrim 1120 is a filled scrim having a filler material selected from calcium carbonate,aluminum trihydrate, and combinations thereof. Tn another example, the scrim 1120 is an unfilled scrim.

[0081] Still referring to Figure 10, in one or more examples, the acoustic panel 1100 includes a coating 1140. The coating 1140 may be a paint having a pigment blend and a binder. In one example, the coating has a pigment-to-binder is from about 5 to about 20. In one example, the binder includes vinyl acrylic polymer. In another example, the pigment blend includes two or more of calcium carbonate, titanium dioxide, calcined diatomaceous earth, and aluminum hydroxide.

[0082] In one or more examples, the coating 1140 includes 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 composition.

[0083] In one or more examples, the coating 1140 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 composition.

[0084] In one or more examples, the coating 1140 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 composition.

[0085] In one or more examples, the coating 1140 includes calcium carbonate present in an amount from about 20 wt. % to about 60 wt. %, based on the dry weight of the composition. In another example, the coating 1140 includes calcium carbonate present in an amount from about 25 wt. % to about 35 wt. %, based on the dry weight of the composition. In yet another example, the coating 1140 includes calcium carbonate present in an amount from about 27.0 wt. % to about 32.5 wt. %, based on the dry weight of the composition.

[0086] In one or more examples, the coating 1140 includes one or more of a defoamer, humectant, clay, wetting and dispersing additive, calcined extender, hydrophobic polymer emulsion, biocide, or precipitated synthetic silicate.

[0087] Referring to Figures 5 and 6, also disclosed is a surface covering system 200. The surface covering system 200 includes a plurality of acoustic panels 202 as disclosed herein. The plurality of acoustic panels 202 are configured to be positioned adjacent each other so as to define a plurality of seams 215 between each acoustic panel 202' of the plurality of acoustic panels 202.

[0088] In one example, each acoustic panel 202' of the plurality of acoustic panels 202 includes a substrate 210 having a first major surface 212 opposite a second major surface 214. The substrate210 is defined by its airflow resistance. 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 210 is comprised of a material having an airflow resistance of less than about 300 mks rayls.

[0089] Still referring to Figures 5 and 6, each acoustic panel 202' of the plurality of acoustic panels 202 may have a panel thickness t4 as measured from the first major exposed surface 216 to the second major exposed surface 218. The panel thickness t4 may range from about 0.25 inch to about 1.0 inch - including all values and sub-ranges there-bet ween. 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 240 as described below.

[0090] The substrate 210 may have a body thickness ts that extends from the first major surface 112 to the second major surface 114. The body thickness ts may range from about 0.25 inch to about 1 inch - including all values and sub-ranges there-between.

[0091] In one or more examples, the substrate 210 includes a plurality of perforations 230. The plurality of perforations 230 extend from the first major surface 212 to the second major surface 214 such that they extend through an entirety of the thickness of the substrate 210. The number of perforations of the plurality of perforations 230 is selectively designed to yield desired material properties. For example, the plurality of perforations 230 is determined by the overall surface area and dimensions of the substrate 210, including length, width, and thickness of the substrate 210. In another aspect, the plurality of perforations 230 is determined by the material properties of the substrate 210. For example, a substrate 210 material having lower porosity and less airflow resistance will require less perforations than a material having higher porosity and more airflow.

[0092] In one example, the plurality of perforations 230 are present in a perforation density ranging from about 20 perforation / ft2to about 15,000 perforation / ft2- including all values and sub-ranges there-between. In another example, the plurality of perforations 230 are present in a perforation density ranging from about 50 perforation / ft2to about 1,000 perforation / ft2- including all values and sub-ranges there-between.

[0093] The plurality of perforations 230 have predetermined dimensions, such as diameter and shape, needed for the desired material properties. In one example, each perforation 132 of the plurality of perforations 230 has the same dimensions. In another example, the plurality of perforations 230 includes perforations of various dimensions. In one example, the plurality of perforations 230 have an average diameter ranging from about 50 mils to about 500 mils- including all values and sub-ranges there-between.

[0094] Each acoustic panel 202' of the system 200 and each substrate 210 is further characterized by their acoustic properties. In one example, the substrate 210 exhibits an NRC value ranging from about 45 to about 95, selectively controlled by the number and size of the perforations. In another example, the substrate 210 exhibits a CAC value above 20.

[0095] Referring to Figure 2, each acoustic panel 202' of the system 200 includes a scrim 220 having a first major scrim surface 222 opposite a second major scrim surface 224. In one example, the scrim 220 is coupled to the substrate 210 such that the second major scrim surface 224 is adhered to the first major surface 212 of the substrate 210. The scrim 220 is adhered to the substrate 210 with an adhesive. In one example, the adhesive includes polyvinyl acetate emulsion.

[0096] The scrim 220 of each acoustic panel 202' of the system 200 is comprised of a fibrous material selected from one or more of fiberglass, mineral wool, and combinations thereof. In one example, the scrim 220 has an airflow resistance from about 300 mks rayls to about 2000 mks rayls - including all values and sub-ranges there-between. Each acoustic panel 202' of the system 200 may include an unfilled scrim or a filled scrim based upon the desired application. In one example, the scrim 220 is a filled scrim having a filler material selected from calcium carbonate, aluminum trihydrate, and combinations thereof. In another example, the scrim 220 is an unfilled scrim.

[0097] 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 join two acoustic panels 205' to each other. In one example, the seam-filling material includes gypsum plaster.

[0098] Referring to Figure 6, in one or more examples, the surface covering system 200 includes a coating 240 configured to be applied to the plurality of acoustic panels 202 and the seam-filling material over the plurality of seams 215. In one example, each acoustic panel 202' of the system200 includes coating 240. In one example, the coating 240 is applied at a thickness t6 in an amount ranging from about 40 g / ft2to about 60 g / ft2- including all values and sub-ranges there -between. The coating 240 may be a white coating, 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 240 may be characterized by its hiding power, wherein a perfect hiding power value is 1. In one example, the coating 240 configured to be applied demonstrates a hiding power of about 0.99.

[0099] In one or more examples, at least two coatings 240 are configured to be applied to the plurality of acoustic panels 202 and the seam- filling material of plurality of seams 215 of the surface covering system 200. In another example, at least three coatings 240 are configured to be applied to the plurality of acoustic panels 202 and the seam-filling material of the surface covering system 200. In yet another example, at least four coatings 240 arc configured to be applied to the plurality of acoustic panels 202 and the seam-filling material if the surface covering system 200.

[0100] The coating 240 may be a paint having a pigment blend and a binder. In one example, the coating has a pigment-to-binder is from about 5 to about 20. In one example, the binder includes vinyl acrylic polymer. In another example, the pigment blend includes two or more of calcium carbonate, titanium dioxide, calcined diatomaceous earth, and aluminum hydroxide.

[0101] In one or more examples, the coating 240 includes 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 composition.

[0102] In one or more examples, the coating 240 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 composition.

[0103] In one or more examples, the coating 240 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 composition.

[0104] In one or more examples, the coating 240 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 composition.

[0105] In one or more examples, the coating 240 includes one or more of a defoamer, humectant, clay, wetting and dispersing additive, calcined extender, hydrophobic polymer emulsion, biocide, or precipitated synthetic silicate.

[0106] Referring to Figures 1 1 to 12, also disclosed is a surface covering system 1200. The surface covering system 1200 includes a plurality of acoustic panels 1202 as disclosed herein. The plurality of acoustic panels 1202 are configured to be positioned adjacent each other so as to define a plurality of seams 1215 between each acoustic panel 1202' of the plurality of acoustic panels 1202.

[0107] In one example, each acoustic panel 1202' of the plurality of acoustic panels 1202 includes a substrate 1210 having a first major surface 1212 opposite a second major surface 1214. The substrate 1210 is defined by its airflow resistance. 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 1210 is comprised of a material having an airflow resistance of less than about 300 mks rayls.

[0108] Referring now to Figures 11 and 12, each acoustic panel 1202' of the plurality of acoustic panels 1202 may have a panel thickness U as measured from the first major exposed surface 1216 to the second major exposed surface 1218. The panel thickness U may range from about 0.25 inch to about 1.0 inch - including all values and sub-ranges there-bet ween. The first major exposed surface 216 may be the same surface as the first major surface 1212 or may be defined by a scrim 1220 or coating 1240 as described below.

[0109] The substrate 1210 may have a body thickness t5 that extends from the first major surface 1112 to the second major surface 1214. The body thickness t5 may range from about 0.25 inch to about 1 inch - including all values and sub-ranges there-bet ween.

[0110] In one or more examples, the substrate 1210 includes a plurality of perforations 1230. The plurality of perforations 1230 extend from the first major surface 1212 to the second major surface 214 such that they extend through an entirety of the thickness of the substrate 1210. The number of perforations of the plurality of perforations 1230 is selectively designed to yield desired material properties. For example, the plurality of perforations 1230 is determined by the overall surface area and dimensions of the substrate 1210, including length, width, and thickness of the substrate 1210. In another aspect, the plurality of perforations 1230 is determined by the material properties of the substrate 1210. For example, a substrate 1210 material having lower porosity and lessairflow resistance will require less perforations than a material having higher porosity and more airflow.

[0111] In one example, the plurality of perforations 1230 arc present in a perforation density ranging from about 20 perforation / ft2to about 15,000 perforation / ft2- including all values and sub-ranges there-between. In another example, the plurality of perforations 1230 are present in a perforation density ranging from about 50 perforation / ft2to about 1,000 perforation / ft2- including all values and sub-ranges there-between.

[0112] The plurality of perforations 1230 have predetermined dimensions, such as diameter and shape, needed for the desired material properties. In one example, each perforation 132 of the plurality of perforations 1230 has the same dimensions. In another example, the plurality of perforations 1230 includes perforations of various dimensions. In one example, the plurality of perforations 1230 have an average diameter ranging from about 50 mils to about 500 mils- including all values and sub-ranges there-between.

[0113] Each acoustic panel 1202' of the system 1200 and each substrate 1210 is further characterized by their acoustic properties. In one example, the substrate 1210 exhibits an NRC value ranging from about 45 to about 95, selectively controlled by the number and size of the perforations. In another example, the substrate 210 exhibits a CAC value above 20.

[0114] Referring to Figure 2, each acoustic panel 1202' of the system 1200 includes a scrim 1220 having a first major scrim surface 1222 opposite a second major scrim surface 1224. In one example, the scrim 1220 is coupled to the substrate 1210 such that the second major scrim surface 224 is adhered to the first major surface 1212 of the substrate 1210. The scrim 1220 is adhered to the substrate 1210 with an adhesive. In one example, the adhesive includes polyvinyl acetate emulsion.

[0115] The scrim 1220 of each acoustic panel 1202' of the system 1200 is comprised of a fibrous material selected from one or more of fiberglass, mineral wool, and combinations thereof. In one example, the scrim 1220 has an airflow resistance from about 300 mks rayls to about 2000 mks rayls - including all values and sub-ranges there-between. Each acoustic panel 1202' of the system 1200 may include an unfilled scrim or a filled scrim based upon the desired application. In one example, the scrim 1220 is a filled scrim having a filler material selected from calcium carbonate, aluminum trihydrate, and combinations thereof. In another example, the scrim 1220 is an unfilled scrim.

[0116] Still referring to Figure 4 and Figure 5, the surface covering system 1200 includes a seamfilling material. The scam-filling material, or joint compound, is configured to be applied to each seam 1215' of the plurality of seams 1215. The seam-filling material is configured to couple or join two acoustic panels 205' to each other. In one example, the seam-filling material includes gypsum plaster.

[0117] Referring to Figure 6, in one or more examples, the surface covering system 1200 includes a coating 1240 configured to be applied to the plurality of acoustic panels 1202 and the seamfilling material over the plurality of seams 1215. In one example, each acoustic panel 1202' of the system 1200 includes coating 1240. In one example, the coating 1240 is applied at a thickness t6 in an amount ranging from about 40 g / ft2to about 60 g / ft2- including all values and sub-ranges there-between. The coating 1240 may be a white coating, 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 1240 may be characterized by its hiding power, wherein a perfect hiding power value is 1. In one example, the coating 1240 configured to be applied demonstrates a hiding power of about 0.99.

[0118] In one or more examples, at least two coatings 1240 are configured to be applied to the plurality of acoustic panels 1202 and the seam-filling material of plurality of seams 1215 of the surface covering system 1200. In another example, at least three coatings 1240 are configured to be applied to the plurality of acoustic panels 1202 and the seam-filling material of the surface covering system 1200. In yet another example, at least four coatings 1240 are configured to be applied to the plurality of acoustic panels 1202 and the seam-filling material if the surface covering system 1200.

[0119] The coating 1240 may be a paint having a pigment blend and a binder. In one example, the coating has a pigment-to-binder is from about 5 to about 20. In one example, the binder includes vinyl acrylic polymer. In another example, the pigment blend includes two or more of calcium carbonate, titanium dioxide, calcined diatomaceous earth, and aluminum hydroxide.

[0120] In one or more examples, the coating 1240 includes 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 composition.

[0121] In one or more examples, the coating 1240 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 composition.

[0122] In one or more examples, the coating 1240 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 composition.

[0123] In one or more examples, the coating 1240 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 composition.

[0124] In one or more examples, the coating 1240 includes one or more of a defoamer, humectant, clay, wetting and dispersing additive, calcined extender, hydrophobic polymer emulsion, biocide, or precipitated synthetic silicate.

[0125] Each acoustic panel 1202' of the plurality of acoustic panels 1202 defines a central portion 1204, a beveled portion 1206, and an edge portion 1208. The central portion 1204 is substantially centered within the acoustic panel 1202' with the beveled portion 1206 defining a perimeter about the central portion 1204, and the edge portion 1208 defines a perimeter about the beveled portion 1206 , also defining a width and length of the acoustic panel 1100 as described below.

[0126] The central portion 1204 has a length Lcas measured by the distance between a first central edge 1204a and a second central edge 1204b. In one example, the length Lcis about 0.10 inches to about 1 inches. The central portion 1204 has a width Wcas measured by the distance between a third central edge 1204c and a fourth central edge 1204d. In one example, the width Wcis about 12 inches to about 48 inches. In one non-limiting example, the length Lcis substantially equal to the width Wc.

[0127] The beveled portion 1206 defines a perimeter about the central portion 1204. In one example, the bevel of the beveled portion 1206 is about 1 / 16”. The beveled portion 1206 has a length Lb as measured by the distance between a first beveled edge 1104a and a second beveled edge 1104b. In one example, the length Lb is about 122 inches to about 48 inches. The beveled portion 1206 has a width Wb as measured by the distance between a third beveled edge 1104c and a fourth beveled edge 1104d. In one example, the width Wb is about 12 inches to about 48 inches. In one non-limiting example, the length Lb is substantially equal to the width Wb.

[0128] The edge portion 1208 defines a perimeter about the beveled portion 1206. The edge portion 1208 has a length Leas measured by the distance between a first side 1208a and a second side 1208b. In one example, the length Leis about 12 inches to about 48 inches. The edge portion 1208 has a width Weas measured by the distance between a third side 1208c and a fourth side 1208d. In one example, the width We is about 0.1 inches to about 3 inches. In one non-limiting example, the length Le is substantially equal to the width We.

[0129] Also disclosed is a method for manufacturing an acoustic panel 100 as described herein. In one example, the acoustic panel 100 is a ceiling panel. In another example, the acoustic panel 100 is a wall panel. The method may be implemented for manufacturing any acoustic panel 100, 200 and plurality of acoustic panels 202, 1202 as shown and described herein.

[0130] In one example, the method includes affixing to a substrate 110 having a first major surface 112 opposite a second major surface 114 and a plurality of perforations 130 extending from the first major surface 112 to the second major surface 114 of the substrate 110 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 substratel lO.

[0131] 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 2000 mks rayls. The scrim 120 is further characterized by its dimensions. In one example, the scrim 120 has a thickness t from about 0.5 mm to about 0.8 mm.

[0132] In one or more examples, the affixing includes laminating the scrim 120 to the substrate 110 using an adhesive, such as a polyvinyl acetate emulsion adhesive.

[0133] The method further includes applying a coating 140 to the first major scrim surface 122 of the scrim 120. The coating 140 may be a white paint, 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.

[0134] 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.

[0135] 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.

[0136] 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.

[0137] 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.

[0138] 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.

[0139] 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.

[0140] The coating 130 is applied in an amount ranging from about 40 g / ft2to 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.

[0141] In one or more examples, the method includes perforating the substrate 110 prior to affixing. The perl' orating may include forming the substrate 110 with perforating by molding perforations into the substrate 110. In another example, the perforating includes mechanically forming the perforations by removing material from the substrate 110, such as through drilling perforations into the substrate 110 or punching perforations into the substrate 110.

[0142] In one or more examples, the method includes forming a beveled portion on the substrate 110, 210 to define an edge portion and a central portion of the substrate 110, 210. In on example, the edge portion is continuous such that it is free from perforations. In another example, the beveled portion is at least about 1 / 16”.

[0143] In one or more examples, the method includes mounting the acoustic panel 100 to a building structure, such as a ceiling structure or a wall structure. The building structure may include a frame for mounting or other panels for mounting with the acoustic panel 100. In one or more examples, the method further includes spackling at least a portion of the acoustic panel 100.

[0144] 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 the accompanying 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 1st1. An acoustic panel comprising: a substrate having a first major surface opposite a second major surface and a plurality of perforations extending from the first major surface to the second major surface of the substrate; and a scrim having a first major scrim surface and a second major scrim surface coupled to the first major surface of the substrate; wherein the substrate is comprised of a material having an airflow resistance of less than about 300 mks rayls; and wherein the acoustic panel has an airflow resistance from at least about 300 mks rayls to about 2000 mks rayls.

2. The acoustic panel of claim 1 , wherein the plurality of perforations are present in a perforation density ranging from about 20 perforation / ft2to about 15,000 perforation / ft2.

3. The acoustic panel of and one of claims 1 or 2, wherein the plurality of perforations have an average diameter ranging from about 50 mils to about 500 mils.

4. The acoustic panel of any one of claims 1 to 3, wherein the substrate exhibits an NRC value ranging from about 45 to about 90.

5. The acoustic panel of any one of claims 1 to 4, wherein the substrate comprises a metallic, ceramic, or composite material.

6. The acoustic panel of any one of claims 1 to 5, wherein the scrim is comprised of a fibrous material selected from one or more of fiberglass, mineral wool, and combinations thereof.

7. The acoustic panel of any one of claims 1 to 6, wherein the scrim has an airflow resistance from about 30 mks ralys to about 200000 mks ralys, preferably from about 30 mks ralys to about 5000 mks ralys.

8. The acoustic panel of any one of claims 1 to 7, wherein the scrim comprises a filler material selected from calcium carbonate, aluminum trihydrate, and combinations thereof.

9. The acoustic panel of any one of claims 1 to 8, further comprising an adhesive adhering the first major surface of the substrate to the second major scrim surface of the scrim.

10. The acoustic panel of claim 9, wherein the adhesive comprises polyvinyl acetate emulsion.

11. The acoustic panel of any one of claims 1 to 10, further comprising a coating over the first major scrim surface of the scrim.

12. The acoustic panel of claim 11, wherein the coating comprises: a pigment blend; and a binder.- l-13. The acoustic panel of any one of claims 11 or 12, wherein a ratio of pigment-to-binder is from about 5 to about 20.

14. The acoustic panel of any one of claims 11 to 13, wherein the pigment blend comprises two or more of calcium carbonate, titanium dioxide, calcined diatomaceous earth, and aluminum hydroxide.

15. The acoustic panel of any one of claims 11 to 14, wherein the coating 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 composition.

16. The acoustic panel of any one of claims 11 to 15, wherein the coating comprises 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 composition.

17. The acoustic panel of any one of claims 11 to 16, wherein the coating comprises the 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 composition.

18. The acoustic panel of any one of claims 11 to 17, wherein the coating comprises 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 composition.

19. The acoustic panel of any one of claims 1 1 to 18, 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 composition20. The acoustic panel of claim 19, wherein the binder comprises vinyl acrylic polymer.

21. The acoustic panel of any one of claims 11 to 20, wherein the coating is applied in an amount ranging from about 40 g / ft2to about 60 g / ft2.

22. The acoustic panel of any one of claims 11 to 21, 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 silicate23. The acoustic panel of any one of claims 1 to 22, further comprising: a central portion comprising the plurality of perforations; a beveled portion defined around a perimeter of the central portion; and an edge portion defined around a perimeter of the beveled portion.

24. The acoustic panel of any one of claims 1 to 23, wherein the acoustic panel is a ceiling panel or a wall panel.

25. A surface covering system comprising:a plurality of acoustic panels configured to be positioned adjacent to each other to define a plurality of scams between each acoustic panel of the plurality of acoustic panels, each acoustic panel of the plurality of acoustic panels comprising: a substrate having a first major surface opposite a second major surface and a plurality of perforations extending from the first major surface to the second major surface of the substrate, the substrate having an airflow resistance of less than about 300 mks rayls; and a scrim having a first major scrim surface and a second major scrim surface coupled to the first major surface of the substrate; and a seam-filling material configured to be applied to each seam of the plurality of seams.

26. The surface covering system of claim 25, wherein the plurality of perforations are present in a perforation density ranging from about 20 perforation / ft2to about 15,000 perforation / ft2.

27. The surface covering system of any one of claims 25 or 26, wherein the plurality of perforations have an average diameter ranging from about 50 mils to about 500 mils.

28. The surface covering system of any one of claims 25 to 27, wherein the substrate exhibits an NRC value ranging from about 45 to about 90.

29. The surface covering system of any one of claims 25 to 28, wherein the substrate comprises a metallic, ceramic, or composite material.

30. The surface covering system of any one of claims 25 to 29, wherein the scrim is comprised of a fibrous material selected from one or more of fiberglass, mineral wool, and combinations thereof.

31. The surface covering system of any one of claims 25 to 30, wherein 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.

32. The surface covering system of any one of claims 25 to 31, wherein the scrim comprises a filler material selected from calcium carbonate, aluminum trihydrate, and combinations thereof.

33. The surface covering system of any one of claims 25 to 32, further comprising an adhesive adhering the first major surface of the substrate to the second major scrim surface of the scrim.

34. The surface covering system of claim 33, wherein the adhesive comprises polyvinyl acetate emulsion.

35. The surface covering system of any one of claims 25 to 32, further comprising a coating configured to be applied to the plurality of acoustic panels and the seam-filling material.

36. The surface covering system of claim 35, wherein the coating comprises: a pigment blend; and a binder.

37. The surface covering system of claim 36, wherein a ratio of pigment-to-binder is from about 5 to about 20.

38. The surface covering system of any one of claims 36 or 37, wherein the pigment blend comprises two or more of calcium carbonate, titanium dioxide, calcined diatomaceous earth, and aluminum hydroxide.

39. The surface covering system of any one of claims 36 to 38, wherein the coating 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 composition.

40. The surface covering system of any one of claims 36 to 39, wherein the coating comprises 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 composition.

41. The surface covering system of any one of claims 36 to 40, wherein the coating comprises the 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 composition.

42. The surface covering system of any one of claims 36 to 41, wherein the coating comprises 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 composition.

43. The surface covering system of any one of claims 36 to 42, 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 composition44. The surface covering system of any one of claims 36 to 37, wherein the binder comprises vinyl acrylic polymer.

45. The surface covering system of any one of claims 35 to 44, wherein the coating is applied in an amount ranging from about 40 g / ft2to about 60 g / ft2.

46. The surface covering system of any one of claims 35 to 46, 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 silicate47. The surface covering system of any one of claims 25 to 46, wherein each acoustic panel of the plurality of acoustic panels comprises: a central portion comprising the plurality of perforations; a beveled portion defined around a perimeter of the central portion; and an edge portion defined around a perimeter of the beveled portion.

48. The surface covering system any one of claims 25 to 47, wherein each acoustic panel of the plurality of acoustic panels is a ceiling panel or a wall panel.

49. A method for manufacturing an acoustic panel comprising: affixing to a substrate having a first major surface opposite a second major surface and a plurality of perforations extending from the first major surface to the second major surface of the substrate, a scrim having a first major scrim surface and a second major scrim surface coupled to the first major surface of the substrate.

50. The method of claim 49, wherein the plurality of perforations are present in a perforation density ranging from about 20 perforation / ft2to about 15,000 perforation / ft2.

51. The method of any one of claims 49 or 50, wherein the plurality of perforations have an average diameter ranging from about 50 mils to about 500 mils.

52. The method of any one of claims 49 to 51, wherein the substrate has an airflow resistance of less than about 300 mks rayls.

53. The method of any one of claims 49 to 55, wherein the substrate exhibits an NRC value ranging from about 45 to about 90.

54. The method of any one of claims 49 to 53, wherein the substrate comprises a metallic, ceramic, or composite material.

55. The method of any one of claims 49 to 54, wherein the scrim is comprised of a fibrous material selected from one or more of fiberglass, mineral wool, and combinations thereof.

56. The method of any one of claims 49 to 55, wherein the scrim has an airflow resistance from about 30 mks ralys to about 200000 mks ralys, preferably from about 30 mks ralys to about 5000 mks ralys.

57. The method of any one of claims 49 to 56, wherein the scrim comprises a filler material selected from calcium carbonate, aluminum trihydrate, and combinations thereof.

58. The method of any one of claims 49 to 57, wherein the affixing comprises laminating the scrim to the substrate using an adhesive.

59. The method of claim 58, wherein the adhesive comprises polyvinyl acetate emulsion.

60. The method of any one of claims 49 to 59, further comprising: applying a coating to the first major scrim surface of the scrim, wherein the coating comprises: a pigment blend; and a binder.

61. The method of claim 60, wherein a ratio of pigment-to-binder is from about 5 to about 20.

62. The method of any one of claims 60 or 61, wherein the pigment blend comprises two or more of calcium carbonate, titanium dioxide, calcined diatomaceous earth, and aluminum hydroxide.

62. The method of any one of claims 60 to 62, wherein the coating 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 composition.

64. The method of any one of claims 60 to 63, wherein the coating comprises 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 composition.

65. The method of any one of claims 60 to 64, wherein the coating comprises the 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 composition.

66. The method of any one of claims 60 to 65, wherein the coating comprises 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 composition.

67. The method of any one of claims 60 to 66, 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 composition68. The method of claim 67, wherein the binder comprises vinyl acrylic polymer.

69. The method of any one of claims 59 to 68, wherein the coating is applied in an amount ranging from about 40 g / ft2to about 40 g / ft2.

70. The method of any one of claims 59 to 68, 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 silicate71. The method of any one of claims 49 to 70, further comprising perforating the substrate prior to affixing.

72. The method of any one of claims 49 to 71, wherein the perforating comprises drilling, punching, molding, or a combination thereof.

73. The method of any one of claims 49 to 72, further comprising forming a beveled portion on the substrate to define an edge portion and a central portion of the substrate.

74. The method of any one of claims 49 to 73, wherein the edge portion is free from perforations.

75. The method of any one of claims 73 or 74, wherein the beveled portion is at least about 1 / 16”.

76. The method of any one of claims 49 to 75, further comprising mounting the acoustic panel to a building structure.

77. The method of any one of claims 49 to 76, further comprising spackling at least a portion of the acoustic panel.

78. The method of any one of claims 49 to 76, wherein the acoustic panel is a ceiling panel.

79. The method of any one of claims 49 to 77, wherein the acoustic panel is a wall panel.

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