Sag resistant acoustical ceiling panel with a filled latex binder system that enhances strength and durability
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Solution Overview
Problem
Building panels, particularly acoustically pervious ceiling panels, tend to sag in high-humidity environments due to water absorption, and previous attempts to improve sag-resistance have increased costs and airflow resistance.
Innovation Solution
A building panel composition comprising a body made of fibers, a latex binder present in a specific weight percentage, and inorganic particles with a defined average size and weight ratio to the latex binder, which enhances sag-resistance while maintaining airflow and mechanical strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If larger amounts of polymer are added to improve sag-resistance, then sag-resistance is improved, but cost increases and airflow resistance increases
Solution Approach 1:
The patent changes the chemical composition parameters of the binder system by incorporating specific polymers (polyvinyl alcohol, carboxymethyl cellulose, or starch) in controlled amounts (0.1-10% by weight) combined with latex binder. This parameter optimization provides adequate sag-resistance while controlling airflow resistance, as these specific polymers offer better sag-performance per unit weight compared to conventional polymers.
Solution Approach 2:
The patent creates a composite binder system combining multiple components: latex binder (3-15% by weight), specific polymers (0.1-10% by weight), and optional additives. This composite approach synergistically combines the adhesive properties of latex with the sag-resistance properties of the specific polymers, achieving both goals without requiring excessive polymer content that would harm airflow.
2Reliability
If larger amounts of polymer are added to improve sag-resistance, then sag-resistance is improved, but manufacturing cost increases
Solution Approach 1:
The patent optimizes the concentration parameters of the binder components, specifically using 0.1-10% by weight of the specified polymers (PVA, CMC, or starch) combined with 3-15% latex binder. This parameter range achieves effective sag-resistance at lower polymer concentrations than conventional formulations, reducing material costs while maintaining performance.
Solution Approach 2:
The patent employs cost-effective, readily available polymers such as polyvinyl alcohol, carboxymethyl cellulose, and starch, which are generally cheaper than specialized engineering polymers. These materials provide adequate sag-resistance for ceiling panels without requiring expensive additives, thereby reducing manufacturing costs.
3Adaptability or versatility
If the panel absorbs more water in high-humidity environments, then the panel becomes more flexible, but sagging increases
Solution Approach 1:
The patent modifies the chemical composition parameters of the binder system by incorporating hydrophobic or water-resistant polymers (polyvinyl alcohol, carboxymethyl cellulose, or starch) that alter the panel's interaction with moisture. These polymers modify the binder's hygroscopic properties, reducing excessive water absorption while maintaining necessary flexibility, thereby preventing sag in high-humidity environments.
Solution Approach 2:
The patent converts the potential harmful effect of water absorption (which causes sagging) into a beneficial property by using polymers that provide controlled moisture response. The PVA, CMC, or starch polymers create a binder system that maintains flexibility for acoustic performance while resisting excessive water uptake that would lead to sag, effectively transforming the moisture challenge into a design advantage.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution effectively reduces sagging in high-humidity conditions without increasing airflow resistance, thereby maintaining the panel's acoustic perviousness and mechanical strength while reducing material costs.
Implementation Method 1
a latex binder present in an amount ranging from about 3 wt. % to about 10 wt. % based on the total weight of the body
Implementation Method 2
an inorganic particle having an average particle size ranging from about 1 micron to about 13 microns; wherein the inorganic particle and the latex binder are present in a weight ratio ranging from about 1:1 to about 6:1
Data Source
AI summary
Described herein is a building panel comprising a body, the body comprising: a fiber; a latex binder present in an amount ranging from about 3 wt. % to about 10 wt. % based on the total weight of the body; and an inorganic particle having an average particle size ranging from about 1 micron to about 13 microns; wherein the inorganic particle and the binder are present in a weight ratio ranging from about greater than 1:1 to about 6:1.