Scrim Attachment System for Ceiling Panels
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Solution Overview
Problem
Ceiling panels face challenges in achieving desirable airflow while maintaining adequate adhesive bonding between layers, as traditional adhesives degrade airflow and increase flammability risks.
Innovation Solution
A ceiling panel design using a gel-forming film-forming polymer adhesive, applied in a specific range to couple an acoustical substrate with a porous scrim, allowing for continuous application that forms a discrete pattern after drying, enhancing airflow and reducing the need for flame retardants.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional adhesive is used to bond substrate and scrim, then adhesive bonding strength is improved, but airflow through the ceiling panel is degraded
Solution Approach 1:
The patent changes the physical and chemical parameters of the adhesive by specifying a polymer content range of 5-20% and a dry adhesive thickness of 0.5-5 mils. These parameter optimizations allow the adhesive to provide sufficient bonding strength while maintaining porosity for airflow. The controlled polymer concentration and thickness ensure the adhesive layer does not completely block the pores of the scrim and substrate.
2Strength
If traditional adhesive is used to bond substrate and scrim, then adhesive bonding strength is improved, but flammability risk is increased
Solution Approach 1:
The patent optimizes the adhesive composition by limiting polymer content to 5-20% and controlling dry thickness to 0.5-5 mils, which reduces the total combustible material while maintaining bonding strength. This parameter control decreases flammability risk without requiring excessive flame retardant additives.
Solution Approach 2:
The adhesive is applied to a porous scrim and substrate combination, creating a composite structure where the porous materials provide airflow pathways that also serve as firebreaks. The composite structure of adhesive-bonded porous layers reduces overall flammability while maintaining structural integrity.
3Strength
If adhesive amount is increased to ensure bonding, then adhesive bonding strength is improved, but airflow obstruction is increased
Solution Approach 1:
The patent precisely controls the adhesive application parameters: polymer content at 5-20% and dry thickness at 0.5-5 mils. This optimized parameter range provides sufficient bonding strength while minimizing the volume of adhesive that could block airflow pathways through the porous structures.
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 maintains sufficient adhesive strength while minimizing airflow obstruction and reducing flammability, achieving a Class A fire rating without excessive flame retardants, thus improving both acoustical performance and safety.
Implementation Method 1
an adhesive adhering the first major substrate surface of the substrate to the second major scrim surface of the scrim, the adhesive comprising a gel-forming film-forming polymer
Implementation Method 2
applying an aqueous mixture comprising water and a gel-forming polymer to a first major surface of a substrate or a second major surface of a scrim, and drying the laminate structure to adhere the substrate and the scrim together
Data Source
AI summary
The present invention is directed to ceiling panels formed from a porous scrim that is coupled to an acoustical substrate using a scrim attachment system that includes an adhesive.