ACOUSTICAL CEILING TILES AND COMPOSITES WITH REDUCED EMISSIONS

Description

CROSS-REFERENCE TO RELATED APPLICATION(S)

This application claims priority under 35 U.S.C. § 119(e) to U.S. Provisional Patent Application No. 63/729,742, entitled “ACOUSTICAL CEILING TILES AND COMPOSITES WITH REDUCED EMISSIONS,” filed Dec. 9, 2024, by Sandhya JAYARAMAN RUKMANI et al., which is assigned to the current assignee hereof and is incorporated herein by reference in its entirety.

FIELD OF THE DISCLOSURE

The present disclosure relates to composites, products, and methods for making the same, for example, suitable for use in a ceiling to control sound. The present disclosure relates more particularly to an acoustical ceiling tile with reduced emissions for better environmental effects.

BACKGROUND

Acoustic panels are useful in a number of applications to attenuate noise. For example, an interior ceiling structure can include one or more acoustic ceiling panels positioned above the occupied space of a room or other interior part of a building. Such panels can be effective for sound reduction and/or insulation, especially in an open space, such as office area, conference room, hallway, cafeteria, auditorium, etc. There are many types of ceiling products available in the market, including gypsum ceilings, fiberglass ceilings, mineral wool ceilings, metal ceilings, wood ceilings, etc. Two important measures of acoustic performance are noise reduction coefficient (NRC), which relates to sound reduction/absorption and ceiling attenuation class (CAC), which relates to sound insulation. Most ceiling products have pros and cons in terms of acoustic performance. Ceilings with high NRC performance often yield lower CAC values. For example, fiberglass ceilings may have 90 NRC or higher but CAC of less than 25. On the other hand, gypsum ceilings may have 50 CAC but NRC of less than 40. Typically, in order to yield high NRC and CAC, more complex and/or expensive ceiling products designs are used.

However, materials and composites used in these ceiling tiles generally have emissions or a carbon footprint to create them that may provide detrimental effects to society, including reduced health statistics of those with continuous exposure, certain included materials being known environmental pollutants or cause toxicities, thermal degradation, and economic costs—in addition to contributing to global warming. The global warming potential (GWP) of such materials is a measurement of the cumulative radiative forcing, both direct and indirect effects, over a specified time horizon resulting from the emission of a unit mass of gas related to a reference gas [CO2: (IPCC 1996)]. Gases with a higher GWP absorb more energy, per ton emitted, than gases with a lower GWP, and thus contribute more to global warming.

Mineral wool fibers have been a staple in ceiling formulations. They provide the key acoustical performance for ceiling products and applications. One of the challenges is the energy intensive process associated with mineral wool manufacture, and typically has a high emission factor of above 1.0 kgCO₂eq/kg. This high emission factor impacts the overall GWP of the product.

In acoustical composites and products, it would be desirable to have materials included with lower GWP to reduce the related emission factors affecting climate change and global warming.

The present applicants have determined that an acoustical ceiling tile or panel that exhibits a combination of favorable NRC and GWP values while using materials that are not cost prohibitive would be attractive to both builders and consumers to help mitigate climate change and decarbonization of the global environment.

SUMMARY

According to a first aspect, an acoustical ceiling tile with reduced emissions is disclosed. The acoustical ceiling tile may include an aggregate core board composition comprising mineral fiber; particulate filler; fiberglass; cellulosic fiber; and a binder, where a ratio of inclusion of the mineral fiber to the binder is 3.0 to 5.5:1.

According to another aspect, an acoustical ceiling tile with reduced emissions is disclosed. The acoustical ceiling tile may include an aggregate core board composition comprising mineral fiber; particulate filler; fiberglass; cellulosic fiber; and a binder, where a ratio of inclusion of the mineral fiber to the binder is 3.0 to 5.5:1; where the aggregate core board has a global warming potential (GWP) of less than 1.00 kgCO2eq/kg, and where the aggregate core board composition has a sound absorption coefficient of at least 0.2 by ASTM E1050-19.

According to a further aspect, an acoustical ceiling tile with reduced emissions is disclosed. The acoustical ceiling tile may include an aggregate core board composition comprising 10 to 45 wt. % mineral fibers; 15 to 35 wt. % particulate filler; 5 to 15 wt. % fiberglass; 1 to 15 wt. % cellulosic fibers; and 4 to 12 wt. % binder, where a ratio of inclusion of the mineral fiber to the binder is 3.0 to 5.5:1.

According to a further aspect, an acoustical ceiling tile with reduced emissions is disclosed. The acoustical ceiling tile may include an aggregate core board composition comprising 10 to 45 wt. % mineral fibers; 15 to 35 wt. % particulate filler; 5 to 15 wt. % fiberglass; 1 to 15 wt. % cellulosic fibers; and 4 to 12 wt. % binder, where a ratio of inclusion of the mineral fiber to the binder is 3.0 to 5.5:1; where the global warming potential (GWP) of the aggregate core board is less than 1.00 kgCO2eq/kg; and where the noise reduction coefficient (NRC) of the finished acoustical ceiling tile is equal to or greater than 0.60 by ASTM C423.

According to another aspect, an acoustical ceiling tile with reduced emissions is disclosed. The acoustical ceiling tile of this aspect may include an aggregate core board composition comprising 10 to 45 wt. % mineral wool; 15 to 35 wt. % of a particulate filler selected from the group consisting of perlite, expanded perlite, vermiculite, hollow glass beads, polymer beads, calcium carbonate, plaster, gypsum, silica, sericite, fly ash, natural clay, ball clay, talc, or combinations thereof, 5 to 15 wt. % fiberglass; 1 to 15 wt. % of paper; and 4 to 12 wt. % of starch, where a ratio of inclusion of the mineral fiber to the binder is 3.0 to 5.5:1; where the global warming potential (GWP) of the aggregate core board is less than 1.00 kgCO2eq/kg; and where the noise reduction coefficient (NRC) of the finished acoustical ceiling tile is equal to or greater than 0.60 by ASTM C423.

According to a further aspect, a composite with reduced emissions is disclosed. The composite of this aspect may include an aggregate core board composition comprising mineral fiber; particulate filler; fiberglass; cellulosic fiber; and a binder, where a ratio of inclusion of the mineral fiber to the binder is 3.0 to 5.5:1; where the aggregate core board has a global warming potential (GWP) of less than 1.00 kgCO2eq/kg; and where the aggregate core board of the composite has a sound absorption coefficient of at least 0.2 by ASTM E1050-19.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments are illustrated by way of example and are not limited to the accompanying figures.

FIG. 1 includes a bottom schematic perspective view of an acoustical ceiling tile according to an embodiment of the disclosure described herein;

FIG. 2A includes a schematic side view of a portion of a system for making an acoustical ceiling tile according to an embodiment of the disclosure described herein;

FIG. 2B includes a schematic side view of another portion of a system for making an acoustical ceiling tile according to an embodiment of the disclosure described herein;

FIG. 3 includes a schematic side view of an acoustic ceiling system according to an embodiment of the disclosure described herein;

FIG. 4 includes a schematic side view of another acoustic ceiling system according to an embodiment of the disclosure; and

FIG. 5 includes a comparison between the sound absorption coefficient of the control core board (C1) and two inventive aggregate core boards (S1 and S3) of the acoustical ceiling tiles according to an embodiment of the disclosure and as disclosed in Table 1.

Skilled artisans appreciate that elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale.

DETAILED DESCRIPTION

The following discussion will focus on specific implementations and embodiments of the teachings. The detailed description is provided to assist in describing certain embodiments and should not be interpreted as a limitation on the scope or applicability of the disclosure or teachings. It will be appreciated that other embodiments can be used based on the disclosure and teachings as provided herein.

The terms “comprises,” “comprising,” “includes,” “including,” “has,” “having” or any other variation thereof, are intended to cover a non-exclusive inclusion. For example, a method, article, or apparatus that comprises a list of features is not necessarily limited only to those features but may include other features not expressly listed or inherent to such method, article, or apparatus. Further, unless expressly stated to the contrary, “or” refers to an inclusive-or and not to an exclusive-or. For example, a condition A or B is satisfied by any one of the following: A is true (or present) and B is false (or not present), A is false (or not present) and B is true (or present), and both A and B are true (or present).

Also, the use of “a” or “an” is employed to describe elements and components described herein. This is done merely for convenience and to give a general sense of the scope of the invention. This description should be read to include one, at least one, or the singular as also including the plural, or vice versa, unless it is clear that it is meant otherwise. For example, when a single item is described herein, more than one item may be used in place of a single item. Similarly, where more than one item is described herein, a single item may be substituted for that more than one item.

Accordingly, one embodiment of the disclosure may be an acoustical ceiling tile that may include reduced emissions. According to the embodiments, described herein, an “acoustical ceiling tile” may include, but is not limited to, ceiling tiles, wall tiles, floor tiles, or acoustical tiles or panels for conventional ceilings, sloped ceilings, vaulted ceilings, exposed ceilings, cove ceilings, beamed ceilings, tray ceilings, walls, barriers, barricades, enclosures, or flooring. Such tiles can be incorporated into or envisioned as an acoustical panel, an office partition, an acoustical baffle, or a room partition. An “acoustical ceiling tile” as well as these other applications for the composite may be suspended or fixed, and may be mounted to a ceiling, floor, or wall.

According to still other embodiments, acoustical ceiling tiles of the present disclosure may include an aggregate core board composition of mineral fiber; a particulate filler; a fiberglass; a cellulosic fiber; and a binder. In some embodiments, the acoustical ceiling tiles of the present disclosure may comprise additional ingredients in the aggregate core board composition. Alternatively, in some embodiments, the aggregate core board composition of the acoustical ceiling tiles of the present disclosure may consist essentially of mineral fiber; a particulate filler; a fiberglass; a cellulosic fiber; and a binder. In further embodiments, the acoustical ceiling tiles may include additional ingredients after the process of drying or finishing the aggregate core board and forming the acoustical ceiling tile.

According to still other embodiments, acoustical ceiling tiles may include a particular ratio of inclusion of the mineral fiber to the binder. For example, the acoustical ceiling tiles may include a ratio of inclusion of the mineral fiber to the binder of at least about 3.0:1, such as, at least about 3.1:1 or at least about 3.2:1 or at least about 3.3:1 or at least about 3.4:1 or at least about 3.5:1 or at least about 3.6:1 or at least about 3.7:1 or at least about 3.8:1 or at least about 3.9:1 or at least about 4.0:1 or at least about 4.1:1 or at least about 4.2:1 or even at least about 4.3:1 or at least about 4.4:1 or at least about 4.5:1 or at least about 4.6:1 or at least about 4.7:1 or at least about 4.8:1 or at least about 4.9:1 or at least about 5.0:1 or at least about 5.1:1 or at least about 5.2:1 or at least about 5.3:1 or at least about 5.4:1 or at least about 5.5:1.

According to still other embodiments, acoustical ceiling tiles may include a particular ratio of inclusion of the glass fiber to the particulate filler. For example, the acoustical ceiling tiles may include a ratio of inclusion of the glass fiber to the particulate filler of at least about 0.2:1, such as, at least about 0.3:1 or at least about 0.4:1 or at least about 0.5:1 or at least about 0.6:1 or at least about 0.7:1 or at least about 0.8:1 or at least about 0.9:1 or at least about 1:1 or at least about 1.1:1 or at least about 1.2:1 or at least about 1.3:1 or at least about 1.4:1 or even at least about 1.5:1.

These acoustical ceiling tiles formed of such materials were found to have better optimized sound absorption coefficients, sound barrier properties (NRC, CAC, and other properties) over commercially available acoustical ceiling tiles, and lower emission factors versus standard acoustical ceiling tiles. In particular, the aggregate core board compositions of the present disclosure may have a sound absorption coefficient of at least 0.2 as measured by impedance tube method ASTM E1050-19; and composites and finished acoustical ceiling tiles of the present disclosure may have a noise reduction coefficient (NRC) of equal to or greater than 0.60 as measured by ASTM C423. Additionally, the overall global warming potential (GWP) of the aggregate core board may be not greater than about 1.00 kgCO₂eq/kg as modeled and measured by the Sphera GaBi version 10.6 software system database further described herein.

Such an acoustical ceiling tile is shown in a bottom perspective view in FIG. 1. Acoustical ceiling tile 110 may have a length 112 extending from a first end 114 to a second end 116, a width 118 extending from a first side 120 to a second side 122, and a thickness 124 extending between an upper surface 126 and a lower surface 128. Acoustical ceiling tile 110 may include a core board 130 formed of an aggregate composition of mineral fiber; particulate filler; fiberglass; cellulosic fiber; and a binder. Acoustical ceiling tile 110 may have an upper face 132 and a lower face 134 which faces and side surfaces may be covered with a veil or scrim layer 155 upon drying and finishing the acoustical ceiling tile 110 that is coextensive over the entire upper face 132 and/or lower face 134 of acoustical ceiling tile 110.

Using acoustical ceiling tiles and composites of the present disclosure with lower or reduced carbon/GWP emissions compared to standard or current commercially available ceiling tiles are less expensive and easier to manufacture, more soundproof, and better for the environment. The lower emission factors of each raw material of a standard acoustical ceiling tile provide more environmental advantages, including progress toward carbon neutrality; by altering the amount of mineral fiber, binder, glass fiber, or particulate filler, the acoustical ceiling tiles provide better sound absorption and lower carbon/greenhouse gas emissions (as well as better manufacturing properties).

Mineral Fiber

According to certain embodiments, the mineral fiber in acoustical ceiling 110 of the present disclosure may be formed of stone wool, glass wool, slag wool, mineral or rock wool, metal wool. The soft texture of these materials can trap air pockets, which can make it difficult for heat and sound to escape through the ceiling. Additionally, the mineral fiber provides structure to a binder to hold the entire panel together with any additional materials and fillers.

According to still other embodiments, mineral wool may be included in the aggregate core board composition. According to yet other embodiments, the mineral wool may be formed of basalt rock, stone wool, glass wool, slag wool, mineral or rock wool, metal wool, or any combination thereof. In more particular embodiments, the mineral wool may be formed of slag wool.

According to yet other embodiments, the mineral fiber may be added together with other materials to combine or aggregate a mixture of materials for forming a core board composition of acoustical ceiling tiles and composites of certain properties.

According to still other embodiments, mineral fiber may be present at a particular content in the aggregate core board composition of acoustical ceiling tile formulations or composites described herein. For instance, mineral fibers may be present at a content of at least about 1.0 wt. % for a total weight of the acoustical ceiling tile formulation, such as at least about 5.0 wt. % or at least about 10 wt. % or at least about 15 wt. % or at least about 20 wt. % or at least about 25 wt. % or at least about 30 wt. % or at least about 35 wt. % or at least about 40 wt. % or even at least about 45 wt. %. According to other embodiments, the mineral wool fibers may be present at a content of not greater than about 45 wt. %, such as not greater than about 35 wt. % or not greater than about 30 wt. % or not greater than about 25 wt. % or not greater than about 20 wt. % or not greater than about 15 wt. % or not greater than about 10 wt. % of the total weight of the aggregate acoustical ceiling tile formulation. In still other embodiments, mineral wool fibers may be present from about 10 wt. % to about 45 wt. % of the total weight of the ceiling tile formulation. It will be appreciated that the mineral fibers may be present in the aggregate core board composition, aggregate core board, and resultant acoustical ceiling tile within a range between any of the minimum and maximum values noted above. It will be further appreciated that the mineral wool fibers may be present at any value between any of the minimum and maximum values noted above.

For particular commercially available mineral fibers, the known GWP indicator as provided through the Sphera GaBi version 10.6 software system database of the raw materials per kgCO₂eq/kg for mineral slag wool as the mineral fiber may be 1.32.

Additionally, acoustical ceiling tile composites and formulations of the present disclosure may also include a particulate filler to improve the acoustical ceiling tile characteristics, including sound absorption, weight, fire resistance, and moisture resistance. In some embodiments, the particulate filler may be selected from the group of materials including perlite, expanded perlite, vermiculite, hollow glass beads, polymer beads, calcium carbonate, plaster, gypsum, silica, sericite, fly ash, natural clay, ball clay, talc, or combinations thereof. In some embodiments, the particulate filler included may be expanded perlite. In other embodiments, the particulate filler included may be vermiculite.

The particulate filler may be added together with other materials to combine or aggregate in the core board composition or mixture of materials for forming acoustical ceiling tiles and composites of certain properties.

Generally, the particulate filler may be present at a particular content in the acoustical ceiling tile formulations or composites described herein. For instance, the particulate filler may be present in the aggregate core board composition at a content of at least about 15.0 wt. % or at least about 20.0 wt. % or at least about 25.0 wt. % or at least about 30.0 wt. % or at least about 35.0 wt. %. According to other embodiments, expanded perlite may be present at a content of not greater than about 35.0 wt. %, such as not greater than about 30.0 wt. % or not greater than about 25.0 wt. % or not greater than about 20.0 wt. % or not greater than about 15.0 wt. % of the total weight of the aggregate acoustical ceiling tile formulation. According to still other embodiments, vermiculite may be present in the aggregate core board composition at a content of not greater than about 35.0 wt. %, such as not greater than about 30.0 wt. % or not greater than about 25.0 wt. % or not greater than about 20.0 wt. % or not greater than about 15.0 wt. % of the total weight of the acoustical ceiling tile formulation. In still other embodiments, particulate fillers may be present from about 15.0 wt. % to about 35.0 wt. % of the total weight of the ceiling tile formulation. It will be appreciated that the mineral fibers may be present in the aggregate core board composition, aggregate core board, and resultant acoustical ceiling tile within a range between any of the minimum and maximum values noted above. It will be further appreciated that the particulate filler may be present at any value between any of the minimum and maximum values noted above.

For particular commercially available particulate filler, the known GWP indicator as provided through the Sphera GaBi version 10.6 software system database of the raw materials per kgCO₂eq/kg for perlite may be 0.00186.

Glass Fibers

According to some embodiments, the acoustical ceiling tile formulations or composites described herein may also include glass fibers, such as fiberglass, which may decrease the overall density of the core board versus standard commercial fiberboards with a higher inclusion of mineral wool.

When present, according to certain embodiments, the glass fiber may be present in an aggregate core board composition at a particular content. For example, the glass fiber may be present at a content of at least about 0.5 wt. % for a total weight of the acoustical ceiling tile formulation, such as at least about 1.0 wt. % or at least about 2.0 wt. % or at least about 3.0 wt. % or at least about 4.0 wt. % or at least about 5.0 wt. % or at least about 6.0 wt. % or at least about 7.0 wt. % or at least about 8.0 wt. % or at least about 9.0 wt. % or at least about 10 wt. % or at least about 11 wt. % or at least about 12 wt. % or at least about 13 wt. % or at least about 14 wt. % or at least about 15 wt. %. According to other embodiments, the glass fiber may be present at a content of not greater than 15 wt. %, such as not greater than 12.5 wt. % or not greater than 10 wt. % or not greater than 7.5 wt. % or even not greater than 5.0 wt. % of the total weight of the acoustical ceiling tile formulation. It will be appreciated that the glass fiber may be present in the aggregate core board composition, aggregate core board, and resultant acoustical ceiling tile within a range between any of the minimum and maximum values noted above. In still other embodiments, the fiberglass is present from about 5 wt. % to about 15 wt. % of the total weight of the ceiling tile formulation or composite.

For particular commercially available glass fiber, the known GWP indicator as provided through the Smart EPD Certified Environmental Product Declaration (SmartEPD-2024-025-0134-01) in accordance with ISO 14025 and ISO 21930:2017 for InsulPure® Building Insulation as manufactured by CertainTeed LLC of the raw materials per kgCO₂eq/kg for fiberglass scrap is 0.70.

In the acoustical ceiling tile formulations 110 described herein, the fiberglass may be added to the aggregate core board composition as loose fibers or scrap to the base core board aggregate mixture. However, in the finished high acoustical ceiling tile product, an optional fiberglass veil or scrim layer 155 may be adhered to the dried acoustical ceiling tile by an adhesive. In some embodiments, the veil or scrim layer 155 is a fiberglass mat that may be applied to the outside of the acoustical ceiling tile surfaces. The thickness of the veil or scrim layer on the external surfaces of the acoustical ceiling tiles 110 as described herein may be from approximately 5.0 mils to 50 mils.

Cellulosic Fiber

Furthermore, acoustical ceiling tile composites and formulations described herein may also include cellulosic fiber. In some embodiments, the cellulosic fiber may be selected from the group including paper, recycled newsprint, recycled paper, wood pulp, cellulose, plant fibers, bio-based fibers (including sugar cane, straw, coir, and hemp) or combinations thereof. In some embodiments, the cellulosic fiber included in the aggregates or composites of the core board may be paper.

When present, the cellulosic fiber may be present in the aggregate core board composition or composite at a content of at least about 4.0 wt. % for a total weight of the acoustical ceiling tile formulation, such as at least about 5.0 wt. % or at least about 6.0 wt. % or at least about 7.0 wt. % or at least about 8.0 wt. % or at least about 9.0 wt. % or at least about 10.0 wt. % or at least about 11.0 wt. % or at least about 12.0 wt. % or at least about 13.0 wt. % or at least about 14.0 wt. % or at least about 15.0 wt. %. According to other embodiments, paper may be present at a content of not greater than 15.0 wt. %, such as not greater than 12.5 wt. % or not greater than 10.0 wt. % or not greater than 7.5 wt. % or not greater than 5.0 wt. % or not greater than 2.5 wt. % or not greater than 1.0 wt. % of the total weight of the ceiling tile formulation. It will be appreciated that the cellulosic fiber may be present in the aggregate core board composition, aggregate core board, and resultant acoustical ceiling tile within a range between any of the minimum and maximum values noted above. It will be further appreciated that paper may be present at any value between any of the minimum and maximum values noted above. In still other embodiments, paper may be present from about 1.0 wt. % to about 15.0 wt. % of the total weight of the aggregate core board of the acoustical ceiling tile formulation or composite.

For particular commercially available cellulosic fiber, such as waste newspaper, the known GWP indicator as provided through the Sphera GaBi version 10.6 software system database of the raw materials per kgCO₂eq/kg for paper is 0.0031.

Binder

Additionally, acoustical ceiling tile composites and formulations described herein may also include a binder to improve the acoustical ceiling tile characteristics and form the ideal board, including improved sound absorption, weight, fire resistance, and moisture resistance. According to some embodiments, the binder may be selected from the group of materials including starch, latex, phenolic resin, or combinations thereof. In some embodiments, the binder is a native starch, such as a potato starch, corn starch, maize starch, sorghum starch, pea starch, rice starch, wheat starch, barley starch, beet starch, cassava starch, arrowroot starch and tapioca starch.

According to some other embodiments, the binder is a cationic starch. The use of cationic starch provides an acoustical ceiling tile with a modulus of rupture (MOR) that is greater than an equivalent ceiling tile without a cationic starch, where the MOR is measured by modified ASTM D 1037. In some embodiments, the modulus of rupture may be at least 10% greater than an equivalent ceiling tile that does not include a cationic starch. “An equivalent ceiling tile without a cationic starch” is defined as an acoustical ceiling tile made from a formulation having all the same components but with a non-modified starch, i.e., natural starch without an ionic charge, in place of the cationic starch. In such embodiments where cationic starch may be added to the aggregate or composite, the acoustical ceiling tile formulation may have a particular composition that may facilitate improved performance and/or manufacturing of the ceiling tile.

According to still other embodiments, the cationic starch has a positive charge from a chemical modification of a natural starch. For instance, any reasonable chemical modification may be envisioned that imparts a positive charge on the starch. In such embodiments, the cationic starch includes an amine group, a phosphate group, an amino group, an imino group, an ammonium group, a sulfonium group, a phosphonium group, or combination thereof. In some embodiments, the chemically modified cationic starch formed from a natural starch that may be selected from the group including a potato starch, corn starch, maize starch, sorghum starch, pea starch, rice starch, wheat starch, barley starch, beet starch, cassava starch, arrowroot starch and tapioca starch, or any combination thereof.

The binder may be added together with other materials to combine or aggregate core board composition or mixture of materials for forming acoustical ceiling tiles and composites of certain properties.

Generally, the binder may be present in the aggregate core board composition at a particular content in the acoustical ceiling tile formulations or composites described herein. For instance, the binder may be present at a content of at least about 4.0 wt. % for a total weight of the acoustical ceiling tile formulation, such as at least about 5.0 wt. % or at least about 6.0 wt. % or at least about 7.0 wt. % or at least about 8.0 wt. % or at least about 9.0 wt. % or at least about 10.0 wt. % or at least about 11.0 wt. % or at least about 12.0 wt. %. According to other embodiments, starch may be present at a content of not greater than 12.0 wt. % or not greater than 11.0 wt. % or not greater than 10.0 wt. % or not greater than 9.0 wt. % or not greater than 8.0 wt. % or not greater than 7.0 wt. % or not greater than 6.0 wt. % or not greater than 5.0 wt. % or not greater than 4.0 wt. % of the total weight of the aggregate acoustical ceiling tile core board formulation. It will be appreciated that the binder may be present in or on the aggregate core board composition, aggregate core board, and resultant acoustical ceiling tile within a range between any of the minimum and maximum values noted above. It will be further appreciated that any starch may be present at any value between any of the minimum and maximum values noted above.

For particular commercially available binders, such as potato starch, the known GWP indicator as provided through the Sphera GaBi version 10.6 software system database of the raw materials per kgCO₂eq/kg for native starch may be 1.48.

Water

In the aggregates and composites of the core boards of the acoustical ceiling tiles described herein, water may be further added to form a slurry that is used to form the acoustical ceiling tiles. According to such embodiments, the slurry mixture consistency may have a solids percentage between about 2-5 wt. % based on the mineral fiber and particulate filler solids added to the aggregate core board composition.

The aggregates and composites as well as the water component of the acoustical ceiling tiles of the present disclosure as described herein may also contain a variety of other known additives such as an adhesion promoter to enhance the bonding strength between the at least one set of fibers, a silica colloid to enhance fire resistance, a surfactant to promote core board stability, a recycled ceiling board, an antifoamer, a biocide, a pigment, the like, or combinations thereof. Other additives may specifically include acrylic polymers, TiO₂ pigment, sodium-potassium alumina silicate, magnesium silicate, CaO (limestone) sources such as magnum fill and Omya SW12, calcined clay, the fiberglass veil, and adhesives including EVA-based glues. In such embodiments, the acoustical ceiling tile formulations with additives as herein described may be included in a content of not greater than 40.0 wt. % for a total weight of the acoustical ceiling tile formulation, such as not greater than about 35.0 wt. % or not greater than about 30.0 wt. % or not greater than about 25.0 wt. % or not greater than about 20.0 wt. % or not greater than about 15.0 wt. % or not greater than about 10.0 wt. % or not greater than about 9.0 wt. % or not greater than about 8.0 wt. % or not greater than about 7.0 wt. % or not greater than about 6.0 wt. % or not greater than about 5.0 wt. % or not greater than about 4.0 wt. % or not greater than about 3.0 wt. % or not greater than about 2.0 wt. % or not greater than about 1.0 wt. % or not greater than about 0.9 wt. % or not greater than about 0.8 wt. % or not greater than about 0.7 wt. % or not greater than about 0.6 wt. % or not greater than about 0.5 wt. % or not greater than about 0.4 wt. % or not greater than about 0.3 wt. % or not greater than about 0.2 wt. % or not greater than about 0.1 wt. %. The additives may be present in a content of at least about 0.1 wt. % of the total weight of the ceiling tile formulation, such as at least about 0.1 wt. % or at least about 0.2 wt. % or at least about 0.3 wt. % or at least about 0.4 wt. % or at least about 0.5 wt. % or at least about 0.6 wt. % or at least about 0.7 wt. % or at least about 0.8 wt. % or at least about 0.9 wt. % or at least about 1.0 wt. % or at least about 5.0 wt. % or at least about 10.0 wt. % or at least about 15.0 wt. % or at least about 20.0 wt. % or at least about 25.0 wt. % or at least about 30.0 wt. % or at least about 35.0 wt. % or at least about 40.0 wt. %. It will be appreciated that additives may be present in the aggregate core board composition, in or on the aggregate core board, and in or on the resultant acoustical ceiling tile within a range between any of the minimum and maximum values noted above. It will be further appreciated that the additive may be present at any value between any of the minimum and maximum values noted above. The GWP of each of the raw additives should be incorporated into the measured global warming potential and would affect the total core board GWP and composition.

According to some embodiments, the acoustical ceiling tile formulations may be substantially free of additives. “Substantially free” as used herein refers to less than about 1% by weight of additives, less than about 0.5% by weight of additives, or even less than about 0.1% by weight of additives of the total weight of the acoustical ceiling tile formulation.

In further embodiments of the aggregates or composites of the acoustical ceiling tiles described herein, the mineral fibers, particulate filler, glass fibers, and cellulosic fibers may have any sizing envisioned. In some embodiments, the sizing enhances the processability, improved performance, and manufacturing of the materials, acoustical ceiling tiles and composites. Although not being bound by theory, the mineral fibers, particulate filler, or glass fibers can be any length such as continuous strand, chopped, or combination thereof. In a more particular embodiments, the fibers are chopped into a suitable length to provide a substantially random orientation of fibers. A “chopped fiber” as used herein typically describes randomly oriented chopped filaments or fibers, where the chopped fibers are randomly oriented individually or in a group. Any reasonable length of fibers may be envisioned and may be the same or different, depending on the particular fibers. Generally, the fibers have an average length of about 0.5 mm to about 15.0 mm. Any reasonable diameter of fibers can be envisioned and may be the same or different, depending on the particular fibers. Generally, the fibers may have an average diameter of about 0.5 microns to about 100 microns. It will be appreciated that the fibers length and diameter may be present within a range between any of the minimum and maximum values noted above.

Once the aggregate of the composites as described herein are thoroughly combined, they may be formed into any particular shape, including planar, curved, and three-dimensional core boards, to be dried and form a final resultant acoustical ceiling tile. In some embodiments, the acoustical ceiling tile is a planar rectangle. Such embodiments are well suited for being held in a ceiling grid or being hung from a ceiling support structure as shown in FIGS. 3 and 4.

According to some embodiments of the acoustical ceiling tiles as described herein, the ceiling support structure may include a ceiling grid. For example, ceiling support structure 702 of acoustic ceiling system 700 of FIG. 3 may include a plurality of grid members that form a ceiling grid. The grid members of ceiling support structure 702 are in the form of T-bar grid members, and the acoustical ceiling tiles 710 are supported by flanges of the grid members. According to other embodiments, the ceiling support structure includes a ceiling grid formed of other types of grid members.

According to still other embodiments of the acoustical ceiling tile sand system as described herein, the acoustical ceiling tile may be hung from the ceiling support structure. For example, in acoustic ceiling system 800 of FIG. 4, each of the acoustical ceiling tiles 810 may be hung from ceiling support structure 802 by wire 804. Wire 804 is secured to acoustical ceiling tile 810 using a mounted fastener 806. In some other embodiments, the wire may be secured to the acoustical ceiling tile in another manner, for example, on a fastener disposed on a perimeter frame of the acoustical ceiling tile.

According to some embodiments of the acoustic ceiling system as otherwise described herein, the acoustical ceiling tiles may be one of an array of acoustical ceiling tiles in the acoustic ceiling system. For example, acoustic ceiling system 700 may include an array of acoustical ceiling tiles 710 supported by the ceiling grid of ceiling support structure 702. FIG. 3 shows a section of one row in a plurality of rows of the acoustical ceiling tiles 710 of system 700. According to some embodiments of the acoustic ceiling system as described herein, the acoustical ceiling tiles may be parallel. Further, in some embodiments, the acoustical ceiling tiles are coplanar. For example, the acoustical ceiling tiles 710 of acoustic ceiling system 700 may be all parallel and lie in the same plane. Accordingly, acoustic ceiling system 700 may form a continuous planar surface that thus may form a ceiling.

The length 112 of the acoustical ceiling tiles 110 as shown in FIG. 1 of the present disclosure may be from approximately 12 inches to 60 feet. The width 118 of the acoustical ceiling tile 110 of the present disclosure may be from approximately 12 inches to 30 feet. The thickness 124 of the acoustical ceiling tiles 110 as described herein may be from approximately 0.25 inches to 1.5 inches. The core board of the acoustical ceiling tiles 110 may also have a density of at least 11 pcf and a minimum strength (max load measured by 3-point bend test) per modified ASTM D 1037 of at least 15 lbs.

The emission properties of the composites and aggregates of the acoustical ceiling tiles as described herein are found to be lower than standard, commercially available acoustical ceiling tiles. Sphera GaBi version 10.6 software system may be used for modeling the raw material impact of the core boards and acoustical ceiling tiles. The Sphera GaBi, US LCI, and Ecoinvent v3.8 databases may also be referenced for the known indicators of the included raw materials. These types of databases utilize the U.S. EPA's Tool for the Reduction and Assessment of Chemical and Other Environmental Impacts (TRACI) 2.1 for North America as the global warming potential (GWP) indicator. This environmental impact indicator is defined as TRACI 2.1, Global Warming Air, excluding biogenic carbon. Global Warming Air, excluding biogenic carbon, is a metric that quantifies the global warming impact of greenhouse gases over a specified temporal span. Excluding biogenic carbon accounts for only fossil-based carbon emissions, TRACI 2.1 GWP indicator is calculated in units of kilograms of carbon dioxide-equivalence.

While the GWP indicators of each raw material included within the aggregate core board may be commonly known or accessible in commercial databases, it was not an expected benefit of forming exemplary acoustical ceiling tiles 110 of the present disclosure to have a reduced carbon emission profile as well as a higher noise reduction coefficient compared to a standard acoustical ceiling tile board (as shown in Table 1). The ratio of adding a particular percentage of mineral fiber to the binder in the aggregate core board of the acoustical tiles of the present disclosure may provide such an advantage to the core boards and finished acoustical ceiling tiles of a global warming potential (GWP) of less than 1.00 kgCO₂eq/kg of board as well as a sound absorption coefficient of at least 0.2 by ASTM E1050-19 and a finished noise reduction coefficient (NRC) of equal to or greater than 0.60 by ASTM C423. Alternatively, the ratio of adding a particular percentage of glass fiber to the particulate filler in the acoustical tiles of the present disclosure may also provide such an advantage of a global warming potential (GWP) of less than 1.00 kgCO₂eq/kg of board as well as a sound absorption coefficient of at least 0.2 by ASTM E1050-19 and a finished noise reduction coefficient (NRC) of equal to or greater than 0.60 by ASTM C423.

According to some embodiments, the ratio of mineral fiber to the binder that may be added to the aggregate core board of the composites and acoustical ceiling tiles of the present disclosure may be from at least about 3.0 and not greater than about 5.5:1. In still other embodiments, the ratio of mineral fiber to the binder as added in the aggregate may be from at least about 3.0 and not greater than about 4.0:1. It will be appreciated that the ratio calculated between the mineral fiber to the binder may be within a range between any of the minimum and maximum values noted above. As a result of this inclusion rate ratio of mineral fiber to the binder, the global warming potential (GWP) may be less than 1.00 kgCO₂eq/kg of board as well as a sound absorption coefficient of at least 0.2 by ASTM E1050-19 and a finished noise reduction coefficient (NRC) of equal to or greater than 0.60 by ASTM C423.

According to other embodiments, the ratio of glass fiber to the particulate fillers that may be added to the aggregate core board of the composites and acoustical ceiling tiles of the present disclosure may be from at least about 0.2 and not greater than about 1.5:1. In still other embodiments, the ratio of the glass fiber to the particulate filler as added in the aggregate may be from at least about 0.2 and not greater than about 1:1. In even further embodiments, the ratio of glass fiber to the particulate filler as added in the aggregate may be from at least about 0.2 and not greater than about 1.5:1. It will be appreciated that the ratio calculated from the glass fiber and particulate filler may be within a range between any of the minimum and maximum values noted above. As a result of this inclusion rate ratio of glass fiber to particulate filler, the aggregate core board may have a sound absorption coefficient of at least 0.2 by ASTM E1050-19 and a finished noise reduction coefficient (NRC) of equal to or greater than 0.60 by ASTM C423 as well as the GWP being not greater than about 1.00 kgCO₂eq/kg of board.

In these embodiments, the global warming potential (GWP) may be calculated for a total weight of the aggregate core board composition, such as at least about 0.50 kgCO₂eq/kg or at least about 0.55 kgCO₂eq/kg or at least about 0.60 kgCO₂eq/kg or at least about 0.65 kgCO₂eq/kg or at least about 0.70 kgCO₂eq/kg or at least about 0.75 kgCO₂eq/kg or at least about 0.80 kgCO₂eq/kg or at least about 0.85 kgCO₂eq/kg or at least about 0.90 kgCO₂eq/kg or at least about 0.95 kgCO₂eq/kg. According to other embodiments, the global warming potential (GWP) may be calculated for a total weight of the aggregate core board composition of not greater than 1.0 kgCO₂eq/kg, such as not greater than 0.95 kgCO₂eq/kg or not greater than 0.90 kgCO₂eq/kg or not greater than 0.85 kgCO₂eq/kg or not greater than 0.80 kgCO₂eq/kg or not greater than 0.75 kgCO₂eq/kg or not greater than 0.70 kgCO₂eq/kg or not greater than 0.65 kgCO₂eq/kg or not greater than 0.60 kgCO₂eq/kg or not greater than 0.55 kgCO₂eq/kg or not greater than 0.50 kgCO₂eq/kg of the total weight of the aggregate acoustical ceiling tile core board formulation. It will be appreciated that the global warming potential (GWP) of the aggregate core board composition and aggregate core board may be within a range between any of the minimum and maximum values noted above.

Method

In another embodiment, the disclosure provides a method of making acoustical ceiling tiles according to the disclosure. The method may include adding water, any additives, and the aggregate of components of the composite or mixture to a mixing tank. The plurality of components and water may then be mixed in the mixing tank so as to form a slurry. Subsequently, the slurry can be dispensed onto a support surface. The slurry may then be dried so as to form an aggregate core board slab. The method also optionally includes applying a veil or scrim layer over the first face of the resultant dried and final acoustical ceiling tile and applying a veil or scrim layer over the second face of the acoustical ceiling tile. The method may then further involve adding paints or finishes to the first and second surfaces, as well as the veils or scrim layers applied to them, and further processing of such surfaces such as perforations or fissuring to further modify the visual and acoustical properties of the acoustical ceiling tiles.

Any order of dispersing the aggregate or composites of the raw material components included in the slurry may be envisioned to form the aqueous dispersion. In some embodiments, the cellulosic fiber may be pre-pulped to assist in separation of recycled materials, then the particulate filler, mineral fibers, glass fibers, and binder are then added. The aqueous dispersion may then be agitated under any reasonable conditions so that the components are uniformly distributed throughout the slurry. Any rate and duration of agitation are envisioned. For instance, the slurry may be mixed for about 10 to 60 minutes by means of a rotary agitator (impeller) revolving at a rate of about 100 to 150 revolutions per minute.

Once agitated, the slurried ceiling tile formulations may be transferred to a support surface. The aqueous solution is removed to form a wet laid mat. The aqueous solution is removed from the wet laid mat, which is subsequently dried via any method envisioned such as gravity, suction, heat, rollers, air blowers, the like, or combination thereof to form a ceiling tile that has a first surface and a second surface. Typically, the dried mat has a moisture content of not greater than about 1.0 wt. % based on the final weight of the acoustical ceiling tile formulation.

Other embodiments may be in accordance with any one or more of the embodiments as listed below and further described and shown in FIGS. 2A and 2B.

As shown in FIG. 2A, manufacturing system 660 may include a mixing tank 662 that receives water 664 and various component materials 666 of an acoustical ceiling tile 610. The water 664 and components 666 may be mixed in mixing tank 662 to form a slurry 670, which is dispensed by a head box 668 onto a support surface 672. The slurry 670 is then dried at several stages 674, 675, 676 as explained in more detail below, and pressed between rollers 678 to form a core board slab 680 of the acoustical ceiling tile 110 that has a first face 682 and a second face 684.

As shown in FIG. 2B, the core board slab 680 may be then processed to form acoustical ceiling tiles 610. For example, the second face 684 of the core board slab 680 may be perforated by a perforation machine 686 and the first face 682 may be covered with the backing layer by a dispenser 688. Furthermore, the second face 684 may also be covered with the veil or scrim that is unwound from a roll 690. Acoustical ceiling tiles 610 may be then cut from the core board slab 680 using a cutting machine 692. In other embodiments, the order of operations that produce acoustical ceiling tiles from the core board slab may differ. For example, in some embodiments, the slab may be cut into segments before the second face is perforated or the backing layer and veil are applied. Further, in some embodiments, the veil may be applied to the second face before the backing layer may be applied to the first face. Other orders of these operations are also possible. Moreover, in some embodiments, one or more of the operations may be conducted simultaneously or in a sequentially overlapping manner. Further, while the system in FIG. 2B shows the first face facing upward and the second face facing downward, in other embodiments, the system may operate with the first face of the slab facing downward and the second face facing upward.

According to some embodiments of the method as otherwise described herein, a solid percentage of the slurry is at least about 2%, such as at least about 3% or at least about 4% or at least about 5% or at least about 6% or at least about 7% or at least about 8% or at least about 9% or at least about 10%, by weight. In some embodiments, a solid percentage of the slurry is not greater than about 10%, such as not greater than about 8% or not greater than about 5% or not greater than about 2%. For example, in some embodiments, the solid percentage of the slurry is in a range from at least about 2% to about 10%, such as from at least about from 3% to about 8% or from at least about 4% to at least about 5%. For example, the proportions of water 664 and components 666 that are mixed in mixing tank 662 may yield a slurry 670 with a solid percentage in a range from 4% to 5%. It will be appreciated that the slurry may be present within a range between any of the minimum and maximum values noted above. It will be further appreciated that any water may be present at any value between any of the minimum and maximum values noted above and below.

According to other embodiments of the method as otherwise described herein, a solids percentage of the water that may be added in an amount between about 2-5 wt. % based on the mineral fiber and particulate filler added to the aggregate core board composition. For example, in some embodiments, the water that is added to the mixing tank may be recycled from the acoustical ceiling tile manufacturing process or another process and includes solids therein. Further, in some embodiments, the recycled water is filtered to regulate the weight percentage of solids in the water.

According to some embodiments of the method as otherwise described herein, drying the slurry may include water removal by gravity. For example, the support surface 672 of manufacturing system 660 may be in the form of a screen and water may be drained from the slurry in section 674 through holes in the screen.

According to other embodiments of the method as otherwise described herein, drying the slurry may include water removal by vacuum suction. For example, manufacturing system 660 may include a vacuum section 675 in which additional water is removed from the slurry through the support surface 672, i.e., through the screen, by the forming of a vacuum below the screen.

According to still other embodiments of the method as otherwise described herein, drying the slurry may include heating the slurry in a dryer. For example, manufacturing system 660 may include a heated dryer 676 in the form of a convection oven that further removes water from the slurry to form core board slab 680.

According to still other embodiments of the method as otherwise described herein, the perforations may be formed by inserting pins into the second face of the acoustical ceiling tile. For example, a perforation machine 686 may include a plate that is covered with a pattern of pins. During operation, the plate may be pressed against the second face of the acoustical ceiling tile so as to form the perforations with the pattern of pins. In some embodiments, the perforations may be formed by a plurality of pins that are moved over the surface and inserted into the second face to produce perforations and various positions. Still, in other embodiments, the perforations may be formed by another method.

According to further embodiments of the method as otherwise described herein, the backing layer may be applied as a coating to a finished acoustical ceiling tile. For example, dispenser 688 may spray a coating on the first face 682 of core board slab 680 that dries to form the backing layer. In other embodiments, the dispenser may be in the form of a film that is applied to the first face of the slab. For example, in some embodiments, the backing layer may be unwound from a roll and adhered to the first face of the slab using an adhesive.

According to other embodiments, the veil or scrim layer may be unwound from a roll and secured to the second face of the core bard slab using an adhesive. In other embodiments, the veil or scrim layer may be applied by another method, such as by a layer of paint or another coating. Further, in some embodiments, the acoustical ceiling tiles as described herein may be produced without a veil or scrim layer.

Many different aspects and embodiments are possible. Some of those aspects and embodiments are described herein. After reading this specification, skilled artisans will appreciate that those aspects and embodiments are only illustrative and do not limit the scope of the present invention. Embodiments may be in accordance with any one or more of the embodiments as listed below.

Embodiment 1. An acoustical ceiling with reduced emissions, comprising: an aggregate core board composition comprising mineral fiber; particulate filler; fiberglass; cellulosic fiber; and a binder, wherein a ratio of inclusion of the mineral fiber to the binder is 3.0 to 5.5:1.

Embodiment 2. The acoustical ceiling tile according to Embodiment 1, wherein the mineral fiber comprises mineral wool formed of basalt rock, stone wool, glass wool, slag wool, mineral or rock wool, metal wool, or any combination thereof.

Embodiment 3. The acoustical ceiling tile according to Embodiment 2, wherein the mineral fiber comprises mineral wool formed of slag.

Embodiment 4. The acoustical ceiling tile according to Embodiment 1, wherein the mineral fiber is added to the aggregate core board composition in an amount of approximately from 10 to 45 wt. %.

Embodiment 5. The acoustical ceiling tile according to Embodiment 4, wherein the mineral fiber is added to the aggregate core board composition in an amount of approximately from 35 to 45 wt. %.

Embodiment 6. The acoustical ceiling tile according to Embodiment 1, wherein the particulate filler comprises perlite, expanded perlite, vermiculite, hollow glass beads, polymer beads, calcium carbonate, plaster, gypsum, silica, sericite, fly ash, natural clay, ball clay, talc, or combinations thereof.

Embodiment 7. The acoustical ceiling tile according to Embodiment 6, wherein the particulate filler is added to the aggregate core board composition in an amount of approximately from 15 to 35 wt. %.

Embodiment 8. The acoustical ceiling tile according to Embodiment 6, wherein the particulate filler comprises expanded perlite.

Embodiment 9. The acoustical ceiling tile according to Embodiment 6, wherein the particulate filler comprises vermiculite.

Embodiment 10. The acoustical ceiling tile according to Embodiment 1, wherein the fiberglass is added to the aggregate core board composition as a loose compound.

Embodiment 11. The acoustical ceiling tile according to Embodiment 10, wherein the fiberglass is added to the aggregate core board composition as loose fibers in an amount of approximately from 5 to 15 wt. %.

Embodiment 12. The acoustical ceiling tile according to Embodiment 1, wherein the cellulosic fiber comprises paper, recycled newsprint, recycled paper, wood pulp, cellulose, plant fibers, bio-based fibers, or combinations thereof.

Embodiment 13. The acoustical ceiling tile according to Embodiment 12, wherein the cellulosic fiber comprises paper.

Embodiment 14. The acoustical ceiling tile according to Embodiment 1, wherein the cellulosic fiber is added to the aggregate core board composition in an amount of approximately from 1 to 15 wt. %.

Embodiment 15. The acoustical ceiling tile according to Embodiment 1, wherein the binder comprises starch, latex, phenolic resin, or combinations thereof.

Embodiment 16. The acoustical ceiling tile according to Embodiment 15, wherein the binder comprises starch.

Embodiment 17. The acoustical ceiling tile according to Embodiment 1, wherein the binder is added to the aggregate core board composition in an amount of approximately from 4 to 12 wt. %.

Embodiment 18. The acoustical ceiling tile according to Embodiment 1, wherein the aggregate further comprises water.

Embodiment 19. The acoustical ceiling tile according to Embodiment 12, wherein a solids percentage of the water in a slurry is added in an amount between about 2-5 wt. %.

Embodiment 20. The acoustical ceiling tile according to Embodiment 1, wherein the ceiling tile is planar.

Embodiment 21. The acoustical ceiling tile according to Embodiment 1, wherein the ceiling tile is curved.

Embodiment 22. The acoustical ceiling tile according to Embodiment 1, wherein the ceiling tile is three-dimensional.

Embodiment 23. The acoustical ceiling tile according to Embodiment 1, wherein a length of the acoustical ceiling tile is from approximately 12 inches to 60 feet.

Embodiment 24. The acoustical ceiling tile according to Embodiment 1, wherein a width of the acoustical ceiling tile is from approximately 12 inches to 30 feet.

Embodiment 25. The acoustical ceiling tile according to Embodiment 1, wherein a thickness of the acoustical ceiling tile is from approximately 0.25 inches to 1.5 inches.

Embodiment 26. The acoustical ceiling tile according to Embodiment 1, wherein the aggregate core board composition has a sound absorption coefficient of at least 0.2 by ASTM E1050-19.

Embodiment 27. The acoustical ceiling tile according to Embodiment 1, wherein the finished acoustical ceiling tile has a noise reduction coefficient (NRC) of equal to or greater than 0.60 by ASTM C423.

Embodiment 28. The acoustical ceiling tile according to Embodiment 1, aggregate core board has a global warming potential (GWP) less than 1.00 kgCO₂eq/kg.

Embodiment 29. The acoustical ceiling tile according to Embodiment 1, wherein the acoustical ceiling tile further comprises a veil layer.

Embodiment 30. The acoustical ceiling tile according to Embodiment 29, wherein the veil layer comprises a fiberglass mat applied to the outside of at least one finished surface of the acoustical ceiling tile.

Embodiment 31. An acoustical ceiling tile with reduced emissions, comprising: an aggregate core board composition comprising mineral fiber; particulate filler; fiberglass; cellulosic fiber; and a binder, wherein a ratio of inclusion of the mineral fiber to the binder is 3.0 to 5.5:1; wherein the aggregate core board has a global warming potential (GWP) of less than 1.00 kgCO₂eq/kg, and wherein the aggregate core board composition has a sound absorption coefficient of at least 0.2 by ASTM E1050-19.

Embodiment 32. The acoustical ceiling tile according to Embodiment 31, wherein the mineral fiber comprises mineral wool formed of basalt rock, stone wool, glass wool, slag wool, mineral or rock wool, metal wool, or any combination thereof.

Embodiment 33. The acoustical ceiling tile according to Embodiment 32, wherein the mineral fiber comprises mineral wool formed of slag.

Embodiment 34. The acoustical ceiling tile according to Embodiment 31, wherein the mineral fiber is added to the aggregate core board composition in an amount of approximately from 10 to 45 wt. %.

Embodiment 35. The acoustical ceiling tile according to Embodiment 34, wherein the mineral fiber is added to the aggregate core board composition in an amount of approximately from 35 to 45 wt. %.

Embodiment 36. The acoustical ceiling tile according to Embodiment 31, wherein the particulate filler comprises perlite, expanded perlite, vermiculite, hollow glass beads, polymer beads, calcium carbonate, plaster, gypsum, silica, sericite, fly ash, natural clay, ball clay, talc, or combinations thereof.

Embodiment 37. The acoustical ceiling tile according to Embodiment 36, wherein the particulate filler is added to the aggregate core board composition in an amount of approximately from 15 to 35 wt. %.

Embodiment 38. The acoustical ceiling tile according to Embodiment 36, wherein the particulate filler comprises expanded perlite.

Embodiment 39. The acoustical ceiling tile according to Embodiment 36, wherein the particulate filler comprises vermiculite.

Embodiment 40. The acoustical ceiling tile according to Embodiment 31, wherein the fiberglass is added to the aggregate core board composition as a loose compound.

Embodiment 41. The acoustical ceiling tile according to Embodiment 31, wherein the fiberglass is added to the aggregate core board composition in an amount of approximately from 5 to 15 wt. %.

Embodiment 42. The acoustical ceiling tile according to Embodiment 31, wherein the cellulosic fiber comprises paper, recycled newsprint, recycled paper, wood pulp, cellulose, plant fibers, bio-based fibers, or combinations thereof.

Embodiment 43. The acoustical ceiling tile according to Embodiment 42, wherein the cellulosic fiber comprises paper.

Embodiment 44. The acoustical ceiling tile according to Embodiment 31, wherein the cellulosic fiber is added to the aggregate core board composition in an amount of approximately from 1 to 15 wt. %.

Embodiment 45. The acoustical ceiling tile according to Embodiment 31, wherein the binder comprises starch, latex, phenolic resin, or combinations thereof.

Embodiment 46. The acoustical ceiling tile according to Embodiment 45, wherein the binder comprises starch.

Embodiment 47. The acoustical ceiling tile according to Embodiment 31, wherein the binder is added to the aggregate core board composition in an amount of approximately from 4 to 12 wt. %.

Embodiment 48. The acoustical ceiling tile according to Embodiment 31, wherein the aggregate core board composition further comprises water.

Embodiment 49. The acoustical ceiling tile according to Embodiment 48, wherein a solids percentage of the water in a slurry is added in an amount between about 2-5 wt. %.

Embodiment 50. The acoustical ceiling tile according to Embodiment 31, wherein the ceiling tile is planar.

Embodiment 51. The acoustical ceiling tile according to Embodiment 31, wherein the ceiling tile is curved.

Embodiment 52. The acoustical ceiling tile according to Embodiment 31, wherein the ceiling tile is three-dimensional.

Embodiment 53. The acoustical ceiling tile according to Embodiment 31, wherein a length of the acoustical ceiling tile is from approximately 12 inches to 60 feet.

Embodiment 54. The acoustical ceiling tile according to Embodiment 31, wherein a width of the acoustical ceiling tile is from approximately 12 inches to 30 feet.

Embodiment 55. The acoustical ceiling tile according to Embodiment 31, wherein a thickness of the acoustical ceiling tile is from approximately 0.25 inches to 1.5 inches.

Embodiment 56. The acoustical ceiling tile according to Embodiment 31, wherein the finished acoustical ceiling tile has a noise reduction coefficient (NRC) of equal to or greater than 0.60 by ASTM C423.

Embodiment 57. The acoustical ceiling tile according to Embodiment 31, wherein the acoustical ceiling tile further comprises a veil layer.

Embodiment 58. The acoustical ceiling tile according to Embodiment 57, wherein the veil layer comprises a fiberglass mat applied to the outside of at least one finished surface of the acoustical ceiling tile.

Embodiment 59. An acoustical ceiling tile with reduced emissions, comprising: a core board composition comprising: 10 to 45 wt. % mineral fibers; 15 to 35 wt. % particulate filler; 5 to 15 wt. % fiberglass; 1 to 15 wt. % cellulosic fibers; and 4 to 12 wt. % binder, wherein a ratio of inclusion of the mineral fiber to the binder is 3.0 to 5.5:1.

Embodiment 60. The acoustical ceiling tile according to Embodiment 59, wherein the mineral fiber comprises mineral wool formed of basalt rock, stone wool, glass wool, slag wool, mineral or rock wool, metal wool, or any combination thereof.

Embodiment 61. The acoustical ceiling tile according to Embodiment 59, wherein the mineral fiber comprises mineral wool formed of slag.

Embodiment 62. The acoustical ceiling tile according to Embodiment 59, wherein the mineral fiber is added to the aggregate core board composition in an amount of approximately from 35 to 45 wt. %.

Embodiment 63. The acoustical ceiling tile according to Embodiment 59, wherein the particulate filler comprises perlite, expanded perlite, vermiculite, hollow glass beads, polymer beads, calcium carbonate, plaster, gypsum, silica, sericite, fly ash, natural clay, ball clay, talc, or combinations thereof.

Embodiment 64. The acoustical ceiling tile according to Embodiment 63, wherein the particulate filler comprises expanded perlite.

Embodiment 65. The acoustical ceiling tile according to Embodiment 63, wherein the particulate filler comprises vermiculite.

Embodiment 66. The acoustical ceiling tile according to Embodiment 59, wherein the cellulosic fiber comprises paper, recycled newsprint, recycled paper, wood pulp, cellulose, plant fibers, bio-based fibers, or combinations thereof.

Embodiment 67. The acoustical ceiling tile according to Embodiment 66, wherein the cellulosic fiber comprises paper.

Embodiment 68. The acoustical ceiling tile according to Embodiment 59, wherein the binder comprises starch, latex, phenolic resin, or combinations thereof.

Embodiment 69. The acoustical ceiling tile according to Embodiment 68, wherein the binder comprises starch.

Embodiment 70. The acoustical ceiling tile according to Embodiment 59, further comprising water.

Embodiment 71. The acoustical ceiling tile according to Embodiment 70, wherein a solids percentage of the water in a slurry is added in an amount between about 2-5 wt. %.

Embodiment 72. The acoustical ceiling tile according to Embodiment 59, wherein the ceiling tile is planar.

Embodiment 73. The acoustical ceiling tile according to Embodiment 59, wherein the ceiling tile is curved.

Embodiment 74. The acoustical ceiling tile according to Embodiment 59, wherein the ceiling tile is three-dimensional.

Embodiment 75. The acoustical ceiling tile according to Embodiment 59, wherein a length of the acoustical ceiling tile is from approximately 12 inches to 60 feet.

Embodiment 76. The acoustical ceiling tile according to Embodiment 59, wherein a width of the acoustical ceiling tile is from approximately 12 inches to 30 feet.

Embodiment 77. The acoustical ceiling tile according to Embodiment 59, wherein a thickness of the acoustical ceiling tile is from approximately 0.25 inches to 1.5 inches.

Embodiment 78. The acoustical ceiling tile according to Embodiment 59, wherein the aggregate core board composition has a sound absorption coefficient of at least 0.2 by ASTM E1050-19.

Embodiment 79. The acoustical ceiling tile according to Embodiment 59, wherein the finished acoustical ceiling tile has a noise reduction coefficient (NRC) of equal to or greater than 0.60 by ASTM C423.

Embodiment 80. The acoustical ceiling tile according to Embodiment 59, wherein the aggregate core board has a global warming potential (GWP) less than 1.00 kgCO₂eq/kg.

Embodiment 81. The acoustical ceiling tile according to Embodiment 59, wherein the acoustical ceiling tile further comprises a veil layer.

Embodiment 82. The acoustical ceiling tile according to Embodiment 81, wherein the veil layer comprises a fiberglass mat applied to the outside of at least one finished surface of the acoustical ceiling tile.

Embodiment 83. An acoustical ceiling tile with reduced emissions, comprising: an aggregate core board composition comprising: 10 to 45 wt. % mineral fibers; 15 to 35 wt. % particulate filler; 5 to 15 wt. % fiberglass; 1 to 15 wt. % cellulosic fibers; and 4 to 12 wt. % binder, wherein a ratio of inclusion of the mineral fiber to the binder is 3.0 to 5.5:1; wherein the global warming potential (GWP) of the aggregate core board is less than 1.00 kgCO₂eq/kg; and wherein the noise reduction coefficient (NRC) of the finished acoustical ceiling tile is equal to or greater than 0.60 by ASTM C423.

Embodiment 84. The acoustical ceiling tile according to Embodiment 83, wherein the mineral fiber comprises mineral wool formed of basalt rock, stone wool, glass wool, slag wool, mineral or rock wool, metal wool, or any combination thereof.

Embodiment 85. The acoustical ceiling tile according to Embodiment 84, wherein the mineral fiber comprises mineral wool formed of slag.

Embodiment 86. The acoustical ceiling tile according to Embodiment 83, wherein the mineral fiber is added to the aggregate core board composition in an amount of approximately from 35 to 45 wt. %.

Embodiment 87. The acoustical ceiling tile according to Embodiment 83, wherein the particulate filler comprises perlite, expanded perlite, vermiculite, hollow glass beads, polymer beads, calcium carbonate, plaster, gypsum, silica, sericite, fly ash, natural clay, ball clay, talc, or combinations thereof.

Embodiment 88. The acoustical ceiling tile according to Embodiment 87, wherein the particulate filler comprises expanded perlite.

Embodiment 89. The acoustical ceiling tile according to Embodiment 88, wherein the particulate filler comprises vermiculite.

Embodiment 90. The acoustical ceiling tile according to Embodiment 83, wherein the cellulosic fiber comprises paper, recycled newsprint, recycled paper, wood pulp, cellulose, plant fibers, bio-based fibers, or combinations thereof.

Embodiment 91. The acoustical ceiling tile according to Embodiment 90, wherein the cellulosic fiber comprises paper.

Embodiment 92. The acoustical ceiling tile according to Embodiment 83, wherein the binder comprises starch, latex, phenolic resin, or combinations thereof.

Embodiment 93. The acoustical ceiling tile according to Embodiment 92, wherein the binder comprises starch.

Embodiment 94. The acoustical ceiling tile according to Embodiment 83, further comprising water.

Embodiment 95. The acoustical ceiling tile according to Embodiment 94, wherein a solids percentage of the water in a slurry is added in an amount between about 2-5 wt. %.

Embodiment 96. The acoustical ceiling tile according to Embodiment 83, wherein the ceiling tile is planar.

Embodiment 97. The acoustical ceiling tile according to Embodiment 83, wherein the ceiling tile is curved.

Embodiment 98. The acoustical ceiling tile according to Embodiment 83, wherein the ceiling tile is three-dimensional.

Embodiment 99. The acoustical ceiling tile according to Embodiment 83, wherein a length of the acoustical ceiling tile is from approximately 12 inches to 60 feet.

Embodiment 100. The acoustical ceiling tile according to Embodiment 83, wherein a width of the acoustical ceiling tile is from approximately 12 inches to 30 feet.

Embodiment 101. The acoustical ceiling tile according to Embodiment 83, wherein a thickness of the acoustical ceiling tile is from approximately 0.25 inches to 1.5 inches.

Embodiment 102. The acoustical ceiling tile according to Embodiment 83, wherein the aggregate core board composition has a sound absorption coefficient of at least 0.2 by ASTM E1050-19.

Embodiment 103. The acoustical ceiling tile according to Embodiment 83, wherein the acoustical ceiling tile further comprises a veil layer.

Embodiment 104. The acoustical ceiling tile according to Embodiment 103, wherein the veil layer comprises a fiberglass mat applied to the outside of at least one finished surface of the acoustical ceiling tile.

Embodiment 105. An acoustical ceiling tile with reduced emissions, comprising: an aggregate core board composition comprising: 10 to 45 wt. % mineral wool; 15 to 35 wt. % of a particulate filler selected from the group consisting of perlite, expanded perlite, vermiculite, hollow glass beads, polymer beads, calcium carbonate, plaster, gypsum, silica, sericite, fly ash, natural clay, ball clay, talc, or combinations thereof, 5 to 15 wt. % fiberglass; 1 to 15 wt. % of paper; and 4 to 12 wt. % of starch, wherein a ratio of inclusion of the mineral fiber to the binder is 3.0 to 5.5:1; wherein the global warming potential (GWP) of the aggregate core board is less than 1.00 kgCO₂eq/kg; and wherein the noise reduction coefficient (NRC) of the finished acoustical ceiling tile is equal to or greater than 0.60 by ASTM C423.

Embodiment 106. The acoustical ceiling tile according to Embodiment 105, wherein the mineral wool is formed of basalt rock, stone wool, glass wool, slag wool, mineral or rock wool, metal wool, or any combination thereof.

Embodiment 107. The acoustical ceiling tile according to Embodiment 106, wherein the mineral wool is formed of slag.

Embodiment 108. The acoustical ceiling tile according to Embodiment 105, wherein the mineral fiber is added to the aggregate core board composition in an amount of approximately from 35 to 45 wt. %.

Embodiment 109. The acoustical ceiling tile according to Embodiment 105, wherein the particulate filler comprises expanded perlite.

Embodiment 110. The acoustical ceiling tile according to Embodiment 105, wherein the particulate filler comprises vermiculite.

Embodiment 111. The acoustical ceiling tile according to Embodiment 105, further comprising water.

Embodiment 112. The acoustical ceiling tile according to Embodiment 111, wherein a solids percentage of the water in a slurry is added in an amount between about 2-5 wt. %.

Embodiment 113. The acoustical ceiling tile according to Embodiment 105, wherein the ceiling tile is planar.

Embodiment 114. The acoustical ceiling tile according to Embodiment 105, wherein the ceiling tile is curved.

Embodiment 115. The acoustical ceiling tile according to Embodiment 105, wherein the ceiling tile is three-dimensional.

Embodiment 116. The acoustical ceiling tile according to Embodiment 105, wherein a length of the acoustical ceiling tile is from approximately 12 inches to 60 feet.

Embodiment 117. The acoustical ceiling tile according to Embodiment 105, wherein a width of the acoustical ceiling tile is from approximately 12 inches to 30 feet.

Embodiment 118. The acoustical ceiling tile according to Embodiment 105, wherein a thickness of the acoustical ceiling tile is from approximately 0.25 inches to 1.5 inches.

Embodiment 119. The acoustical ceiling tile according to Embodiment 105, wherein aggregate core board composition has a sound absorption coefficient of at least 0.2 by ASTM E1050-19.

Embodiment 120. The acoustical ceiling tile according to Embodiment 105, wherein the acoustical ceiling tile further comprises a veil layer.

Embodiment 121. The acoustical ceiling tile according to Embodiment 120, wherein the veil layer comprises a fiberglass mat applied to the outside of at least one finished surface of the acoustical ceiling tile.

Embodiment 122. A composite with reduced emissions, comprising: an aggregate core board composition comprising mineral fiber; particulate filler; fiberglass; cellulosic fiber; and a binder, wherein a ratio of inclusion of the mineral fiber to the binder is 3.0 to 5.5:1; wherein the aggregate core board has a global warming potential (GWP) of less than 1.00 kgCO₂eq/kg; and wherein the aggregate core board of the composite has a sound absorption coefficient of at least 0.2 by ASTM E1050-19.

Embodiment 123. The composite according to Embodiment 122, wherein the mineral fiber comprises mineral wool formed of basalt rock, stone wool, glass wool, slag wool, mineral or rock wool, metal wool, or any combination thereof.

Embodiment 124. The composite according to Embodiment 123, wherein the mineral fiber comprises mineral wool formed of slag.

Embodiment 125. The composite according to Embodiment 122, wherein the mineral fiber is added to the aggregate core board composition in an amount of approximately from 10 to 45 wt. %.

Embodiment 126. The composite according to Embodiment 125, wherein the mineral fiber is added to the aggregate core board composition in an amount of approximately from 35 to 45 wt. %.

Embodiment 127. The composite according to Embodiment 122, wherein the particulate filler comprises perlite, expanded perlite, vermiculite, hollow glass beads, polymer beads, calcium carbonate, plaster, gypsum, silica, sericite, fly ash, natural clay, ball clay, talc, or combinations thereof.

Embodiment 128. The composite according to Embodiment 122, wherein the particulate filler is added to the aggregate core board composition in an amount of approximately from 15 to 35 wt. %.

Embodiment 129. The composite according to Embodiment 127, wherein the particulate filler comprises expanded perlite.

Embodiment 130. The composite according to Embodiment 127, wherein the particulate filler comprises vermiculite.

Embodiment 131. The composite according to Embodiment 122, wherein the fiberglass is added to the aggregate core board composition as a loose compound.

Embodiment 132. The composite according to Embodiment 122, wherein the fiberglass is added to the aggregate core board composition in an amount of approximately from 5 to 15 wt. %.

Embodiment 133. The composite according to Embodiment 122, wherein the cellulosic fiber comprises paper, recycled newsprint, recycled paper, wood pulp, cellulose, plant fibers, bio-based fibers, or combinations thereof.

Embodiment 134. The composite according to Embodiment 133, wherein the cellulosic fiber comprises paper.

Embodiment 135. The composite according to Embodiment 122, wherein the cellulosic fiber is added to the aggregate core board composition in an amount of approximately from 1 to 15 wt. %.

Embodiment 136. The composite according to Embodiment 122, wherein the binder comprises starch, latex, phenolic resin, or combinations thereof.

Embodiment 137. The composite according to Embodiment 131, wherein the binder comprises starch.

Embodiment 138. The composite according to Embodiment 122, wherein the binder is added to the aggregate core board composition in an amount of approximately from 4 to 12 wt. %.

Embodiment 139. The composite according to Embodiment 122, wherein the aggregate further comprises water.

Embodiment 140. The composite according to Embodiment 139, wherein a solids percentage of the water in a slurry is added in an amount between about 2-5 wt. %.

Embodiment 141. The composite according to Embodiment 122, wherein the composite is formed into an acoustical ceiling tile.

Embodiment 142. The composite according to Embodiment 141, wherein the acoustical ceiling tile is planar.

Embodiment 143. The composite according to Embodiment 141, wherein the acoustical ceiling tile is curved.

Embodiment 144. The composite according to Embodiment 141, wherein the acoustical ceiling tile is three-dimensional.

Embodiment 145. The composite according to Embodiment 141, wherein a length of the acoustical ceiling tile is from approximately 12 inches to 60 feet.

Embodiment 146. The composite according to Embodiment 141, wherein a width of the acoustical ceiling tile is from approximately 12 inches to 30 feet.

Embodiment 147. The composite according to Embodiment 141, wherein a thickness of the acoustical ceiling tile is from approximately 0.25 inches to 1.5 inches.

Embodiment 148. The composite according to Embodiment 141, wherein the finished acoustical ceiling tile has a noise reduction coefficient (NRC) of equal to or greater than 0.60 by ASTM C423.

Embodiment 149. The composite according to Embodiment 141, wherein the acoustical ceiling tile further comprises a veil layer.

Embodiment 150. The composite according to Embodiment 149, wherein the veil layer comprises a fiberglass mat applied to the outside of at least one finished surface of the acoustical ceiling tile.

EXAMPLES

The following non-limiting examples illustrate the embodiments described herein.

Example 1—Standard/Control Acoustical Ceiling Tile

A standard acoustical ceiling tile that does not contain any glass fiber was prepared according to the process below. To prepare the standard acoustical ceiling tile core board C1 sample that should be generally known and/or commercially available with standard NRC levels (such as Symphony® EPD 80/85% acoustical ceiling tile), 350 g to 360 g mineral slag wool fiber was mixed with 50 g to 60 g of paper, 40 g to 50 g starch, and 75 g to 80 g expanded perlite to create an aggregate core board slab. 13.5 L water (to create a slurry of 2-5 percent solids by wt. %) was added. The slurry was then allowed to set and dried to remove excess water, forming the final standard acoustical ceiling tile. A core sample was taken of the aggregate core board before drying and placed inside the impedance tube for measurement of the sound absorption coefficient by ASTM E1050-19 methodology and based on an average of set frequencies as shown in FIG. 5 for C1. Final total emission factors and global warming potential calculation of the finished board and analysis were conducted after drying as described above and testing by ASTM C423 methodology. The emission results can be found in Table 1 below.

Example 2=Reduced Emissions Acoustical Ceiling Tile

Samples S1-S5 of acoustical ceiling tiles as described herein were prepared according to the process below. To prepare the acoustical ceiling tile core boards, 200 g to 250 g mineral slag wool fiber was mixed with 50 g to 70 g of paper, 40 g to 50 g starch, 160 g to 180 g expanded perlite, and 30 g to 60 g fiberglass to create an aggregate compound. 13.5 L water (to create a slurry of 2-5 percent solids by wt. %) was added. The slurry was then allowed to set and dried to remove excess water, forming the final acoustical ceiling tile. A core sample was taken of the aggregate core board before drying and placed inside the impedance tube for measurement of the sound absorption coefficient by ASTM E1050-19 methodology and based on an average of set frequencies as shown in FIG. 5 for S3. Final total emission factors and global warming potential calculation of the finished board and analysis for S1-S5 were conducted after drying as described above and testing by ASTM C423 methodology. The noise reduction co-efficient (NCR) of the finished board and analysis for S5 was conducted after drying as described above and testing by ASTM C423 methodology. The emission results can be found in Table 1 below, highlighting the differing inclusion ratios of the mineral slag wool (mineral fiber) to the native starch (binder).

TABLE 1
	Mineral	Cellulosic		Particulate	Glass	Total	Total	Total
	Fiber	Fiber	Binder	Filler	Fiber	Dry	GWP of	NRC of
Samples	(wt. %)	(wt. %)	(wt. %)	(wt. %)	(wt. %)	(wt. %)	core board	core board

C1	66.30	10.10	9.00	14.60	n/a	100	1.009	0.75
S1	45.00	10.00	9.00	30.00	6.00	100	0.770	—
S2	38.00	12.00	8.00	32.00	10.00	100	0.691	—
S3	40.00	12.00	8.00	30.00	10.00	100	0.717	—
S4	40.00	10.00	9.00	31.00	10.00	100	0.732	—
S5	41.00	10.00	8.0	30.00	11.00	100	0.737	0.75

Note that not all of the activities described above in the general description or the examples are required, that a portion of a specific activity may not be required, and that one or more further activities may be performed in addition to those described. Still further, the order in which activities are listed is not necessarily the order in which they are performed.

Benefits, other advantages, and solutions to problems have been described above with regard to specific embodiments. However, the benefits, advantages, solutions to problems, and any feature(s) that may cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as a critical, required, or essential feature of any or all the claims.

The specification and illustrations of the embodiments described herein are intended to provide a general understanding of the structure of the various embodiments. The specification and illustrations are not intended to serve as an exhaustive and comprehensive description of all of the elements and features of apparatus and systems that use the structures or methods described herein. Separate embodiments may also be provided in combination in a single embodiment, and conversely, various features that are, for brevity, described in the context of a single embodiment, may also be provided separately or in any sub combination. Further, reference to values stated in ranges includes each and every value within that range. Many other embodiments may be apparent to skilled artisans only after reading this specification. Other embodiments may be used and derived from the disclosure, such that a structural substitution, logical substitution, or another change may be made without departing from the scope of the disclosure. Accordingly, the disclosure is to be regarded as illustrative rather than restrictive.