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07/09/09 - USPTO Class 181 |  98 views | #20090173570 | Prev - Next | About this Page  181 rss/xml feed  monitor keywords

Acoustically absorbent ceiling tile having barrier facing with diffuse reflectance

USPTO Application #: 20090173570
Title: Acoustically absorbent ceiling tile having barrier facing with diffuse reflectance
Abstract: An acoustically absorbent ceiling tile includes a core of acoustically absorbing material having two major surfaces, and a facing for covering the core on at least one major surface. The facing comprises a porous flash spun plexifilamentary film-fibril sheet having a coherent surface and comprising a plurality of pores having a pore diameter between about 100 nm and about 20,000 nm and a mean pore diameter of less than about 20,000 nm. The facing has highly diffuse reflectance of light, and a reflectance of greater than about 86%. The use of the facing improves the acoustic absorption of ambient sound at frequencies below about 1200 Hz. The facing provides a barrier to moisture and particles including microorganisms so that the ceiling tile is suitable for use in environments in which cleanliness is critical. (end of abstract)



Agent: E I Du Pont De Nemours And Company Legal Patent Records Center - Wilmington, DE, US
Inventors: Natalia V. Levit, Eric W. Teather
USPTO Applicaton #: 20090173570 - Class: 181286 (USPTO)

Acoustically absorbent ceiling tile having barrier facing with diffuse reflectance description/claims


The Patent Description & Claims data below is from USPTO Patent Application 20090173570, Acoustically absorbent ceiling tile having barrier facing with diffuse reflectance.

Brief Patent Description - Full Patent Description - Patent Application Claims
  monitor keywords BACKGROUND OF THE INVENTION

1. Field of the Invention

The invention relates to ceiling tiles for use in a building interior.

2. Description of the Related Art

Acoustically absorbent ceiling tiles are known in the art for use reducing the amount of noise and/or reverberation within a given area, such as a building interior. In such ceiling tiles, a core of acoustically absorbing materials, i.e., materials having a high absorption coefficient, reduces noise by absorbing acoustic energy as sound waves strike and enter the acoustically absorbing material. Many known acoustically absorbing materials are formed of unconsolidated or partially unconsolidated, lofty fibrous materials including compressed fibers, recycled fiber or shoddy materials, fiberglass or mineral fiber batts and felts and require a facing to contain the core of fibrous materials. Other known acoustically absorbing core materials including foam, materials having a honeycomb structure, microperforated materials and acoustically absorbing materials utilizing air spaces also utilize a protective and/or decorative facing for use in a building interior.

Facings for covering acoustic absorbent ceiling tiles serve as durable coverings that protect the core during handling, use and maintenance. It is desirable that facings for covering acoustically absorbent materials be materials that are either acoustically transparent or absorbent, but not acoustically reflective, in order to enhance the absorption of sound. Facings which are acoustically reflective undesirably contribute to the ambient noise. Known facings for covering acoustically absorbent ceiling tiles include fabric, nonwoven sheet, paper, film and perforated solid materials.

U.S. Pat. Nos. 5,824,973 and 6,877,585 disclose a sound absorption laminate useful as a ceiling tile comprising a porous insulation substrate and a paper, fabric or perforated film facing sheet having an air flow resistance between 200 and 1210 rayls. U.S. Pat. Appl. Pub. 2007/0151800 discloses an acoustic insulating sheet material comprising a primary sound absorbing sheet and a dense porous membrane which can be a spunbond web, melt blown web, spunlaced web, carded or airlaid staple fiber web, woven web, wet-laid web or combination of such webs having an airflow resistance of about 5,000 rayls or less. U.S. Pat. No. 3,858,676 discloses a thin sound-absorbing panel especially for frequencies below 500 Hz and its use in a ceiling system wherein the panel comprises a perforated backing, a heavy textile facing having a basis weight of 12 to 2,140 g/m2 and a specific airflow resistance of 300 to 1,800 rayls, and a fiberglass core. U.S. Pat. No. 5,832,685 discloses a self-supporting sound absorbing panel and its use in a ceiling system comprising a nonwoven fabric having a basis weight of about 10 to 15 oz/yd2 which can be a spunbond fabric or a fabric comprising bonded staple fibers. These known facing materials have the disadvantage that they are open to the penetration of water, dust, mold and microorganisms, thus limiting their application in critical environments.

It is desirable that visible light be reflected from the surface of ceiling tile facings in a diffuse, even distribution, as opposed to specular (mirror-like) reflection in which light is reflected only at an angle equal to the incident angle. Diffuse or Lambertian reflectance is the uniform diffuse reflection of light from a material in all directions with no directional dependence for the viewer, according to Lambert\'s cosine law. Diffuse reflectance originates from a combination of external scattering of light from features on the surface of a material, and internal scattering of light from features within a material. Internal light scattering can arise, for example, from features within a material such as pores and particles. The light scattering cross section per unit feature volume of materials containing closely spaced refractive index inhomogeneity is maximized when the mean diameter of the features is slightly less than one-half the wavelength of the incident light. The degree of light scattering is also increased when there is a large difference between the refractive index of the scattering feature and refractive index of the phase in which the feature is dispersed.

It would be desirable to have acoustically absorbing ceiling tiles having a combination of diffuse reflectance of light and acoustic absorption which are suitable for use in a variety of critical environments.

SUMMARY OF THE INVENTION

According to one embodiment, the invention is directed to a ceiling tile comprising:

a core of acoustically absorbing material having two major surfaces; and

a facing for covering the core on at least one major surface thereof, the facing comprising a flash spun plexifilamentary film-fibril sheet having a coherent surface, having a basis weight of no greater than about 140 g/m2, comprising a plurality of pores having a pore diameter between about 100 nm and about 20,000 nm and a mean pore diameter of less than about 20,000 nm and having a light reflectance of greater than about 86%.

According to another embodiment, the invention is directed to a method of improving acoustic absorption and light reflectance in an environment comprising:

(a) providing a ceiling tile comprising a core of acoustically absorptive material covered by a facing of flash spun sheet having a plurality of pores having a pore diameter between about 100 nm and about 20,000 nm and a mean pore diameter of less than about 20,000 nm and having a light reflectance of greater than about 86%; and

(b) positioning the ceiling tile within the environment to cause ambient sound to be absorbed and light to be reflected by the ceiling tile.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a graph depicting the acoustic absorption, reflection and sound transmission of a flash spun sheet (block measurement).

FIG. 2 is a graph depicting the acoustic absorption, reflection and sound transmission of a flash spun sheet (anechoic measurement).

FIG. 3 is a graph comparing the acoustic absorption coefficients of an acoustic absorber without a facing and two acoustic absorbers with facings useful in the ceiling tile according to the invention.



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