FIRE PERFORMANCE FOR WOOD VENEER LAMINATED CEILING TILE

• US 20170121982A1
• Filed: 10/26/2016
• Published: 05/04/2017
• Est. Priority Date: 10/28/2015
• Status: Active Grant

• Current Assignee: Armstrong World Industries Incorporated
• Original Assignee: Armstrong World Industries Incorporated
• Inventors: Kehrer, Kenneth P., Wang, Michelle X., Bischel, Marsha S., Lu, Lida
• Granted Patent: US 10,745,920 B2
• Time in Patent Office: Days
• CPC Class Codes: B32B 15/10 of wood
• CPC Class Codes: B32B 15/18 comprising iron or steel B32B15/011, B32B15/012 and B32B15/013 take precedence
• CPC Class Codes: B32B 15/20 comprising aluminium or copper B32B15/016 and B32B15/017 take precedence
• CPC Class Codes: B32B 2037/1215 Hot-melt adhesive
• CPC Class Codes: B32B 21/02 the layer being formed of fibres, chips, or particles , e.g. MDF, HDF, OSB, chipboard, particle board, hardboard
• CPC Class Codes: B32B 21/04 comprising wood as the main or only constituent of a layer, which is next to another layer of the same or of a different material next to a layer of a particular substance B32B9/042; next to a bituminous or tarry layer B32B11/042; next to a water setting substance layer B32B13/10; next to a metal layer B32B15/10; next to a glass layer B32B17/062; next to a layer formed of natural mineral fibres or particles B32B19/042; next to a cellulosic plastic layer B32B23/044
• CPC Class Codes: B32B 21/14 comprising wood board or veneer
• CPC Class Codes: B32B 2250/02 2 layers
• CPC Class Codes: B32B 2255/08 on wood layer
• CPC Class Codes: B32B 2255/26 Polymeric coating
• CPC Class Codes: B32B 2255/28 Multiple coating on one surface
• CPC Class Codes: B32B 2307/304 Insulating
• CPC Class Codes: B32B 2307/3065 Flame resistant or retardant, fire resistant or retardant
• CPC Class Codes: B32B 2307/412 Transparent
• CPC Class Codes: B32B 2307/50 having particular mechanical properties
• CPC Class Codes: B32B 2307/7246 Water vapor barrier
• CPC Class Codes: B32B 2307/73 Hydrophobic
• CPC Class Codes: B32B 2307/732 Dimensional properties
• CPC Class Codes: B32B 2311/24 Aluminium
• CPC Class Codes: B32B 2419/00 Buildings or parts thereof walls, panels B32B2607/00
• CPC Class Codes: B32B 2607/00 : Walls, panels
• CPC Class Codes: B32B 37/1207 : Heat-activated adhesive B32B37/04 takes precedence
• CPC Class Codes: B32B 7/12 : using interposed adhesives or interposed materials with bonding properties
• CPC Class Codes: B32B 9/005 : comprising one layer of ceramic material, e.g. porcelain, ceramic tile layered products with at least two ceramic layers composed mainly of ceramic B32B18/00
• CPC Class Codes: B32B 9/042 : of wood
• CPC Class Codes: E04B 9/045 : being laminated
• CPC Class Codes: E04B 9/225 : with the slabs, panels, sheets or the like hanging at a distance below the supporting construction
• CPC Class Codes: E04B 9/34 : Grid-like or open-work ceilings, e.g. lattice type box-like modules, acoustic baffles E04B9/30 takes precedence
• CPC Class Codes: E04F 13/077 : composed of several layers, e.g. sandwich panels E04F13/075 takes precedencenot used, see E04F13/0866
• CPC Class Codes: E04F 13/0866 : composed of several layers, e.g. sandwich panels or layered panels layered products as such in general B32B; producing decorative panels or veneers B44C5/04; E04F13/0864, E04F13/0875 take precedence
• CPC Class Codes: E04F 13/12 : of metal or with an outer layer of metal or enameled metal E04F13/0864 takes precedence

Abstract

The present invention is directed to a building panel having a laminate structure, the laminate structure including a topcoat layer comprising a first intumescent composition, a cellulosic veneer layer, an adhesive layer formed from an adhesive composition comprising a second intumescent composition, and a metallic substrate layer and wherein the cellulosic veneer layer is at least partially bonded to the metallic substrate by the adhesive layer. The resulting building panel exhibits superior flame retardancy resulting in a Class A fire rating, according to ASTM E-84.

Claims

1. A ceiling panel comprising a laminate structure, the laminate structure comprising:

a topcoat layer comprising an intumescent composition;

a cellulosic veneer layer comprising a first major surface opposite a second major surface;

an adhesive layer formed from an adhesive composition comprising a thermoplastic polymer; and

a metallic substrate layer;

wherein the cellulosic veneer layer is at least partially bonded to the metallic substrate by the adhesive layer.

2. The ceiling panel according to claim 1, wherein the topcoat layer comprises:

a first sub-layer atop the cellulosic veneer layer, the first sub-layer comprising a sealant composition comprising a first polymer; and

a second sub-layer atop the first sub-layer, the second sub-layer comprising the intumescent composition.

3. The ceiling panel according to claim 2, wherein the topcoat layer is substantially clear.

4. The ceiling panel according to claim 1, wherein the topcoat layer directly contacts the first major surface of the cellulosic veneer layer and the adhesive layer directly contacts the second major surface of the cellulosic veneer layer.

5. The ceiling panel according to claim 2, wherein the first major surface of the cellulosic veneer layer comprises pores, and wherein the first sub-layer directly contacts the first major surface of the cellulosic veneer layer thereby sealing at least a portion of the pores.

6. The ceiling panel according to claim 2, wherein the adhesive layer directly contacts the second major surface of the veneer layer and the second sub-layer is separated from the first major surface of the veneer layer by a height of the first sub-layer.

7. The ceiling panel according to claim 1, wherein the intumescent composition comprises:

a carbon donor compound; and

an acid donor compound comprising ammonium phosphate, di-ammonium phosphate, ammonium dihydrogen phosphate, ammonium polyphosphate, melamine phosphate, guanylurea phosphate, urea phosphate, p-toluenesulphonic acid, ammonium sulfate, ammonium borate, and combinations thereof.

8. The ceiling panel according to claim 2, wherein the first polymer comprises one or more of vinyl or acrylic homopolymers or copolymers formed from ethylenically unsaturated monomers such as ethylene or butadiene and vinyl monomers such as styrene, vinyl esters such as vinyl acetate, vinyl propionate, vinyl butyrates, acrylic acid, methacrylic acid, or esters of acrylic acid and/or esters of methacrylic acid.

9. The ceiling panel according to claim 2, wherein the topcoat layer further comprises a third sub-layer that is atop the second sub-layer, the third sub-layer being substantially impervious to ambient moisture.

10. The ceiling panel according to claim 9, wherein the second sub-layer comprises a second polymer having a second glass transition temperature and the third sub-layer comprises a third polymer having a third glass transition temperature, the third glass transition temperature being equal to or less than the second glass transition temperature.

11. The ceiling panel according to claim 7, wherein the second sub-layer comprises a second polymer that is the carbon donor compound of the intumescent composition.

12. The ceiling panel according to claim 1, wherein the adhesive composition is a hot-melt composition and the thermoplastic polymer comprises polyester modified polyurethane.

13. The ceiling panel according to claim 1, wherein the metallic substrate has a thickness ranging from about 35 mils to about 65 mils and the cellulosic veneer layer has a thickness ranging from about 25 mils to about 45 mils.

14. A ceiling panel comprising a laminate structure, the laminate structure comprising:

a topcoat layer comprising;

a sealant composition; and

an intumescent composition;

a cellulosic veneer layer having a first major surface opposite a second major surface;

an adhesive layer formed from an adhesive composition comprising a thermoplastic polymer; and

a metallic substrate layer;

wherein the first sub-layer is atop the first major surface of the cellulosic veneer layer; and

the second sub-layer is atop the first sub-layer.

15. The ceiling panel according to claim 14, wherein the topcoat includes a first sub-layer comprising the sealant composition and a second sub-layer comprising the intumescent composition.

16. The ceiling panel according to claim 15, wherein the first major surface of the cellulosic veneer layer comprises pores that are at least partially sealed by the first sub-layer of the topcoat layer.

17. The ceiling panel according to claim 15, wherein the second sub-layer is separated from the first major surface of the veneer layer by a height of the first sub-layer.

18. A building panel comprising a laminate structure, the laminate structure comprising:

a cellulosic layer; and

a topcoat layer that is substantially impervious to ambient moisture and comprising an intumescent composition.

19. The building panel according to claim 18, wherein the topcoat layer comprises:

a barrier sub-layer that is substantially impervious to ambient moisture, the barrier sub-layer comprising a first polymer having a first glass transition temperature

an intumescent sub-layer comprising the intumescent composition and a second polymer having a second glass transition temperature;

wherein the barrier sub-layer is atop the intumescent sub-layer and the intumescent sub-layer is atop the cellulosic layer; and

wherein the first glass transition temperature being equal to or less than the second glass transition temperature.

20. The building panel according to claim 18, wherein the cellulosic layer comprises a first major surface opposite a second major surface, and the topcoat layer further comprises:

a sealant sub-layer; and

an intumescent sub-layer comprising the intumescent composition;

wherein the sealant sub-layer is positioned between the cellulosic layer and the intumescent sub-layer such that the intumescent sub-layer is separated from the first major surface of the cellulosic layer by the sealant sub-layer.