Patents by Inventor Martin W. Brown
Martin W. Brown has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).
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Patent number: 10464846Abstract: A method of decreasing the water load needed to form a fibrous panel. The process includes admixing a mineral wool, a cellulose, and a binder to provide a pre-mixed slurry, admixing a mineral filler with water to provide a mineral filler slurry, admixing the pre-mixed slurry and the mineral filler slurry to form a dispersion, flowing the dispersion onto a foraminous support wire to provide a green board, dewatering the green board to form a dewatered green board and drying the dewatered green board to provide a fibrous panel.Type: GrantFiled: August 17, 2017Date of Patent: November 5, 2019Assignee: USG INTERIORS, LLCInventors: Thomas M. Mayers, Wei Xu, Martin W. Brown
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Publication number: 20190055162Abstract: The disclosure provides a method of decreasing the water load needed to form a fibrous panel. The process includes admixing a mineral wool, a cellulose, and a binder to provide a pre-mixed slurry, admixing a mineral filler with water to provide a mineral filler slurry, admixing the pre-mixed slurry and the mineral filler slurry to form a dispersion, flowing the dispersion onto a foraminous support wire to provide a green board, dewatering the green board to form a dewatered green board and drying the dewatered green board to provide a fibrous panel.Type: ApplicationFiled: August 17, 2017Publication date: February 21, 2019Applicant: USG Interiors, LLCInventors: Thomas M. Mayers, Wei Xu, Martin W. Brown
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Patent number: 9909310Abstract: An acoustical tile having a wet laid mineral fiber basemat, a non-woven porous fiberglass veil adhered to the basemat and covered with a light reflecting air permeable coating, at least 90% of the weight of the basemat comprising mineral wool and binder, a weight of the binder being less than 1/11 of the weight of the mineral fiber, the basemat having a density of between about 11.4 and about 14.2 lbs/cubic foot, the mineral fiber having an average diameter of between 4.5 and 8.3 microns, the composite of the basemat, veil and coating exhibiting good NRC and CAC performance values.Type: GrantFiled: April 27, 2016Date of Patent: March 6, 2018Assignee: USG INTERIORS, LLCInventors: William A. Frank, Matthew T. Langdon, Wenqi Luan, Martin W. Brown
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Publication number: 20170204604Abstract: An acoustical tile having a wet laid mineral fiber basemat, a non-woven porous fiberglass veil adhered to the basemat and covered with a light reflecting air permeable coating, at least 90% of the weight of the basemat comprising mineral wool and binder, a weight of the binder being less than 1/11 of the weight of the mineral fiber, the basemat having a density of between about 11.4 and about 14.2 lbs/cubic foot, the mineral fiber having an average diameter of between 4.5 and 8.3 microns, the composite of the basemat, veil and coating exhibiting good NRC and CAC performance values.Type: ApplicationFiled: April 27, 2016Publication date: July 20, 2017Inventors: William A. Frank, Matthew T. Langdon, Wenqi Luan, Martin W. Brown
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Patent number: 9492961Abstract: An acoustic tile with excellent anti-sagging properties is provided. The tile comprises a soy-protein binder selected from the group consisting of soy flour, soy protein concentrate, soy protein isolate and any combination thereof. In further embodiments, the tile further comprises polyamide-epichlorohydrin. Other tiles include those made with a thermosetting binder selected from the group consisting of an acrylic binder, a polyester binder, an acrylo-polyester binder and any mixture thereof. Energy-efficient methods for making the tiles are also provided.Type: GrantFiled: January 28, 2015Date of Patent: November 15, 2016Assignee: USG INTERIORS, LLCInventors: Wei Xu, Brian A. Kemp, Mark H. Englert, Martin W. Brown, Terry L. Rosenstiel
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Publication number: 20160032583Abstract: An acoustic tile with excellent anti-sagging properties is provided. The tile comprises a soy-protein binder selected from the group consisting of soy flour, soy protein concentrate, soy protein isolate and any combination thereof. In further embodiments, the tile further comprises polyamide-epichlorohydrin. Other tiles include those made with a thermosetting binder selected from the group consisting of an acrylic binder, a polyester binder, an acrylo-polyester binder and any mixture thereof. Energy-efficient methods for making the tiles are also provided.Type: ApplicationFiled: January 28, 2015Publication date: February 4, 2016Inventors: Wei Xu, Brian A. Kemp, Mark H. Englert, Martin W. Brown, Terry L. Rosenstiel
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Patent number: 8945295Abstract: An article of manufacture comprising a building panel such as ceiling tile for example includes, in addition to any by-product perlite fines, additional perlite fines in an amount sufficient to improve the fire resistance of the building panel over the fire resistance of the building panel without the additional perlite fines. In one aspect, the additional perlite fines can comprise at least approximately 3.5% perlite fines by weight. In another aspect, the additional perlite fines can have an average diameter of approximately 23 microns or less. Methods of manufacture related to the building panel also are disclosed.Type: GrantFiled: May 4, 2012Date of Patent: February 3, 2015Assignee: USG Interiors, LLCInventor: Martin W. Brown
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Patent number: 8894811Abstract: A method of forming a dilute water slurry for water felting a basemat for an acoustical ceiling tile comprising delivering a bale of compressed mineral wool with a density of at least 8 lbs. per cubic foot at an unbaling station, releasing a binding holding the bale in compression, mechanically separating the fibers of a mineral wool bale with mechanical instrumentalities arranged to disperse the fibers to a generally uniform density of less than 2 lbs. per cubic foot prior to passage of the fibers through the tank inlet, and causing the separated mineral fibers to pass into the mixing tank for contact with water suspended binder.Type: GrantFiled: October 16, 2013Date of Patent: November 25, 2014Assignee: USG Interiors, LLCInventor: Martin W. Brown
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Patent number: 8801902Abstract: A system and a method for dewatering an acoustical tile basemat comprising a continuously traveling wire, a device for depositing a dilute water slurry of solids including fiber and binder on the wire, a vacuum box below the wire for separating water from the solids deposited on the wire to form a basemat, a vacuum source, and a valve for cyclically connecting the vacuum source to the vacuum box at a cyclic rate that limits vacuum exposure to a length of the basemat newly arriving at the vacuum box to less than four inches per cycle.Type: GrantFiled: September 18, 2013Date of Patent: August 12, 2014Assignee: USG Interiors, LLCInventors: Martin W. Brown, William A. Frank
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Patent number: 8697588Abstract: Provided is a mineral wool that includes recycled material. The mineral wool is characterized by an acid to base ratio within a specified range. Also provided is a method of manufacturing the mineral wool that includes selection of post-consumer or post-industrial recyclable materials. Application of the mineral wool to products such as an acoustical ceiling panel is also provided.Type: GrantFiled: April 11, 2011Date of Patent: April 15, 2014Assignee: USG Interiors, Inc.Inventor: Martin W. Brown
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Publication number: 20130291762Abstract: An article of manufacture comprising a building panel such as ceiling tile for example includes, in addition to any by-product perlite fines, additional perlite fines in an amount sufficient to improve the fire resistance of the building panel over the fire resistance of the building panel without the additional perlite fines. In one aspect, the additional perlite fines can comprise at least approximately 3.5% perlite fines by weight. In another aspect, the additional perlite fines can have an average diameter of approximately 23 microns or less. Methods of manufacture related to the building panel also are disclosed.Type: ApplicationFiled: May 4, 2012Publication date: November 7, 2013Applicant: USG INTERIORS, LLC.Inventor: Martin W. Brown
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Patent number: 8133357Abstract: A panel includes about 0.1% to about 95% by weight of a ground renewable component. In an embodiment, the panel has at least one core comprising: from about 0.1% to about 95% by weight of the ground renewable component; from about 0.1% to about 95% by weight of one or more fibers; and from about 1% to about 30% by weight of one or more binders, all based on dry panel weight. In an embodiment, the ground renewable component has a particle size distribution whereby less than 5% of the particles are retained by a mesh screen with openings of about 0.312 inches and less than 5% of the particles pass through a mesh screen with openings of about 0.059 inches. A method for manufacturing such panels is also provided.Type: GrantFiled: March 30, 2009Date of Patent: March 13, 2012Assignee: USG Interiors, Inc.Inventors: Bangji Cao, Te Hua Lau, W. David Song, Martin W. Brown
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Patent number: 8080133Abstract: A panel includes about 0.1% to about 95% by weight of a renewable component. The panel has at least one of a CAC value of at least about 25, an NRC value of at least about 0.25 and an STC of at least about 25. A method for manufacturing such panels is also provided.Type: GrantFiled: April 5, 2011Date of Patent: December 20, 2011Assignee: USG Interiors, Inc.Inventors: Bangii Cao, Te Hua Lau, Curt Malone, W. David Song, Martin W. Brown
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Patent number: 8057915Abstract: The acoustical product of the present invention comprises an acoustical product including a matrix of calcium sulfate dihydrate crystals and expanded perlite distributed throughout the matrix. The expanded perlite has a particle size distribution with at least 10% of the perlite having a particle diameter of 700 microns or more, and the amount of expanded perlite to calcium sulfate dihydrate is about 35% to about 75% by weight, based upon the dry weight of the calcium sulfate dihydrate. A dispersing agent and glass fibers having a particle length of about ¼ inch to about 1 inch are dispersed throughout the gypsum matrix.Type: GrantFiled: May 31, 2007Date of Patent: November 15, 2011Assignee: United States Gypsum CompanyInventors: W. David Song, Mark H. Englert, Qiang Yu, Martin W. Brown, Richard B. Stevens
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Publication number: 20110251043Abstract: Provided is a mineral wool that includes recycled material. The mineral wool is characterized by an acid to base ratio within a specified range. Also provided is a method of manufacturing the mineral wool that includes selection of post-consumer or post-industrial recyclable materials. Application of the mineral wool to products such as an acoustical ceiling panel is also provided.Type: ApplicationFiled: April 11, 2011Publication date: October 13, 2011Inventor: Martin W. Brown
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Publication number: 20110180225Abstract: A panel includes about 0.1% to about 95% by weight of a renewable component. The panel has at least one of a CAC value of at least about 25, an NRC value of at least about 0.25 and an STC of at least about 25. A method for manufacturing such panels is also provided.Type: ApplicationFiled: April 5, 2011Publication date: July 28, 2011Inventors: Bangii Cao, Te Hua Lau, Curt Malone, W. David Song, Martin W. Brown
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Patent number: 7935223Abstract: A panel includes about 0.1% to about 95% by weight of a renewable component. The panel has at least one of a CAC value of at least about 25, an NRC value of at least about 0.25 and an STC of at least about 25. A method for manufacturing such panels is also provided.Type: GrantFiled: April 18, 2008Date of Patent: May 3, 2011Assignee: ISG Interiors, Inc.Inventors: Bangji Cao, Te Hua Lau, Curt Malone, W. David Song, Martin W. Brown
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Publication number: 20090260918Abstract: A panel includes about 0.1% to about 95% by weight of a ground renewable component. In an embodiment, the panel has at least one core comprising: from about 0.1% to about 95% by weight of the ground renewable component; from about 0.1% to about 95% by weight of one or more fibers; and from about 1% to about 30% by weight of one or more binders, all based on dry panel weight. In an embodiment, the ground renewable component has a particle size distribution whereby less than 5% of the particles are retained by a mesh screen with openings of about 0.312 inches and less than 5% of the particles pass through a mesh screen with openings of about 0.059 inches. A method for manufacturing such panels is also provided.Type: ApplicationFiled: March 30, 2009Publication date: October 22, 2009Inventors: Bangji Cao, Te Hua Lau, W. David Song, Martin W. Brown
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Publication number: 20090260770Abstract: A panel includes about 0.1% to about 95% by weight of a renewable component. The panel has at least one of a CAC value of at least about 25, an NRC value of at least about 0.25 and an STC of at least about 25. A method for manufacturing such panels is also provided.Type: ApplicationFiled: April 18, 2008Publication date: October 22, 2009Inventors: Bangii CAO, Te Hua Lau, Curt Malone, W. David Song, Martin W. Brown
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Publication number: 20080299413Abstract: The acoustical product of the present invention comprises an acoustical product including a matrix of calcium sulfate dihydrate crystals and expanded perlite distributed throughout the matrix. The expanded perlite has a particle size distribution with at least 10% of the perlite having a particle diameter of 700 microns or more, and the amount of expanded perlite to calcium sulfate dihydrate is about 35% to about 75% by weight, based upon the dry weight of the calcium sulfate dihydrate. A dispersing agent and glass fibers having a particle length of about ¼ inch to about 1 inch are dispersed throughout the gypsum matrix.Type: ApplicationFiled: May 31, 2007Publication date: December 4, 2008Inventors: W. David Song, Mark H. Englert, Qiang Yu, Martin W. Brown, Richard B. Stevens