Abstract: 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.

Abstract: An acoustical tile including: 8 to 25 wt % mineral wool, 9 to 15 wt % starch binder, 9 to 15 wt % cellulosic fiber, wherein preferably the cellulosic fiber is newsprint, and 40 to 65 wt % perlite, wherein the weight ratio of the starch to the cellulosic fiber is 0.6 to 1.3:1; and a process for making the acoustical tile.

Abstract: 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.

Abstract: An acoustical tile including: 8 to 25 wt % mineral wool, 9 to 15 wt % starch binder, 9 to 15 wt % cellulosic fiber, wherein preferably the cellulosic fiber is newsprint, and 40 to 65 wt % perlite, wherein the weight ratio of the starch to the cellulosic fiber is 0.6 to 1.3:1; and a process for making the acoustical tile.

Abstract: An acoustical panel for forming a monolithic ceiling or wall, the panel extending across a rectangular area, and having a core made primarily of gypsum, the core being essentially coextensive with the panel area such that it has two opposed sides, each of an area substantially equal to the area of the panel, the core having a multitude of perforations extending generally between its sides, the perforations being distributed substantially uniformly across the full area of the core and being open at both sides of the core, the face side of the core being covered by a porous layer, the perforations being optionally restricted at a rear side of the core, the porous layer at the face side of the core being suitable for adherence of drywall joint compound and a water-based non-blocking paint.

Abstract: 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.

Abstract: An apparatus and process for depositing slurry upon a moving forming web. The apparatus includes a pivotally mounted headbox for depositing slurry from the inner bottom surface of the headbox down an inclined spillway as a continuous curtain onto a moving web. The headbox is mounted transverse to the direction of travel of the moving web. The headbox also has vertical edge boards, including a headbox back edge board and two opposed headbox side edgeboards, on three respective sides of the headbox to prevent slurry from spilling over the sides and back of the headbox. The headbox is supplied with slurry from a slurry mixer by a feed line mounted on a reciprocating trolley which moves, transverse to the direction of travel of the moving web, back and forth along the length of the headbox.

Abstract: A wet laid basemat for an acoustical ceiling tile comprising on a dry weight basis, 50% or more mineral wool fiber, including shot, less than 9% binder, and between 5 and 20% chopped strand glass fiber, and, optionally, minor amounts of other constituents, whereby the chopped strand glass fibers serve to promote and/or maintain voids in the mat such that the dry basemat has a density of between about 7½ to about 10½ lbs. per cubic foot and an NRC substantially greater than 0.55.

Abstract: An acoustical panel for forming a monolithic ceiling or wall, the panel extending across a rectangular area, and having a core made primarily of gypsum, the core being essentially coextensive with the panel area such that it has two opposed sides, each of an area substantially equal to the area of the panel, the core having a multitude of perforations extending generally between its sides, the perforations being distributed substantially uniformly across the full area of the core and being open at both sides of the core, the face side of the core being covered by a porous layer, the perforations being optionally restricted at a rear side of the core, the porous layer at the face side of the core being suitable for adherence of drywall joint compound and a water-based non-blocking paint.

Abstract: An acoustical panel for forming a monolithic ceiling or wall, the panel extending across a rectangular area, and having a core made primarily of gypsum, the core being essentially coextensive with the panel area such that it has two opposed sides, each of an area substantially equal to the area of the panel, the core having a multitude of perforations extending generally between its sides, the perforations being distributed substantially uniformly across the full area of the core and being open at both sides of the core, the face side of the core being covered by a porous layer, the perforations being optionally restricted at a rear side of the core, the porous layer at the face side of the core being suitable for adherence of drywall joint compound and a water-based non-blocking paint.

Abstract: An acoustical panel for forming a monolithic ceiling or wall, the panel extending across a rectangular area, and having a core made primarily of gypsum, the core being essentially coextensive with the panel area such that it has two opposed sides, each of an area substantially equal to the area of the panel, the core having a multitude of perforations extending generally between its sides, the perforations being distributed substantially uniformly across the full area of the core and being open at both sides of the core, the face side of the core being covered by a porous layer, the perforations being optionally restricted at a rear side of the core, the porous layer at the face side of the core being suitable for adherence of drywall joint compound and a water-based non-blocking paint.

Abstract: A process is disclosed for curing a composition containing a triacylglycerol oligomer which includes exposing the composition to ultraviolet radiation to form a cured product. The composition can also include any or all of the following: a pigment, an initiator, a fatty acid methyl ester, a surfactant, a drying agent, and other additives.

Abstract: A process for making a fiber reinforced cementitious product such as a panel which hardens to an ultra-high compressive strength composite for use in making panels with ballistic and blast resistant properties. The panel has a continuous phase resulting from curing an aqueous mixture, in the absence of silica flour, of inorganic cement binder, inorganic mineral filler having a particle size of about 150-450 microns, pozzolanic mineral filler, and polycarboxylate based superplasticizer self-leveling agent, and water. The mixture may also include alkanolamine and acid or acid salt. The continuous phase may be reinforced with fiber distributed in the continuous phase before curing to form a panel. The panel may be reinforced with a fiber reinforced skin attached to at least one surface of the core, e.g., by lamination with an adhesive, e.g., epoxy, to form a ballistic and blast resistant cementitious armor panel.

Abstract: A cementitious armor panel assembly including cementitious armor panel with ballistic and blast resistant properties attached to a frame structure to produce a protective structure. The cementitious armor panels have a continuous phase resulting from the curing of an aqueous mixture of an inorganic cement binder, an inorganic mineral filler having a particle size of about 150-450 microns, a pozzolanic mineral filler, a polycarboxylate based superplasticizer self-leveling agent, and water. The mixture may also contain alkanolamine, and acid or acid salt. Prior to curing, the continuous phase is reinforced with fiber uniformly distributed in the continuous phase before it is cured to form the panel. The panel may be reinforced with a skin attached to at least one surface of the panel.

Abstract: A cementitious panel with ballistic and blast resistant properties having a core layer of ultra-high compressive strength composite and at least one skin layer. The panels can also be used in walls, ceiling and flooring panels which require high compressive strength for resistance to earthquakes and surfaces resistant to surface abuse such as in prison and other institutions. The panel core layer has a continuous cementitious phase resulting from the curing of an aqueous mixture, in the absence of silica flour, of inorganic cement binder, inorganic mineral filler having a particle size of about 150-450 microns, a pozzolanic mineral filler, polycarboxylate based superplasticizer, alkanolamine and acid or alkali metal acid salt; and water. The mixture may be uniformly reinforced with fiber added before curing. The cementitious core layer is then reinforced with the skin, such as fiber reinforced polymer, attached to at least one panel surface.

Abstract: A cementitious panel with ballistic and blast resistant properties having a core layer of ultra-high compressive strength composite and at least one skin layer. The panels can also be used in walls, ceiling and flooring panels which require high compressive strength for resistance to earthquakes and surfaces resistant to surface abuse such as in prison and other institutions. The panel core layer has a continuous cementitious phase resulting from the curing of an aqueous mixture, in the absence of silica flour, of inorganic cement binder, inorganic mineral filler having a particle size of about 150-450 microns, a pozzolanic mineral filler, polycarboxylate based superplasticizer, alkanolamine and acid or alkali metal acid salt; and water. The mixture may be uniformly reinforced with fiber added before curing. The cementitious core layer is then reinforced with the skin, such as fiber reinforced polymer, attached to at least one panel surface.

Abstract: A process for making a fiber reinforced cementitious product such as a panel which hardens to an ultra-high compressive strength composite for use in making panels with ballistic and blast resistant properties. The panel has a continuous phase resulting from curing an aqueous mixture, in the absence of silica flour, of inorganic cement binder, inorganic mineral filler having a particle size of about 150-450 microns, pozzolanic mineral filler, and polycarboxylate based superplasticizer self-leveling agent, and water. The mixture may also include alkanolamine and acid or acid salt. The continuous phase may be reinforced with fiber distributed in the continuous phase before curing to form a panel. The panel may be reinforced with a fiber reinforced skin attached to at least one surface of the core, e.g., by lamination with an adhesive, e.g., epoxy, to form a ballistic and blast resistant cementitious armor panel.

Abstract: A cementitious armor panel assembly including cementitious armor panel with ballistic and blast resistant properties attached to a frame structure to produce a protective structure. The cementitious armor panels have a continuous phase resulting from the curing of an aqueous mixture of an inorganic cement binder, an inorganic mineral filler having a particle size of about 150-450 microns, a pozzolanic mineral filler, a polycarboxylate based superplasticizer self-leveling agent, and water. The mixture may also contain alkanolamine, and acid or acid salt. Prior to curing, the continuous phase is reinforced with fiber uniformly distributed in the continuous phase before it is cured to form the panel. The panel may be reinforced with a skin attached to at least one surface of the panel.

Abstract: An apparatus and process for depositing slurry upon a moving forming web. The apparatus includes a pivotally mounted headbox for depositing slurry from the inner bottom surface of the headbox down an inclined spillway as a continuous curtain onto a moving web. The headbox is mounted transverse to the direction of travel of the moving web. The headbox also has vertical edge boards, including a headbox back edge board and two opposed headbox side edgeboards, on three respective sides of the headbox to prevent slurry from spilling over the sides and back of the headbox. The headbox is supplied with slurry from a slurry mixer by a feed line mounted on a reciprocating trolley which moves, transverse to the direction of travel of the moving web, back and forth along the length of the headbox.

Abstract: A head-box for depositing slurry upon a moving web including a main metering roll, a companion roll disposed in closely spaced relation to the metering roll and a vibrating gate which forms a nip between the metering roller and the gate. The nip is arranged to retain a supply of the slurry, and the rolls are driven so slurry retained in the nip progresses over an upper outer peripheral surface of the metering roll to be deposited upon the web. Also, preferably included is a doctor blade disposed in operational relationship to the metering roll for directing the slurry downwardly from the outer metering roll surface to a point above the surface of a carrier for a fiberglass layer upon which the slurry layer is deposited. The vibrating gate and doctor blade may be pivotally mounted to either side of the surfaces of the head-box.