Laminate acoustic panel and method for installing a ceiling system

[0002] Embodiments of the present invention relate to laminate acoustic ceiling panels, methods for preparing laminate acoustic ceiling panels, ceiling systems comprising the laminate acoustic ceiling panels, and methods for installing a ceiling system including acoustic ceiling panels.

Background

[0003] Various types of ceiling systems have been used in commercial and residential building construction to provide the desired acoustical performance. Noise blocking between rooms is required for a variety of purposes, including speech privacy as well as not bothering the occupants of adjacent rooms. Sound dampening within a single room is also required for a variety of purposes, including decreasing volume levels within a single space.

[0004] Previous attempts have been made to improve noise blocking between adjacent rooms. However, such previous attempts have either been directed to single layered structures or laminate-structures having layers that are bonded together across substantially the entire interface of layers. Such previous attempts fail to address how the interface between layers impacts both noise blocking and sound dampening characteristics of the acoustic ceiling panels. Thus, there is a need for a new laminate acoustic ceiling panel having an interface that can enhance the desired acoustical properties.

Summary

[0005] According to some embodiments, the present invention is directed to an acoustic ceiling panel comprising a laminate structure having a first layer and a second layer. The first layer comprises a first major surface and a second major surface. The second major

Date Reçue/Date Received 2022-07-26

CA 02976489 2017-08-11

WO 2016/144504 PCT/US2016/018650 surface of the first layer is defined by a perimeter. The second major surface of the first layer comprises a perimeter region adjacent the perimeter of the second major surface of the first layer. The second major surface further comprises a central region circumscribed by the perimeter region of the second major surface of the first layer. The second layer comprises a first major surface and a second major surface. The first major surface of the second layer is defined by a perimeter. The first major surface of the second layer comprises a perimeter region adjacent the perimeter of the first major surface of the second layer. The first major surface of the second layer further comprises a central region circumscribed by the perimeter region of the first major surface of the second layer. The second major surface of the first layer is coupled to the first major surface of the second layer by an adhesive applied to at least one of the perimeter region of the second major surface of the first layer or the perimeter region of the first major surface of the second layer. The central region of the second major surface of the first layer and the central region of the first major surface of the second layer being are each free of adhesive.

[0006] According to other embodiments, the present invention is directed to an acoustic ceiling panel comprising a laminate structure having a first layer and a second layer. The first layer comprises a first major surface and a second major surface. The second major surface of the first layer is defined by a perimeter. The second major surface of the first layer comprises a perimeter region adjacent the perimeter of the second major surface of the first layer. The second major surface of the first layer further comprises a central region circumscribed by the perimeter region of the second major surface of the first layer. The second layer comprises a first major surface and a second major surface. The first major surface of the second layer is defined by a perimeter. The first major surface of the second layer comprises a perimeter region adjacent the perimeter of the first major surface of the second layer. The first major surface of the second layer further comprises and a central region circumscribed by the perimeter region of the first major surface of the second layer. The second major surface of the first layer is coupled to the first major surface of the second layer by a plurality of adhesive strips applied to at least one of the perimeter region of the second major surface of the first layer or the perimeter region of the first major surface of the second layer. The plurality of adhesive strips collectively

CA 02976489 2017-08-11

WO 2016/144504 PCT/US2016/018650 forming a closed-geometry that circumscribes the central region of the second major surface of the first layer and the central region of the first major surface of the second layer.

[0007] In other embodiments, the present invention is directed to an acoustic ceiling panel comprising a first layer and a second layer. The first layer comprises a first major surface, a second major surface, and a side surface extending between the first and second major surfaces of the first layer. The side surface of the first layer intersects the second major surface of the first layer to form an upper edge of the first layer. The upper edge of the first layer forms a perimeter of the second major surface. The second major surface comprises a perimeter region adjacent the perimeter and a central region circumscribed by the perimeter region. The upper edge of the first layer comprises a first upper edge portion, a second upper edge portion, a third upper edge portion, and a fourth upper edge portion. The second upper edge portion is opposite the first upper edge portion. The third upper edge portion extends between the first and second upper edge portions. The fourth upper edge portion is opposite the third upper edge portion and extends between the first and second upper edge portions. The second layer comprises a first major surface, a second major surface, and a side surface extending between the first and second major surfaces of the second layer. The second major surface of the first layer coupled to the first major surface of the second layer by at least a first adhesive strip, a second adhesive strip, a third adhesive strip, and a fourth adhesive strip. The first adhesive strip extends adjacent to and substantially parallel to the first edge portion. The second adhesive strip extends adjacent to and substantially parallel to the second edge portion. The third adhesive strip extends adjacent to and substantially parallel to the third edge portion. The fourth adhesive strip extending adjacent to and substantially parallel to the fourth edge portion.

[0008] According to further embodiments, the preset invention is directed to a suspended ceiling system comprising a ceiling grid, a plenary space, a room environment, and at least one acoustic ceiling panel according to the present invention. The ceiling grid may comprise a plurality of first members and a plurality of second members, the first and second members intersecting at a substantially perpendicular angle defining a plurality of grid openings. The plenary space is above the ceiling grid. The room environment is

CA 02976*89 2017-08-11

WO 2016/144504 PCT/US2016/018650 below the ceiling grid. The at least one acoustic ceiling panels according to the present invention rests in one of the plurality of grid openings of the ceiling grid.

[0009] In still other embodiments, the present invention is directed to a method of installing a ceiling system. The method may comprise step a) mounting a support grid within an internal space of a building so that a plenary space is formed above the support grid and an active room environment is formed below the support grid. The support grid may comprise a plurality of intersecting struts forming a plurality of openings. In some embodiments of the present invention, the method further comprises step b) of mounting a first ceiling panel to the support grid within a first one of the openings. The first ceiling panel may be formed of a sound absorbing material and having an upper major surface and a lower major surface that is opposite the upper major surface of the first ceiling panel. In some embodiments the upper major surface of the first ceiling panel facing the plenary space. According to some embodiments, the method further comprises, subsequent to step b), positioning a first sound attenuation layer in a free-floating relationship atop the upper major surface of the first ceiling panel, thereby forming a first multi-component panel having a CAC value greater than 37.

[0010] In still further embodiments, the present invention is directed to a method of installing a ceiling system. The method of installing the ceiling system may comprise step a) of mounting a support grid within an internal space of a building so that a plenary space is formed above the support grid and an active room environment formed below the support grid. The support grid may comprise a plurality of intersecting struts forming a plurality of openings. In some embodiments of the present invention, the method may further comprise step b) of providing a first ceiling panel having an upper major surface and a lower major surface that is opposite the upper major surface. In some embodiments of the present invention, subsequent to step b), the method may further comprise step c) of overlaying a first sound attenuation layer in a free-floating relationship on the upper major surface of the first ceiling panel, thereby forming a multi-component panel having a CAC value greater than 37. In other embodiments of the present invention, subsequent to step c), the method may further comprise step d) of mounting the multi-component panel to the support grid within a first one of the openings. The upper major surface of the first ceiling panel may face the plenary space.

CA 02976489 2017-00-11

WO 2016/144504 PCT/US2016/018650

[0011] Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention.

Brief Description of the Drawings

[0012] The features of the exemplary embodiments of the present invention will be described with reference to the following drawings, where like elements are labeled similarly, and in which:

[0013] FIG. 1 is a perspective view of a ceiling system according to a first embodiment of the present disclosure;

[0014] FIG. 2 is a side profile view of a portion of the ceiling system of FIG. 1 according to the present disclosure;

[0015] FIG. 3 is a perspective view of a ceiling panel of the ceiling system of FIG. 1 according to an embodiment of the present disclosure;

[0016] FIG. 4 is a side view of the ceiling panel of FIG. 3;

[0017] FIG. 5 is a cross-sectional view of the ceiling panel taken along line IV of FIG. 3;

[0018] FIG. 6 is an exploded perspective view of the ceiling panel of FIG. 3;

[0019] FIG. 7 is a top view of a first layer of the ceiling panel of FIG. 3 in accordance with one embodiment of the present disclosure;

[0020] FIG. 8 is a top view of the first layer of the ceiling panel of FIG. 3 in accordance with another embodiment of the present disclosure;

[0021] FIG. 9 is a top view of the first layer of the ceiling panel of FIG. 3 in accordance with yet another embodiment of the present disclosure;

[0022] FIG. 10 is a top view of the first layer of the ceiling panel of FIG. 3 in accordance with still another embodiment of the present disclosure;

[0023] FIG. 11 is a bottom view of a second layer of the ceiling panel of FIG. 3 according to an embodiment of the present disclosure;

[0024] FIG. 12 is a perspective view of a support grid according to a second embodiment of the present disclosure;

[0025] FIG. 13 is a perspective view of a ceiling system using the support grid of FIG. 12

CA 02976489 2017-08-11

WO 2016/144504 PCT/US2016/018650 according to toe present disclosure;

[0026] FIG. 14 is a perspective view of a multi-component panel of the ceiling system of FIG. 13 according to an embodiment of the present disclosure;

[0027] FIG. 15 is an exploded cross-sectional view taken along line XV of FIG. 14;

[0028] FIG. 16 is a cross-sectional view taken along line XV of FIG. 14;

[0029] FIG. 17 is a side view of the support grid of FIG. 12 with ceiling panels resting in openings according to the present disclosure;

[0030] FIG. 18 is a side view of the ceiling system of FIG. 13 in a partially installed configuration according to toe present disclosure;

[0031] FIG. 19 is a side view of the ceiling system of FIG. 13 according to one embodiment of the present disclosure;

[0032] FIG. 20 is a side view of the ceiling system of FIG. 13 according to another embodiment of the present disclosure; and

[0033] FIG. 21 is a side view of the ceiling system of FIG. 13 in a partially installed configuration according to another embodiment of the present disclosure.

[0034] All drawings are schematic and not necessarily to scale. Parts given a reference numerical designation in one figure may be considered to be the same parts where they appear in other figures without a numerical designation for brevity unless specifically labeled with a different part number and described herein.

Detailed Description

[0035] The following description of the preferred embodiment(s) is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses.

The description of illustrative embodiments according to principles of the present invention is intended to be read in connection with the accompanying drawings, which are to be considered part of the entire written description. In the description of embodiments of the invention disclosed herein, any reference to direction or orientation is merely intended for convenience of description and is not intended in any way to limit the scope of the present invention. Relative terms such as “lower,” “upper,” “horizontal,” “vertical,” “above,” “below,” “up,” “down,” “top,” and “bottom” as well as derivatives thereof (e.g., “horizontally,” “downwardly,” “upwardly,” etc.) should be construed to refer to the orientation as then described or as shown in the drawing under discussion. These relative

CA 02976489 2017-08-11

WO 2016/144504 PCT/US2016/018650 terms are for convenience of description only and do not require that the apparatus be constructed or operated in a particular orientation unless explicitly indicated as such. Terms such as “attached,” “affixed,” “connected,” “coupled,” “interconnected,” and similar refer to a relationship wherein structures are secured or attached to one another either directly or indirectly through intervening structures, as well as both movable or rigid attachments or relationships, unless expressly described otherwise. Moreover, the features and benefits of the invention are illustrated by reference to the exemplified embodiments. Accordingly, the invention expressly should not be limited to such exemplary embodiments illustrating some possible non-limiting combination of features that may exist alone or in other combinations of features; the scope of the invention being defined by the claims appended hereto.

[0036] Multiple inventive concepts are described herein and are distinguished from one another using headers in the description that follows. Specifically, Figures 1-11 are relevant to a first inventive concept and Figures 12-21 are relevant to a second inventive concept. The first and second inventive concepts should be considered in isolation from one another. It is possible that there may be conflicting language or terms used in the description of the first and second inventive concepts. For example, it is possible that in the description of the first inventive concept a particular term may be used to have one meaning or definition and that in the description of the second inventive concept the same term may be used to have a different meaning or definition. In the event of such conflicting language, reference should be made to the disclosure of the relevant inventive concept being discussed. Similarly, the section of the description describing a particular inventive concept being claimed should be used to interpret claim language when necessary.

I. Ceiling Panel Having Adhesively Coupled Lavers

[0037] As shown in Figures 1 and 2, one embodiment of the present invention is directed to a ceiling system 1 comprising a ceiling grid 5 and at least one acoustic ceiling panel 20. A plenary space 2 may exist above the ceiling grid 5. The plenary space 2 is the space that exists above the acoustic ceiling panels 20 and above the ceiling grid 5 and below a roof or a subfloor 4 of an above adjacent floor in a building. The plenary space 2 provides room for mechanical lines to be nm throughout a building - e.g. HVAC, plumbing, data

CA 02976489 2017-08-11

WO 2016/144504 PCT/US2016/018650 lines, etc. A room environment 3 may exist below the acoustic ceiling panels 20 and below the ceiling grid 5. The room environment 3 is the space occupied by inhabitants of a room - e.g. room environments 3 in an office building would be the space occupied by desks, office workers, computers, etc. The combination of the ceiling grid 5 and the acoustic ceiling panels 20 may act as an acoustic and aesthetic barrier between the room environment 3 and the plenary space 2, as well as a sound deadening layer for noise that exists within the room environment 3, as discussed herein.

[0038] The ceiling grid 5 may comprise a plurality of first members 6 extending parallel to each other. In some embodiments, the ceiling grid 5 may further comprise a plurality of second members 7 that extend parallel to each other. The plurality of first members 6 may intersect the plurality of second members 7 to form a grid pattern having a plurality of grid openings 8. In some embodiments, the plurality of first members 6 intersects the plurality of second members 7 at a substantially perpendicular angle, thereby forming rectangular grid openings 8. The rectangular grid openings 8 may be square or any other shape that is aesthetical or functional.

[0039] As shown in Figure 2, each of the plurality of first members 6 and each of the plurality of second members 7 may comprises T-bars having a horizontal flange 10 and a web 11. The plenary space 2 exists above the T-bars and the room environment 3 exists below the T-bars.

[0040] The ceiling system 1 of the present disclosure comprises at least one acoustic ceiling panel 20 that is mounted to the ceiling grid 5 within one of the plurality of grid openings 8. The ceiling system 1 may comprises a plurality of acoustic ceiling panels 20 mounted to the ceiling grid 5, each of the plurality of acoustic ceiling panels 20 resting within one of the plurality of grid openings 8. In some embodiments, something other than the acoustic ceiling panel 20 (for example, light fixture or an air duct vent) may be mounted to the ceiling grid 5 within at least one of the grid openings 8 (not pictured).

[0041] As demonstrated by Figures 3-6, the acoustic ceiling panel 20 may comprise a first layer 100 and a second layer 200. In some embodiments of the present invention, the acoustic ceiling panel 20 may further comprise a scrim 300. As demonstrated by Figure 2, the acoustic ceiling panel 20 may be mounted on the ceiling grid 5 of the ceiling system 1 so that the first layer 100 of the acoustic ceiling panel 20 is adjacent to the room

CA 02976489 2017-08-11

WO 2016/144504 PCT/US2016/018650 environment 3 and the second layer 200 is adjacent to the plenary space 2.

[0042] As shown by Figures 4-6, the first layer 100 of the acoustic ceiling panel 20 comprises a first major surface 101 and a second major surface 102. The first layer 100 further comprises a side surface 103 extending between the first major surface 101 and the second major surface 102. The side surface 103 of the first layer 100 intersects the first major surface 101 of the first layer 100 to form a lower edge 107 of the first layer 100. The side surface 103 of the first layer 100 intersects the second major surface 102 of the first layer 100 to form an upper edge 104 of the first layer 100.

[0043] In some embodiments of the present invention, the side surface 103 of the first layer 100 may comprise a stepped profile having an upper side surface 103b and a lower side surface 103a. The lower side surface 103a of the first layer 100 intersects the first major surface 101 of the first layer 100 to form the lower edge 107 of the first layer 100. The upper side surface 103b of the first layer 100 intersects the second major surface 102 of the first layer 100 to form the upper edge 104.

[0044] An intermediate surface 108 extends between the lower side surface 103a and the upper side surface 103b in a direction that is substantially perpendicular to the side surface 103, the upper side surface 103a, and the lower side surface 103b of the first layer 100. In some embodiments, the intermediate surface 108 faces the same direction as the first major surface 101 of the first layer 100. In other embodiments, the intermediate surface 108 faces a direction oblique to the first major surface 101.

[0045] The stepped profile comprises the combination of the upper side surface 103b, the intermediate surface 108, and the lower side surface 103a. According to this embodiment, the second major surface 102 of the first layer 100 has an area that is greater than an area of the first major surface 101 of the first layer 100. In some embodiments the surface area of the second major surface 102 of the first layer 100 is equal to the sum of the area of the first major surface 102 and the area of the intermediate surface 108 of the first layer 100. As shown in Figure 2, after the acoustic ceiling panel 20 have been mounted to the ceiling grid 5, the intermediate surface 108 of the first layer 100 may abut at least a portion of a top surface of the horizontal flange 10 of at least one of the first member 6 or the second member 7 of the ceiling grid 5. The abutment between the intermediate surface 108 of the first layer 100 and the top surface of the horizontal flange 10 allows the acoustical ceiling

CA 02976489 2017-08-11

WO 2016/144504 PCT/US2016/018650 panel 10 to rest in a fully installed position

[0046] As shown in Figures 6-10, the upper edge 104 of the first layer 100 forms a perimeter of the second major surface 102 of the first layer 100. The second major surface 102 comprises a perimeter region 105 that is adjacent to both the upper edge 104 of the first layer 100 and the perimeter of the second major surface 102. The second major surface 102 of the first layer 100 may further comprise a central region 106 that is circumscribed by the perimeter region 105 of the second major surface 102 of the first layer 100. Figures 6-10 show non-limiting embodiments of a dotted boundary 170 between the central region 106 and the perimeter region 105 of the first layer 100- In Figures 6-10, the dotted boundary 170 is rectangular; however, the present invention does not limit the shape of the dotted boundary 170 to any particular shape (e.g., polygon, circle, ellipsis, non-geometric shapes, etc.).

[0047] The upper edge 104 of the first layer 100 comprises a first upper edge portion 120, a second upper edge portion 121, a third upper edge portion 122, and a fourth upper edge portion 123. The second upper edge portion 121 is opposite the first upper edge portion 120, and the fourth upper edge portion 123 is opposite the third upper edge portion 122. The third upper edge portion 122 extends between the first upper edge portion 120 and the second upper edge portion 121. The fourth upper edge portion 123 extends between the first upper edge portion 120 and the second upper edge portion 121.

[0048] In some embodiments, the third upper edge portion 122 extends perpendicular to both of the first upper edge portion 120 and the second upper edge portion 121. In some embodiments, the fourth upper edge portion 123 extends substantially perpendicular to both of the first upper edge portion 120 and the second upper edge portion 121. In some embodiments the first upper edge portion 120 extends substantially parallel to the second upper edge portion 121.

[0049] In some embodiments, the stepped profile of the first layer 100 may be present on each of the side surfaces 103 of the first layer 100. In other embodiments, the stepped profile may only be present on two opposite side surfaces 103 of the first layer 100. For example, the side surfaces 103 of the first layer 100 that form the first upper edge portion 120 and the second upper edge portion 121 may comprise a stepped profile while the side surfaces 103 of the first layer 100 that form the third upper edge portion 122 and the

CA 02976489 2017-08-11

WO 2016/144504 PCT/US2016/018650 fourth upper edge portion 123 do not comprise a stepped profile. In a preferred embodiment, the first layer 100 is closer to the sound source, e.g., the room environment 3.

[0050] In some embodiments, the first layer 100 may be comprised of fiberglass, mineral wool (such as rock wool, slag wool, or a combination thereof), synthetic polymers (such as melamine foam, polyurethane foam, or a combination thereof), mineral cotton, silicate cotton, or combinations thereof. In some embodiments the first layer 100 is produced from fiberglass. In some embodiments the first layer 100 predominantly provides a sound absorption function and preferred materials for providing the sound absorption function for the first layer 100 include fiberglass The first layer provides a ceiling NRC rating of 0.7 or greater, preferably 0.9 or greater. NRC (Noise Reduction Coefficient) is further described below. In some non-limiting embodiments of the present disclosure, the first

TX/f layer may be selected from the Optima and Lyra fiberglass panel lines produced by Armstrong (Armstrong World Industries, Inc.) - for example, Lyra 8372 or Optima 3251.

[0051] As demonstrated by Figures 3-6, the second layer 200 comprises a first major surface 201 and a second major surface 202. The second layer 200 may further comprise a side surface 203 extending between the first major surface 201 of the second layer 200 and the second major surface 202 of the second layer 200. The side surface 203 of the second layer 200 intersects the second major surface 202 of the second layer 200 to form an upper edge 204 of the second layer 200. The side surface 203 of the second layer 200 intersects the first major surface 201 of the second layer 200 to form a lower edge 207 of the second layer 200.

[0052] As shown in Figures 3 and 6, the upper edge 204 of the second layer 200 forms a perimeter of the second major surface 202 of the second layer 200. As demonstrated in Figure 11, the lower edge 207 of the second layer 200 forms a perimeter of the first major surface 201 of the second layer 200. The lower edge 207 of the second layer 200 comprises a first lower edge portion 220, a second lower edge portion 221, a third lower edge portion 222, and a fourth lower edge portion 223. The second lower edge portion 221 is opposite the first lower edge portion 220, and the fourth lower edge portion 223 is opposite the third lower edge portion 222. The third lower edge portion 222 extends between the first lower edge portion 220 and the second lower edge portion 221. The

CA 02976489 2017-08-11

WO 2016/144504 PCT/US2016/018650 fourth lower edge portion 223 extends between the first lower edge portion 220 and the second lower edge portion 221.

[0053] As shown in Figures 4-6, the side surface 203 of the second layer 200 may further comprise an upper side surface 203b and a lower side surface 203a. The upper side surface 203b of the second layer 200 intersects with the second major surface 202 of the second layer 200 forming the upper edge 204 of the second layer 200. The lower side surface 203a of the second layer 200 intersects with the first major surface 201 of the second layer 200 forming the lower edge 207 of the second layer 200.

[0054] In some embodiments the upper side surface 203b of the second layer 200 is coplanar with the lower side surface 203a of the second layer 200 - such that the area of the second major surface 202 of the second layer 200 is equal to the area of the first major surface 201 of the second layer. In some embodiments, the upper side surface 203b of the second layer 200 is beveled inward at an angle of 30, 45, or 60 degree angle relative to lower side surface 203a of the second layer - such that the area of the second major surface 202 of the second layer 200 is less than the area of the first major surface 201 of the second layer. In a preferred embodiment, the second layer 200 is away from the sound source, e.g., facing toward the plenary space 2.

[0055] In some embodiments the second layer 200 may comprise fiberglass, mineral wool (such as rock wool, slag wool, or a combination thereof), synthetic polymers (such as melamine foam, polyurethane foam, or a combination thereof), mineral cotton, silicate cotton, gypsum, or combinations thereof. In some embodiments the second layer 200 is produced from mineral wool. In some embodiments, the second layer 200 predominantly provides a sound attenuation function and preferred materials for providing the sound attenuation function for the second layer 200 include mineral wool. The second layer 200 provides a ceiling CAC rating of at least 35, preferably at least 40. CAC (Ceiling Attenuation Class) is further described below. In some non-limiting embodiments of the present disclosure, the second layer may be selected from the School Zone and Calla panel lines produced by Armstrong - for example, School Zone 1810.

[0056] As shown in Figure 5, the acoustic ceiling panel 20 is formed by positioning the first major surface 201 of the second layer 200 adjacent to the second major surface 102 of the first layer 100, thereby creating an interface between the first layer 100 and the second

CA 02976489 2017-08-11

WO 2016/144504 PCT/US2016/018650 layer 200. Specifically, the interface exists between the first major surface 201 of the second layer 200 and the second major surface 102 of the first layer 100.

[0057] The first layer 100 may be attached to the second layer 200 with an adhesive 50. Specifically, the second major surface 102 of the first layer 100 may be coupled to the first major surface 201 of the second layer 200 by the adhesive 50 to create a cohesively adhere the first and second layers 100, 200 to form a cohesive multilayer laminate. The second major surface 102 of the first layer 100 may be coupled to the first major surface 201 of the second layer 200 by the adhesive 50 so that the perimeter and the upper edge 104 of the first layer 100 is aligned with the perimeter and the lower edge 207 of the second layer 200, In other embodiments, the first layer 100 may be attached to the second layer 200 by mechanical coupling.

[0058] In some embodiments, the second major surface 102 of the first layer 100 and the first major surface 201 of the second layer 200 may be coupled by the adhesive 50 so that the first upper edge 120 of the first layer 100 is aligned with the first lower edge 220 of the second layer 200; the second upper edge 121 of the first layer 100 is aligned with the second lower edge 221 of the second layer 200; the third upper edge 122 of the first layer 100 is aligned with the fourth lower edge 223 of the second layer 200; and the fourth upper edge 123 of the first layer 100 is aligned with third lower edge 222 of the second layer 200.

[0059] In some embodiments, the first layer 100 and the second layer 200 may be coupled so that the perimeter and the upper edge 104 of the first layer 100 is not aligned with the perimeter and the lower edge 207 of the second layer 200 (not pictured). Specifically, the first upper edge 120 of the first layer 100 may extend oblique to the first lower edge 220 of the second layer 200. The second upper edge 121 of the first layer 100 may extend oblique to the second lower edge 221 of the second layer 200. The third upper edge 122 of the first layer 100 may extend oblique to the fourth lower edge 223 of the second layer 200. The fourth upper edge 123 of the first layer 100 may extends oblique to the third lower edge 222 of the second layer 200.

[0060] According to another embodiment of the present disclosure, the area of the first major surface 201 of the second layer 200 may be larger than the area the second major surface 102 of the first layer 100, thereby leaving at least a portion of the first major

CA 02976489 2017-08-11

WO 2016/144504 PCT/US2016/018650 surface 201 of the second layer 200 exposed (not pictured). The exposed portion of the first major surface 201 of the second layer 200 creates a step between the side surface 103 of the first layer 100 and the side surface 203 of the second layer 200. According to this embodiment, the perimeter of the first layer 100 is smaller than the perimeter of the second layer 200. The portion of the first major surface 201 of the second layer 200 that remains exposed by the step between the side surfaces 103, 104 may abut a portion of the top surface of the horizontal flange 10 of the first and second members 6, 7 after the acoustic ceiling panel 20 is mounted to the ceiling grid 5 - similar to the intermediate surface 108 of the first layer 100 may abut the horizontal flange 10 of the first and second members 6,7 of the ceiling grid 5. According to this embodiment, the first layer 100 has a side surface 103 that may or may not comprise the stepped profile of the lower side surface 103a, intermediate surface 108, and upper side surface 103b. In other embodiments, the area of the first major surface 201 of the second layer 200 may be smaller than the area the second major surface 102 of the first layer 100.

[0061] Each of the side surfaces 103 of the first layer 100 may extend coplanar to each of the side surfaces 203 of the second layer 200. Specifically, each of the upper edge portions 103b of the first layer 100 may extend coplanar to each of the lower edge portions 203a of the second layer 100.

[0062] The adhesive 50 may be applied to at least one of the perimeter region 105 of the second major surface 102 of the first layer 100 or the perimeter region 205 of the first major surface 201 of the second layer 200. The central region 106 of the second major surface 102 of the first layer 100 is substantially free of any adhesive 50 that couples the central region 106 of the second major surface 102 of the first layer 100 to the first major surface 201 of the second layer 200. The central region 206 of the first major surface 201 of the second layer 200 is substantially free of any adhesive that couples the central region 206 of the first major surface 201 of the second layer 200 to the second major surface 102 of the first layer 100.

[0063] In some embodiments, the central region 106 of the second major surface 102 of the first layer 100 is in free floating contact with the first major surface 201 of the second layer 200. In some embodiments, the central region 206 of the first major surface 201 of the second layer 200 is in free floating contact with the second major surface 102 of the

CA 02976489 2017-08-11

WO 2016/144504 PCT/US2016/018650 first layer 100. The interface between the first major surface 201 of the second layer 200 and the second major surface 102 of the first layer is substantially free of adhesive within the central region 106 of the first layer 100 and the central region 206 of the second layer. [0064] In some embodiments, the first layer 100 and the second layer 200 are coupled by mechanical attachment means (e.g., needle bunching, or clips) in addition to or alternatively to the adhesive 50. In some embodiments, the central region 106 of the first layer 100 is not in physical contact with the central region 206 of the second layer 200[0065] According to the present invention, the adhesive 50 may be any adhesive that provides structural integrity to the acoustic ceiling panel 20 having the attached first and second layers 100, 200 such that the acoustic ceiling panel 20 can be handled without separating the first and second layers 100, 200 - e.g., even when certain section or sections of the acoustic ceiling panel 20 are cut for installation. Suitable adhesives include aqueous adhesives and solvent based adhesives, including adhesives of polyvinyl acetate, urethane, acrylates, and polyester. The adhesives may be a hot-melt adhesive, pressure sensitive adhesive, or acoustical adhesive. The adhesive may be applied as dots, continuous strips, or discontinuous strips to one or more of the perimeter regions 105, 205 of the first and second layers 100, 200 of the acoustic ceiling panel 20, as discussed further herein.

[0066] According to some embodiments of the present disclosure, the adhesive 50 applied to at least one of the perimeter region 105 of the second major surface 102 of the first layer 100 and the perimeter region 205 of the first major surface 201 of the second layer 200 comprises, for example, a plurality of adhesive strips. In other embodiments, the adhesive is applied in a pattern to minimize the area of contact between the first and second layers occupied by the applied adhesive. For example, the adhesive is applied as a dot in each of the four comers of the perimeter regions of a rectangular panel.

10067] As shown in Figures 6-10, the plurality of adhesive strips may comprise a first adhesive strip 130, a second adhesive strip 131, a third adhesive strip 132, a fourth adhesive strip 133. The first adhesive strip 130, the second adhesive strip 131, the third adhesive strip 132, and the fourth adhesive strip 133 may each independently be a continuous or a discontinuous strip of adhesive. The first adhesive strip 130, the second adhesive strip 131, the third adhesive strip 132, and the fourth adhesive strip 133 may each

CA 02976489 2017-08-11

WO 2016/144504 PCT/US2016/018650 independently be linear or curvilinear.

[0068] The first adhesive strip 130 may extend adjacent to the first upper edge portion 120 of the first layer 100. The second adhesive strip 131 may extend adjacent to the second upper edge portion 121 of the first layer 100. The third adhesive strip 132 may extend adjacent to the third upper edge portion 122 of the first layer 100. The fourth adhesive strip 133 may extend adjacent to the fourth upper edge portion 123 of the first layer 100. According to this embodiment, the first adhesive strip 130, the second adhesive strip, 131, the third adhesive strip 132, and the fourth adhesive strip 133 may each independently extend to the corresponding first upper edge portion 120, second upper edge portion 121, third upper edge portion 122, and fourth upper edge portion 123 at an oblique or substantially parallel angle.

[0069] In non-limiting the embodiments, the first adhesive strip 130 may extend adjacent to the first lower edge portion 220 of the second layer 200. The second adhesive strip 131 may extend adjacent to the second lower edge portion 221 of the second layer 200. The third adhesive strip 132 may extend adjacent to the third lower edge portion 222 of the second layer 200. The fourth adhesive strip 133 may extend adjacent to the fourth lower edge portion 223 of the second layer 200. According to this embodiment, the first adhesive strip 130, the second adhesive strip, 131, the third adhesive strip 132, and the fourth adhesive strip 133 may each independently extend to the corresponding first lower edge portion 220, second lower edge portion 221, third lower edge portion 222, and fourth lower edge portion 223 at an oblique or substantially parallel angle.

[0070] As shown in Figures 7 and 8, the first adhesive strip 130 may be spaced a first distance Di from the first upper edge portion 120 of the first layer 100. The second adhesive strip 131 may be spaced a second distance Di from the second upper edge portion 121 of the first layer 100. The third adhesive strip 132 may be spaced a third distance D3 from the third upper edge portion 122 of the first layer 100. The fourth adhesive strip 133 may be spaced a fourth distance D4 from the fourth upper edge portion 123 of the first layer 100.

[0071] In some embodiments the first distance Di, the second distance D2, the third distance D3, and the fourth distance D4, each independently range from about 1/8 of an inch to about 5/8 of an inch. In some embodiments, the first distance Di, the second

CA 02976489 2017-08-11

WO 2016/144504 PCT/US2016/018650 distance D2, the third distance D3, and the fourth distance D4, each independently range from about 1/4 of an inch to about 1/2 of an inch. In some embodiments, the first distance Di, the second distance D₂, the third distance D₃, and the fourth distance D₄, is about 3/8 of an inch.

[0072] The first adhesive strip 130 may be spaced from the dotted boundary 170 of the central region 106 by a fifth distance D5. The second adhesive strip 131 may be spaced from the dotted boundary 170 of the central region 106 by a sixth distance D₆. The third adhesive strip 132 may be spaced from the dotted boundary 170 of the central region 106 by a seventh distance D7. The fourth adhesive strip 133 may be spaced from the dotted boundary 170 of the central region 106 by an eighth distance Ds.

[0073] In some embodiments the fifth distance D5, the sixth distance De, the seventh distance D₇, and the eighth distance Ds, each independently range from about 0 inches to about 5/8 of an inch. In some embodiments, the fifth distance D5, the sixth distance De, the seventh distance D₇, and the eighth distance Ds, each independently range from about 1/8 of an inch to about 1/2 of an inch. In some embodiments, the fifth distance D₅, the sixth distance De, the seventh distance D₇, and the eighth distance Ds is about 0 inches or about 3/8 of an inch.

[0074] According to the embodiments when the fifth distance D5, the sixth distance De, the seventh distance D₇, and the eighth distance Ds, are independently 0 inches, the central region 106 is directly circumscribed by at least one of the first adhesive strip 130, the second adhesive strip 131, the third adhesive strip 132, and the fourth adhesive strip 133.

[0075] The first adhesive strip 130, the second adhesive strip 131, the third adhesive strip 132, and the fourth adhesive strip 132 may each be independently applied to at least one of the first major surface 201 of the second layer 200 or the second major surface 102 of the first layer 100 in a width of about 1/4 of an inch to about 1/2 of an inch. The first adhesive strip 130, the second adhesive strip 131, the third adhesive strip 132, and the fourth adhesive strip 132 may each be applied to at least one of the first major surface 201 of the second layer 200 or the second major surface 102 of the first layer 100 in a width of about 3/8 of an inch.

[0076] Depending on the width of the first, second, third, and fourth adhesive strip 130, 131, 132, and 133 and the first, second, third, fourth, fifth, sixth, seventh, and eighth

CA 02976489 2017-08-11

WO 2016/144504 PCT/US2016/018650 distance Di, D2, D3, D₄, D5, De, D7, and D₈, the central region 106 of the first layer 100 may occupy between about 70% to about 99% of the surface area of the second major surface 102 of the first layer 100 - the same surface area percentages apply to the central region 206 of the second layer 200. In some embodiments, the central region 106 of the first layer 100 may occupy between about 85% to about 95%, for example about 95%, of the surface area of the second major surface 102 of the first layer 100 - the same surface area percentages apply to the central region 206 of the second layer 200.

[0077] The first adhesive strip 130, the second adhesive strip 131, the third adhesive strip 132, and the fourth adhesive strip 132 may each be applied to at least one of the first major surface 201 of the second layer 200 or the second major surface 102 of the first layer 100 in a thickness of about 0.01 inches to about 0.25 inches. The first adhesive strip 130, the second adhesive strip 131, the third adhesive strip 132, and the fourth adhesive strip 132 may each be independently applied to at least one of the first major surface 201 of the second layer 200 or the second major surface 102 of the first layer 100 in a thickness of about 0.03 inches.

[0078] In some embodiments, the adhesive 50 is applied to at least one of the comers of the perimeter region 105 of the second major surface 102 of the first layer 100 or the perimeter region 205 of the first major surface 201 of the second layer 200.

[0079] The first, second, third, fourth, fifth, sixth, seventh, and eighth distances Di, D2, D3, D4, D5, Dg, D7, and Dg, described with respect to the central region 106 of the second major surface 102 of the first layer 100 also apply to the central region 206 of the first major surface 201 of the second layer 200.

[0080] In some embodiments of the present invention, the adhesive 50 is applied to at least one of the first major surface 201 of the second layer 200 or the second major surface 102 of the first layer 100 such that a total of about 10 g to about 30 g of adhesive 50 exists in the acoustic ceiling panel 20. In some embodiments of the present invention, the adhesive 50 is applied to at least one of the first major surface 201 of the second layer 200 or the second major surface 102 of the first layer 100 such that a total of about 15 g to about 30 g of adhesive 50 exists in the acoustic ceiling panel 25. In some embodiments of the present invention, the adhesive 50 is applied to at least one of the first major surface 201 of the second layer 200 or the second major surface 102 of the first layer 100 such

CA 02976489 2017-08-11

WO 2016/144504 PCT/US2016/018650 that a total of about 20 g is applied.

[0081] As demonstrated by the non-limiting embodiments of Figures 7 and 8, the first adhesive strip 130, the second adhesive strip 131, the third adhesive strip 132, and the fourth adhesive strip 133 may each be a continuous strip of adhesive that collectively define and form a closed-geometry that circumscribes the central region 106 of the second major surface 102 of the first layer 100.

[0082] As demonstrated by the non-limited embodiment of Figure 9, the first adhesive strip 130, the second adhesive strip 131, the third adhesive strip 132, and the fourth adhesive strip 133 may each be a continuous strip of adhesive, wherein the first adhesive strip 130, the second adhesive strip 131, the third adhesive strip 132, and the fourth adhesive strip 133 of this embodiment are each discontinuous relative to one another.

[0083] As demonstrated by the non-limited embodiment of Figure 10, the first adhesive strip 130, the second adhesive strip 131, the third adhesive strip 132, and the fourth adhesive strip 133 may each be intersecting, however, each of the first adhesive strip 130, the second adhesive strip 131, the third adhesive strip 132, and the fourth adhesive strip 133 may be a discontinuous strip of adhesive.

[0084] In one embodiment shown in shown in Figure 7, the first adhesive strip 130 may span a length that is equal to a length of the first upper edge portion 120, the second adhesive strip 131 may span a length that is equal to a length of the second upper edge portion 121, the third adhesive strip 132 may span a length that is equal to a length of the third upper edge portion 122, and the fourth adhesive strip 130 may span a length that is equal to a length of the fourth upper edge portion 123. In this embodiment, the first adhesive strip 130 and third adhesive strip 132 overlap, the third adhesive strip 132 and the second adhesive strip 131 overlap, the second adhesive strip 131 and the fourth adhesive strip 133 overlap, and the fourth adhesive strip 133 and the first adhesive strip 130 overlap.

[0085] In one embodiment shown in shown in Figure 8, the first adhesive strip 130 may span a length that is less than the length of the first upper edge portion 120, the second adhesive strip 131 may span a length that less than the length of the second upper edge portion 121, the third adhesive strip 132 may span a length that less than the length of the third upper edge portion 122, and the fourth adhesive strip 130 may span a length that is

CA 02976489 2017-08-11

WO 2016/144504 PCT/US2016/018650 less than the length of the fourth upper edge portion 123. In this embodiment, each of the first adhesive strips 130, the second adhesive strip 131, the third adhesive strip 132, and the fourth adhesive strip 133 are contacting to form a closed-geometry.

[0086] Adhesive 50 may be applied to the first major surface 201 of the second layer using the same process, wherein the central region 106 of the first layer corresponds to the central region 206 of the second layer 200; the dotted boundary 170 of the first layer corresponds to a dotted boundary 270 of the second layer 270; the first, second, third, and fourth lower edge portions 220, 221, 222, and 223 of the second layer 200 conrespond to the first, second, third, and fourth upper edge portions 120, 121, 122, and 123 of the first layer 100; and the first, second, third and fourth adhesive strips 130, 131, 132, and 133 may be applied adjacent to the corresponding first, second, third, and fourth lower edge portions 220,221,222, and 223 of the second layer 200.

[0087] In some embodiments of the present invention, the acoustic ceiling panels 20 of the present invention may be formed using a continuous process that includes passing the first layer 100 down a conveyor along a machine direction, wherein the second major surface 102 of the first layer 100 is exposed facing upward. As the first layer 100 passes along the machine direction, the second major surface 102 passes underneath a first glue unit which simultaneously applies the first adhesive strip 130 and the second adhesive strip 131 (not pictured). The first layer 100 can then turned 90 degrees and passed along the machine direction under a second glue unit that simultaneously applies the third adhesive strip 132 and the fourth adhesive strip 133 (not pictured). The continuous process is also suitable for applying the first adhesive strip 130, the second adhesive strip 131, the third adhesive strip 132, and the fourth adhesive strip 133 to the first face 201 of the second layer 200.

[0088] After application of the first adhesive strip 130, the second adhesive strip 131, the third adhesive strip 132, and the fourth adhesive strip 133 to at least one of the second major surface 102 of the first layer 100 and the first major surface 201 of the second layer 200, the second major surface 102 of the first layer 100 is joined to the first major surface 201 of the second layer 100.

[0089] Pressure may be applied to at least one of the second major surface 202 of the second layer 200 or the first major surface 101 of the first layer to aid in the adhesive

CA 02976*89 2017-08-11

WO 2016/144504 PCT/US2016/018650 bonding between the first and second layers 100. Heat may also be applied to the first layer 100 and the second layer 200 to ensure proper adhesive bonding between the first layer 100 and the second layer 200. Optionally, a scrim 300 may later be applied to the first major surface 101 of the first layer 100.

[0090] In non-limiting embodiments, the ceiling panel 20 may be a circle, oval, or polygon - e.g., rectangular (including square and non-square shapes) or triangular. According to these embodiments the first layer 100 and the second layer 200 share the shape of the overall ceiling panel 20. In some embodiments, the polygonal ceiling panels 20 may have rounded or sharp comers.

[0091] According to some embodiments, the ceiling panel 20 is substantially rectangular the term “substantially rectangular” means a shape having four edges and four comers. Each comer forms angle ranging from 88 to 92 degrees - alternatively about a 90 degrees. The four edges are either the same length (square) or have a first pair of edges that are parallel to each other and extend a first length and a second pair of edges that are parallel to each other and extend a second length, wherein the first and second lengths are not equal (non-square). In some embodiments, the first pair of edges comprise the first upper edge portion 120 and the second upper edge portion 121, and the second pair of edges comprise the third upper edge portion 122 and the fourth upper edge portion 123.

[0092] In some embodiments, the ceiling panel 20 is rectangular, wherein the first pair of edges and second pair of edges each have a length of 2 feet. In some embodiments, the ceiling panel 20 has an overall thickness ranging from about 1.25 inches to about 2 inches - alternatively about 1.75 inches.

[0093] The acoustic ceiling panel of the present invention exhibits certain acoustical performance properties. Specifically, the American Society for Testing and Materials (ASTM) has developed test method E1414 to standardize the measurement of airborne sound attenuation between room environments 3 sharing a common plenary space 2. The rating derived from this measurement standard is known as the Ceiling Attenuation Class (CAC). Ceiling materials and systems having higher CAC values have a greater ability to reduce sound transmission through the plenary space 2 - i.e. sound attenuation function.

[0094] Another important characteristic for the acoustic ceiling panel materials is the ability to reduce the amount of reflected sound in a room. One measurement of this ability

CA 02976489 2017-08-11

WO 2016/144504 PCT/US2016/018650 is the Noise Reduction Coefficient (NRC) rating as described in ASTM test method C423. This rating is the average of sound absorption coefficients at four octave bands (250, 500, 1000, and 2000 Hz), where, for example, a system having an NRC of 0.90 has about 90% of the absorbing ability of an ideal absorber. A higher NRC value indicates that the material provides better sound absorption and reduced sound reflection - sound absorption function.

[0095] Previous attempts to design acoustic ceiling panel shaving increased CAC values (i.e., desirable reduction of sound transmission through the plenary space 2), has been tied with a simultaneous decrease in sound absorption (NRC), which causes an increased amount of sound reflected within a given room environment 3. It has been discovered that by using the acoustic ceiling panel 20 of the present disclosure, an increase in CAC performance can be achieved without substantial loss in NRC performance.

[0096] Specifically, by coupling together the first layer 100 and the second layer 200 using adhesive 50 that is only applied to at least one of the perimeter regions 105,205 of the first layer 100 or the second layer 200, while also keeping the central regions 106,206 of the first layer 100 and the second layer substantially free of adhesive 50, it has been discovered that the resulting acoustic ceiling panel 20 will demonstrate a marked improvement in CAC performance while avoiding substantial detrimental change in NRC performance. According to the present disclosure, an insubstantial change in NRC performance is a loss of NRC value of less than or equal to (<) 0.05.

[0097] Specifically, the acoustic ceiling panel 20 of the present disclosure has a CAC value of 35 or greater, preferably 40 or greater, and has an NRC value of 0.7 or greater, preferably 0.9 or greater. The first layer 100 may have an NRC value of at least 0.80, alternatively of at least 0.90. The second layer 100 may have an NRC value of at least 0.65, and a CAC value of at least 35.

[0098] In some embodiments, the acoustic ceiling panel 20 of the present disclosure is formed by using a second layer 200 that has a CAC value that is greater than a CAC value of the first layer 100. The second layer 200 may also have an NRC value that is less than the NRC value of the first layer 200. The first layer 100 may be a noise absorption layer that provides sound dampening within a single room environment 3. The second layer 200 may be a noise blocking layer that provides soundproofing between adjacent room

CA 02976489 2017-08-11

WO 2016/144504

PCT/US2016/018650 environments 3 that share the same plenary space 2.

[0099] According to the present invention, once the acoustic ceiling panel 20 has been properly installed into ceiling grid 5 of the ceiling system 1, the second major surface 202 of the second layer 200 faces the plenary space 2 of the ceiling system 1.

[00100] The invention will be described in greater detail by way of specific examples. The following examples are offered for illustrative purposes and are not intended to limit the invention in any manner.

Examples

[00101] The Examples were prepared using a first layer comprised of fiberglass having the dimensions of 24 inches x 24 inches x 1 inch. The Examples were prepared using a second layer comprised of mineral wool having the dimensions of 24 inches x 24 inches x 0.75 inches. The first and second layers have the following acoustical properties:

Fiberglass First Layer

<td> NRC Value</td><td> 0.95</td>

<td> CAC Value</td><td> N/A</td>

Mineral Wool Second Layer

<td> NRC Value</td><td> 0.70</td>

<td> CAC Value</td><td> 40</td>

[00102] For the purpose of this disclosure, each of the individual fiberglass ceiling panels has the same starting acoustical performance. For the puipose of this disclosure, each of the individual mineral wool sound attenuation layers has the same starting acoustical performance.

[00103] Examples 1 and 2 were prepared by adhering together the first and second layers using polyvinyl acetate as the adhesive. The adhesive was applied within the perimeter region of the first layer as first, second, third, and fourth continuous adhesive strips. Each of the adhesive strips were adjacent to the corresponding first, second, third, and fourth upper edges of the first layer by an offset distance of 3/8 inches. Each adhesive strip was applied with a width of 3/8 of an inch. Examples 1 and 2 each used a total of 20g of adhesive. The central region of Examples 1 and 2 were substantially free of adhesive. Each of the central regions of the first and second layers each have the dimensions of about 22.5 inches x 22.5 inches (506.25 sq. inches), making up about 88% of the surface area of each of the second major surface of the first layer and the first major surface of the second layer. The final thickness of the overall acoustic ceiling panel is set

CA 02976489 2017-08-11

WO 2016/144504

PCT/US2016/018650 forth in the table below.

[00104] Comparative Example 1 was prepared by evenly applying eight parallel lines of polyvinyl acetate adhesive across the first major surface of the first layer - i.e. through the central region of the first layer. Comparative Example 1 used a total of 20g of adhesive. Comparative Examples 2 and 3 were prepared by applying sixteen checker board lines across the first major surface of the first layer - i.e. through the central region of the first layer. Comparative Examples 2 and 3 each use a total of 20g of adhesive. The final thickness of the comparative acoustic ceiling panels are set forth in the table below.

Table 1

<td></td><td> Gauge (inches)</td><td> Glued</td><td> NRC</td><td> ANRC to Comp. Example 1</td><td> CAC</td>

<td> Example 1</td><td> 1.75</td><td> Perimeter (20g)</td><td> 0.95</td><td> 0.05 (Insubstantial)</td><td> 43</td>

<td> Example 2</td><td> 1.75</td><td> Perimeter (20g)</td><td> 0.95</td><td> 0.05 (Insubstantial)</td><td> 43</td>

<td> Comparative Example 1</td><td> 1.76</td><td> 8 parallel Lines (20g)</td><td> 1.00</td><td> -</td><td> 40</td>

<td> Comparative Example 2</td><td> 1.77</td><td> 16 check pattern lines (40g)</td><td> 1.00</td><td> -</td><td> 40</td>

<td> Comparative Example 3</td><td> 1.78</td><td> 16 check pattern lines (40g)</td><td> 1.00</td><td> -</td><td> 39</td>

[00105] As demonstrated by Table 1, applying adhesive according to the present disclosure results in a marked improvement in CAC performance with only an insubstantial drop of five one-hundredths in NRC value. Thus, applying the adhesive according to the present disclosure allows for improved CAC performance without substantial detrimental affects to the NRC performance.

[00106] Furthermore, applying adhesive according to the present disclosure surprisingly results in improved CAC performance with an overall ceiling panel thickness. CAC performance is a measure of soundproofing between adjacent room environments

CA 02976*89 2017-08-11

WO 2016/144504 PCT/US2016/018650 typically, it is expected that as thickness of the barrier between adjacent room environments decreases, so does CAC performance. Thus, applying the adhesive according to the present disclosure allows for improved CAC performance while decreasing the volume required for such ceiling panel.

Π. Ceiling System With Ceiling Panels and Free-Floating Sound Attenuation Lavers [00107] As shown in Figures 12 and 13, this embodiment of the present invention is directed to a ceiling system 1001 comprising a support grid 1005 and at least one multicomponent panel 1020. A plenary space 1002 may exist above the support grid 1005. The plenary space 1002 is the space that exists above the multi-component panels 1020 and above the support grid 1005 and below a roof or a subfloor 1004 of an above adjacent floor in a building. The plenary space 1002 provides room for mechanical lines to be run throughout a building - e.g. HVAC, plumbing, data lines, etc. A room environment 1003 may exist below the multi-component panels 1020 and below the support grid 1005. The room environment 1003 is the space occupied by inhabitants of a room - e.g. room environments 1003 in an office building would be the space occupied by desks, office workers, computers, etc. The combination of the support grid 1005 and the multicomponent panels 1020 may act as an acoustic, thermal, and aesthetic barrier between the room environment 1003 and the plenary space 1002, as well as a sound deadening layer for noise that exists within the room environment 1003, as discussed herein.

[00108] The support grid 1005 may comprise a plurality of first struts 1006 extending parallel to each other. In some embodiments, the support grid 1005 may further comprise a plurality of second struts 1007 that extend parallel to each other. The plurality of first struts 1006 may intersect the plurality of second struts 1007 to form a grid pattern having a plurality of grid openings 1008. In some embodiments, the plurality of first struts 1006 intersects the plurality of second struts 1007 at a substantially perpendicular angle, thereby forming rectangular grid openings 1008. The rectangular grid openings 1008 may be square or any other shape that is aesthetical or functional.

[00109] As shown in Figure 17-21, each of the plurality of first struts 1006 and each of the plurality of second struts 1007 may comprises T-bars having a horizontal flange 1010 and a web 1011. The plenary space 1002 exists above the T-bars and the room environment 1003 exists below the T-bars.

CA 02976489 2017-08-11

WO 2016/144504 PCT/US2016/018650

[00110] The ceiling system 1001 of the present disclosure comprises at least one multi-component panel 1020 that is mounted within of the grid openings 1008 of the support grid 1005. The ceiling system 1001 may comprises a plurality of multicomponent panels 1020 mounted to the support grid 1005, each of the plurality of multicomponent panels 1020 resting within one of the plurality of grid openings 1008. In some embodiments, something other than the multi-component panel 1020 (for example, light fixture or an air duct vent) may be mounted to the support grid 1005 within at least one of the grid openings 1008 (not pictured).

[00111] As demonstrated by Figures 14 and 16, the multi-component panel 1020 may comprise a ceiling panel 1100 and a sound attenuation layer 1200, In some embodiments of the present invention, the multi-component panel 1020 may further comprise a scrim (not pictured). As demonstrated by Figures 19 and 21, the multicomponent panel 1020 may be mounted on the support grid 1005 of the ceiling system 1001 so that the ceiling panel 1100 of the multi-component panel 1020 is adjacent to the room environment 1003 and the sound attenuation layer 1200 is adjacent to the plenary space 1002.

[00112] As shown by Figure 15, the eeiling panel 1100 comprises a lower major surface 1101 and an upper major surface 1102. The lower major surface 1101 of the ceiling panel 1100 may be opposite the upper major surface 1102 of the ceiling panel 1100. The first layer 1100 further comprises a side surface 1103 extending between the lower major surface 1101 and the upper major surface 1102.

[00113] The ceiling panel 1100 may have an overall length and width. In some embodiments, the length of the ceiling panel 1100 may be 12,18, 24, 30,48, 60,72, or 96 inches. In some embodiments, the width of the ceiling panel 1100 may be 4, 6,12,18,20, 24,30, or 48 inches.

[00114] The upper major surface 1102 of the ceiling panel 1100 may have a length and a width. The lower major surface 1101 of the ceiling panel 1100 may have a length and a width. In some embodiments each of the lengths and widths of the upper major surface 1102 and lower major surface 1101 of the ceiling panel 1100 may share the overall length and widths of the ceiling panel. In some embodiments the length of the upper major surface 1102 and the lower major surface 1101 are equal. In some embodiments the

CA 02976489 2017-08-11

WO 2016/144504 PCT/US2016/018650 width of the upper major surface 1102 and the lower major surface 1101 are equal. In some embodiments the length of the upper major surface 1102 is greater than the length of the lower major surface 1101. In some embodiments the width of the upper major surface 1102 is greater than the width of the lower major surface 1101.

[00115] In some embodiments of the present invention, the side surface 1103 of the ceiling panel 1100 may comprise a stepped profile having an upper side surface 1103b and a lower side surface 1103a. An intermediate surface 1108 extends between the lower side surface 1103a and the upper side surface 1103b in a direction that is substantially perpendicular to the side surface 1103, the upper side surface 1103a, and the lower side surface 1103b of the ceiling panel 1100. In some embodiments, the intermediate surface 1108 faces the same direction as the lower major surface 1101 of the ceiling panel 1100. In other embodiments, the intermediate surface 1108 faces a direction oblique to the lower major surface 1101.

[00116] The stepped profile comprises the combination of the upper side surface 1103b, the intermediate surface 1108, and the lower side surface 1103a. According to this embodiment, the upper major surface 1102 of the ceiling panel 1100 has an area that is greater than an area of the lower major surface 1101 of the ceiling panel 1100. In some embodiments the surface area of the upper major surface 1102 of the first layer 1100 is equal to the sum of the area of the lower major surface 1102 and the area of the intermediate surface 1108 of the ceiling panel 1100. According to this embodiment, at least one of the width and length of the lower major surface 1101 of the ceiling panel 1100 is less than the length and the width of the upper major surface 1102 of the ceiling panel.

[00117] In some embodiments, the ceiling panel 1100 comprising the stepped profile will have at least one of the length or width of the lower major surface 1101 be less than the length or the width of the upper major surface 1102 by a distance ranging from about 0.5 inches to about 2 inches.

[00118] In some embodiments, the stepped profile of the ceiling panel 1100 may be present on each of the side surfaces 1103 of the ceiling panel 1100. In other embodiments, the stepped profile may only be present on two opposite side surfaces 1103 of the ceiling panel 1100. In a preferred embodiment, the ceiling panel 1100 is closer to the sound source, e.g., facing the room environment 1003.

CA 02976489 2017-08-11

WO 2016/144504 PCT/US2016/018650

[00119] In some embodiments, the ceiling panel 1100 may be comprised of fiberglass, mineral wool (such as rock wool, slag wool, or a combination thereof), synthetic polymers (such as melamine foam, polyurethane foam, or a combination thereof), mineral cotton, silicate cotton, or combinations thereof. In some embodiments the ceiling panel 1100 is produced from fiberglass. In some embodiments the ceiling panel 1100 is formed of a sound absorbing material that predominantly provides a sound absorption function and preferred materials for providing the sound absorption function for the first layer 1100 include fiberglass. The ceiling panel 1100 provides a ceiling NRC rating of at least 0-9, preferably at least 0-95- NRC (Noise Reduction Coefficient) is further described below. The NRC value of the ceiling panel 1100 is measured prior to the sound attenuation layer 1200 being positioned atop the ceiling panel 1100, as discussed herein. The ceiling panel 1100 has a first rigidity. In some non-limiting embodiments of the present disclosure, the ceiling panel may be selected from the Optima™, and Lyra™ fiberglass panel lines produced by Armstrong (Armstrong World Industries, Inc.) - for example Lyra 8372 or Optima 3251.

[00120] As demonstrated by Figures 15 and 16, the sound attenuation layer 1200 comprises a lower major surface 1201 and an upper major surface 1202. The lower major surface 1201 of the sound attenuation layer 1200 may be opposite the upper major surface 1202 of the sound attenuation layer 1200. The sound attenuation layer 1200 may further comprise a side surface 1203 extending between the lower major surface 1201 of the sound attenuation layer 1200 and the upper major surface 1202 of the sound attenuation layer 1200.

[00121] The upper major surface 1202 of the sound attenuation layer 1200 may have a length and a width. The lower major surface 1201 of the sound attenuation layer 1200 may have a length and a width. In some embodiments the length of the upper major surface 1202 and the lower major surface 1201 of the sound attenuation layer 1200 are equal. In some embodiments the width of the upper major surface 1202 and the lower major surface 1201 of the sound attenuation layer 1200 are equal. In some embodiments the length of the upper major surface 1202 is smaller than the length of the lower major surface 1201 of sound attenuation layer 1200. In some embodiments the width of the upper major surface 1202 is smaller than the width of the lower major surface 1201.

CA 02976489 2017-08-11

WO 2016/144504 PCT/US2016/018650

[00122] In some embodiments the sound attenuation layer 1200 may comprise fiberglass, mineral wool (such as rock wool, slag wool, or a combination thereof), synthetic polymers (such as melamine foam, polyurethane foam, or a combination thereof), mineral cotton, silicate cotton, gypsum, or combinations thereof. In some embodiments the sound attenuation layer 1200 is produced from mineral wool. In some embodiments, the sound attenuation layer 1200 predominantly provides a sound attenuation function and preferred materials for providing the sound attenuation function for the sound attenuation layer 1200 include mineral wool.

[00123] The sound attenuation layer 1200 provides a ceiling CAC rating of at least 37, preferably at least 40 and an NRC value of at least 0.65. CAC (Ceiling Attenuation Class) is further described below. The CAC and NRC values of the sound attenuation layer 1200 are measured prior to being positioned atop the ceiling panel 1100, as discussed herein. The sound attenuation layer 1200 has a second rigidity. In some embodiments, the first rigidity of the ceiling panel 1100 is greater than the second rigidity of the sound attenuation layer 1100. In some embodiments, the first rigidity of the ceiling panel 1100 and the second rigidity of the sound attenuation layer 1100 are equal. In some non-limiting embodiments of the present disclosure, the ceiling panel may be selected from the School Zone * , and Cortega mineral wool panel lines produced by Armstrong - for example, School Zone 1810.

[00124] According to some embodiments and as shown in Figure 14, the length of the upper major surface 1102 of the first ceiling panel 1100 is substantially equal to the length of the lower major surface 1201 of the first sound attenuation layer 1200. In some embodiments, the width of the upper major surface 1102 of the first ceiling panel 1100 is substantially equal to the width of the lower major surface 1201 of the first sound attenuation layer 1200.

[00125] According to some embodiments, the length of the upper major surface 1102 of the first ceiling panel 1100 is greater than the length of lower major surface 1201 of the sound attenuation layer 1200. According to some embodiments, the width of the upper major surface 1102 of the first ceiling panel 1100 is greater than the width of the lower major surface 1201 sound attenuation layer 1200. According to some embodiments, both the length and the width of the upper major surface 1102 of the first ceiling panel

CA 02976489 2017-08-11

WO 2016/144504 PCT/US2016/018650

1100 are greater than the width of the lower major surface 1201 sound attenuation layer 1200.

[00126] According to some embodiments, the length of the upper major surface 1102 of the first ceiling panel 1100 is less than the length of lower major surface 1201 of the sound attenuation layer 1200. According to some embodiments, the width of the upper major surface 1102 of the first ceiling panel 1100 is less than the width of the lower major surface 1201 sound attenuation layer 1200- According to some embodiments, both the length and the width of the upper major surface 1102 of the first ceiling panel 1100 are less than the width of the lower major surface 1201 sound attenuation layer 1200.

[00127] In some non-limiting embodiments, the ceiling system 1001 of the present invention may be installed according to a first methodology. The first methodology may comprise a first step a) of mounting the support grid 1005 within an internal space of a building so that the plenary space 1002 is formed above the support grid 1005 and the active room environment 1002 is formed below the support grid 1005. The support grid 1005 comprises the plurality of intersecting first and second struts 1006,1007 that form a plurality of grid openings 1008. The grid openings 1008 may be defined by sections 1006A of opposing first ones of the intersecting struts (first struts 1006) and sections 1007A of opposing second ones of intersecting struts (second struts 1007).

[00128] Subsequent to step a), step b) comprises a first ceiling panel 1100a being mounted to the support grid 1005, as shown in Figure 17. A second ceiling panel 1100b and optionally a third ceiling panel 1100c may also be mounted to the support grid 1005 during step b). The first ceiling panel 1100 is positioned within a first one of the openings 1008 of the grid support 1005 so that the upper major surface 1102 of the first ceiling panel 1100 is facing the plenary space 1002 - the same applies to the second and third ceiling panels 1100. According to some embodiments, at least one of the ceiling panels 1100 may positioned within the grid opening 1008 so that the ceiling panel 1100 is are circumscribed by the sections 1006A, 1007A of intersecting first and second struts 1006, 1007.

[00129] As shown in Figure 17, when the ceiling panel 1100 is mounted to the support grid 1005, at least one of the lower major surface 1101 or the intermediate surface 1108 of the ceiling panel 1100 may abut at least a portion of a top surface of the horizontal

CA 02976489 2017-08-11

WO 2016/144504 PCT/US2016/018650 flange 1010 of at least one of the first member 1006 or the second member 1007 of the support grid 1005. The abutment between at least one of the lower major surface 1101 or the intermediate surface 1108 of the ceiling panel layer 1100 and the top surface of the horizontal flange 1010 allows the ceiling panel 1010 to rest in a fully installed position within the ceiling system 1001.

[00130] Subsequent to step b), step c) includes positioning a first sound attenuation layer 1200a a free-floating relationship atop the upper major surface 1102 of the first ceiling panel 1100a, thereby forming a first multi-component panel 1020a - as shown in Figure 18. As shown in Figures 18 and 19, at least a second sound attenuation layer 1200b may be positioned in a free-floating relationship atop the upper major surface 1102 of the second ceiling panel 1100b thereby forming a second multi-component panel 1020b during step c). A third sound attenuation layer 1200c may also be positioned in a freefloating relationship atop the upper major surface 1102 of the third ceiling panel 1100c thereby forming a third multi-component panel 1020c during step c).

[00131] The multi-component panels 1020, 1020a, 1020b, 1020c have a CAC value greater than 37 and an NRC value of at least 0.95. According to some embodiments, at least one of the first, second, or third ceiling panels 1100,1100a, 1100b, 1100c may be positioned within the grid opening 1008 so that the ceiling panel 1100 and the sound attenuation layer 1200 are circumscribed by the sections 1006A, 1007A of intersecting first and second struts 1006, 1007. The multi-component panels 1020,1020a, 1020b, 1020c have a CAC value greater than 37 and an NRC value of at least 0.95.

[00132] In some embodiments of the present invention, the sound attenuation layer 1200 may be cut to its final dimensions at the installation site. Specifically, prior to step b), the present invention may further include providing a sound attenuation sheet having a length greater than the length of the ceiling panel 1100 (not pictured). At least one sound attenuation layer 1200 may be cut from the sound attenuation sheet, wherein the at least one sound attenuation layer 1200 has a length that is less than, substantially equal to, or greater than the length of the ceiling panel 1100. Cutting sound attenuation layers 1200 from the sound attenuation sheet prior to mounting of the ceiling panels allows for a variety of custom shaped sound attenuation layers 1200 that correspond to a variety ceiling panel shapes 1100 that may be used in a ceiling system 1001. In some

CA 02976489 2017-08-11

WO 2016/144504 PCT/US2016/018650 embodiments, the sound attenuation layer 1200 may be cut from the sound attenuation sheet after step b) but prior to step c).

[00133] In an alternative embodiment shown in Figure 20, step b) may include the first ceiling panel 1100a and the second ceiling panel 1100b being mounted to the support grid 1005 in adjacent first and second openings 1008. Following step b), an attenuation layer 1200 is positioned in a free-floating relationship atop the upper major surface 1102 of both the first and the second ceiling panels 1100, 1100a, 1100b. The lower major surface 1201 of the sound attenuation layer 1200 may cover at least one of the sections 1006A, 1007A of the first or second strut 1006, 1007 that is positioned between the adjacent first and second ceiling panels 1100,1200. The resulting first and second multicomponent panels 1020a, 1020b have a sound attenuation layer 1200 that provides a continuous structure across at least two openings 1008, optionally three openings 1008, in the support grid 1005. The resulting sound attenuation layer may exhibit a CAC value greater than 37 and an NRC value of at least 0.95.

[00134] In other non-limiting embodiments, the ceiling system 1001 of the present invention may be according to a second methodology. The second methodology may include a first step a) of mounting the support grid 1005 within an internal space of a building so that the plenary space 1002 is formed above the support grid 1005 and the active room environment 1002 is formed below the support grid 1005. The support grid 1005 comprises the plurality of intersecting first and second struts 1006, 1007 that form a plurality of grid openings 1008. The grid openings 1008 may be defined by sections 1006A of opposing first ones of the intersecting struts (first struts 1006) and sections 1007A of opposing second ones of intersecting struts (second struts 1007).

[00135] Subsequent to step a), step b) may include providing a first ceiling panel 1100 and providing a first sound attenuation layer 1100 - as shown in Figure 15. Subsequent to step b), step c) includes overlaying the first sound attenuation layer 1200 in a free-floating relationship on the upper major surface 1102 of the first ceiling panel 100, thereby forming an un-mounted multi-component panel 1020 having a CAC value greater than 37 - as shown in Figure 16.

[00136] Steps b) and c) may be repeated multiple times until reaching a number of multi-component panels 1020 necessary to complete the installation of the ceiling system

CA 02976489 2017-08-11

WO 2016/144504 PCT/US2016/018650

1001. Furthermore, it is possible that the sound attenuation layer 1200 may be cut to its final dimensions at the installation site from a sound attenuation sheet - as previously discussed.

[00137] Subsequent to step c), step d) includes at least the first multi-component panel 1020 being mounted to the support grid 1005 - as shown in Figure 21. The first multi-component panel 1020 may positioned within one of the plurality of openings 1008 so that the upper major face 1102 of the ceiling panel 1100 is facing the plenary space 1002. According to some embodiments, at least the first ceiling panels 1100a is positioned within the opening 1008 so that the ceiling panel 1100 and the sound attenuation layer 1200 are circumscribed by the sections 1006A, 1007A of intersecting first and second struts 1006,1007.

[00138] In non-limiting embodiments, step d) may include mounting the multicomponent panel 1020b to the support grid 1005 by dropping the multi-component panel 1020b vertically downward from the plenary space 1002 onto the support grid 1005. The vertical drop of the multi-component panel 1020b continues until at least one of the lower major surface 1101 or the intermediate surface 1108 of the ceiling panel 1100 abuts the top surface of the flange 1010. Using the drop down methodology, the multi-component panel 1020b may stay substantially level with respect to the support grid 1005 entirely during step d). The term “substantially” in this case means a change in relative orientation of +/-15°. During this step, the side surfaces 1203 of the sound attenuation layer 1200 do not pass the support flange 1010 of the first and second struts 1006,1007.

[00139] In other non-limiting embodiments, the multi-component panel 1020c may be raised vertically up into the support grid 1005 from the room environment 1003. To raise the multi-component panel 1020 onto the support grid 1005, the multi-component panel 1020c must be temporarily oriented at an oblique angle relative to the support grid 1005 for the side surfaces 1103, 1203 of the ceiling panel 1100 and the sound attenuation layer 1200 to clear the horizontal flange 1010 of the support grid 1005. Once the side surfaces 1103, 1203 of the ceiling panel 1100 and the sound attenuation layer 1200 have cleared the horizontal flanges 1010 of the support grid 1005, the multi-component panel 1020 can be reoriented to level position relative to the support grid 1005. The multicomponent panel 1020 may then be lowered vertically until at least one of the lower major

CA 02976489 2017-08-11

WO 2016/144504 PCT/US2016/018650 surface 1101 or the intermediate surface 1108 of the ceiling panel 1100 abuts the top surface of the flange 1010 - as shown in Figure 21.

[00140] As shown in Figure 17, after the ceiling panel 1100 has been mounted to the support grid 1005, at least one of the intermediate surface 1108 or the lower major surface of the ceiling panel 1100 may abut at least a portion of a top surface of the horizontal flange 1010 of at least one of the first member 1006 or the second member 1007 of the support grid 1005. The abutment between the intermediate surface 1108 of the ceiling panel layer 1100 and the top surface of the horizontal flange 1010 allows the ceiling panel 1010 to rest in a fully installed position. Once fully mounted, both the ceiling panel 1100 and the sound attenuation layer 1200 are circumscribed by the sections 1006A, 1007A of intersecting first and second struts 1006,1007.

[00141] The term free-floating as used in the present disclosure refers to an interface that is substantially free of adhesive or mechanical attachment. The term “substantially free of adhesive” means an amount of adhesive that is less than enough sufficient to impart structural integrity between the ceiling panel 1100 and the sound attenuation layer 1200. In some embodiments, after the first sound attenuation layer 1200 is positioned in a free-floating relationship atop the upper major surface 1102 of the ceiling panel 1100, the only coupling between the lower major surface 1201 of the first sound attenuation layer 1200 and the upper major surface 1102 of the ceiling panel 1100 is contact between the lower major surface 1201 of the first sound attenuation layer 1200 and the upper major surface of the first ceiling panel 1100 resulting from gravitational pull on the first sound attenuation layer 1200.

[00142] According to some embodiments, at least one of the multi-component panels 1020 may positioned within a grid opening 1008 so that the ceiling panel 1100 and the sound attenuation layer 1200 are circumscribed by the sections 1006A, 1007A, of the intersecting first and second struts 1006, 1007. As shown in Figure 16, after the sound attenuation layer 1200 is positioned atop the ceiling panel 1100, a surface contact interface 1300 is between the lower major surface 1201 of the sound attenuation layer 1200 and the upper major surface 1102 of the ceiling panel 1100. The surface contact interface 1300 may be substantially free of adhesive.

[00143] According to some embodiments, as shown in Figure 19, the web portion

CA 02976489 2017-08-11

WO 2016/144504 PCT/US2016/018650

1011 of each of the sections of the intersecting struts - i.e. the sections of the plurality of first struts 1006 and the sections of the plurality of second struts 1007 (not pictured) extend above the surface contact interface 1300 of the multi-component panel 1020. According to some embodiments, the web portion 1011 of each of the sections of the intersecting struts - i.e. the sections of the plurality of first struts 1006 and the sections of the plurality of second struts 1007 - are lower than the surface contact interface 1300 (not pictured).

[00144] In non-limiting embodiments, the multi-component panel 1020 may be a circle, oval, or polygon - e.g., rectangular (including square and non-square shapes) or triangular. According to these embodiments the ceiling panel 1100 and the sound attenuation layer 1200 share the shape of the overall multi-component panel 1020. In some embodiments, the polygonal ceiling panels 1020 may have rounded or sharp comers. [00145] According to some embodiments, the multi-component panel 1020 is substantially rectangular - the term “substantially rectangular” means a shape having four edges and four comers. Each comer forms angle ranging from 88 to 92 degrees alternatively about a 90 degrees. The four side surfaces 1103 are either the same length (square) or have a first pair of edges that are parallel to each other and extend a first length and a second pair of edges that are parallel to each other and extend a second length, wherein the first and second lengths are not equal (non-square).

[00146] In some embodiments, the multi-component panel 1020 is rectangular, wherein the first pair of edges and second pair of edges each have a length of 2 feet. In some embodiments, the multi-component panel 1020 has an overall thickness ranging from about 1.25 inches to about 2 inches - alternatively about 1.75 inches.

[00147] The multi-component panel 1020 of the present invention exhibits certain acoustical performance properties. Specifically, the American Society for Testing and Materials (ASTM) has developed test method E1414 to standardize the measurement of airborne sound attenuation between room environments sharing a common plenary space. The rating derived from this measurement standard is known as the Ceiling Attenuation Class (CAC). Ceiling materials and systems having higher CAC values have a greater ability to reduce sound transmission through the plenary space - i.e. sound attenuation function.

CA 02976*89 2017-08-11

WO 2016/144504 PCT/US2016/018650

[00148] Another important characteristic for the acoustic ceiling panel materials is the ability to reduce the amount of reflected sound in a room. One measurement of this ability is the Noise Reduction Coefficient (NRC) rating as described in ASTM test method C423. This rating is the average of sound absorption coefficients at four Ά octave bands (250, 500, 1000, and 2000 Hz), where, for example, a system having an NRC of 0.90 has about 90% of the absorbing ability of an ideal absorber. A higher NRC value indicates that the material provides better sound absorption and reduced sound reflection - sound absorption function.

[00149] Previous attempts to design acoustic ceiling panel shaving increased CAC values (i.e., desirable reduction of sound transmission through the plenary space), has been tied with a simultaneous decrease in sound absorption (NRC), which causes an increased amount of sound reflected within a given room environment. It has been discovered that by using the multi-component panel 1020 of the present disclosure, an increase in CAC performance can be achieved without loss in NRC performance.

[00150] Specifically, by positioning the sound attenuation layer 1200 in a freefloating relationship atop the upper major surface 1102 of the ceiling panel 1100, it has been discovered that the resulting multi-component panel 1020 will demonstrate a marked improvement in CAC performance while avoiding degradation in NRC performance.

[00151] Specifically, the multi-component panel 1020, of the present disclosure has a CAC value of at least 37 and an NRC value of at least 0.95. The ceiling panel 1100 may exhibit an NRC value of 0.90 prior to the sound attenuation layer being positioned atop the ceiling panel 1100. The sound attenuation layer may have a CAC value of at least 35 and an NRC value of at least 0.65 prior to being positioned atop the ceiling panel 1100.

[00152] In some embodiments, the multi-component panel 1020 of the present disclosure is formed by using a sound attenuation layer 1200 that has a CAC value that is greater than a CAC value of the ceiling panel 1100. The sound attenuation layer 1200 may also have an NRC value that is less than the NRC value of the ceiling panel 1200. The ceiling panel layer 1100 may be a noise absorption layer that provides sound dampening within a single room environment 1003. The sound attenuation layer 1200 may be a noise blocking layer that provides soundproofing between adjacent room

CA 02976489 2017-08-11

WO 2016/144504

PCT/US2016/018650 environments 1003 that share the same plenary space 1002.

[00153] The invention will be described in greater detail by way of specific examples. The following examples are offered for illustrative purposes and are not intended to limit the invention in any manner.

Examples

[00154] The examples were prepared using a 24 inch x 24 inch x 1 inch ceiling panel comprised of fiberglass and a 24 inch x 24 inch x 0.75 inch sound attenuation layer comprised of mineral wool. The ceiling panel and sound attenuation layers have the following acoustical properties:

Fiberglass Ceiling Panel Mineral Wool Sound Attenuation Layer

<td> NRC Value</td><td> 0.95</td>

<td> CAC Value</td><td> N/A</td>

<td> NRC Value</td><td> 0.70</td>

<td> CAC Value</td><td> 40</td>

[00155] For the purpose of this disclosure, each of the individual fiberglass ceiling panels has the same starting acoustical performance. For the purpose of this disclosure, each of the individual mineral wool sound attenuation layers has the same starting acoustical performance.

[00156] Regarding Examples 1 and 2, each of the sound attenuation layers were laid on the upper major surface of the ceiling panel in a free-floating relationship without any adhesive present in the contact interface.

[00157] Regarding Comparative Example 1, the upper major surface of the ceiling panel and the sound attenuation layer were adhered together using polyvinyl acetate adhesive. Twenty grams of the adhesive was applied as eight parallel lines that extend diagonally across the upper major surface of the ceiling panel.

[00158] Regarding Comparative Examples 2 and 3, the upper major surface of the ceiling panel and the sound attenuation layer were adhered together using polyvinyl acetate adhesive. Twenty grams of the adhesive was applied as sixteen checker board lines extend across the upper major surface of the ceiling panel.

[00159] For the purposes of this invention, the starting acoustical performance of the Lyra 8361 panel and the Optima 3251 panel are essentially equal.

Table 1

CA 02976489 2017-08-11

WO 2016/144504

PCT/US2016/018650

<td></td><td> Gauge (inches)</td><td> Interface (Amount of Adhesive)</td><td> NRC</td><td> CAC</td>

<td> Example 1</td><td> 1.76</td><td> Free-Floating (0g)</td><td> 1.0</td><td> 44</td>

<td> Example 2</td><td> 1.75</td><td> Free-Floating (0g)</td><td> 1.0</td><td> 43</td>

<td> Comparative Example 1</td><td> 1.76</td><td> 8 parallel lines (20g)</td><td> 1.00</td><td> 40</td>

<td> Comparative Example 2</td><td> 1.77</td><td> 16 check pattern lines (40g)</td><td> 1.0</td><td> 40</td>

<td> Comparative Example 3</td><td> 1.78</td><td> 16 check pattern lines (40g)</td><td> 1.0</td><td> 39</td>

[00160] As demonstrated by Table 1, positioning the sound attenuation layer in a free-floating relationship atop the upper major surface of the ceiling panel results in a marked improvement in CAC performance without and degradation in NRC value performance.

[00161] Furthermore, positioning the sound attenuation layer in a free-floating relationship atop the upper major surface of the ceiling panel according to the present invention surprisingly resulted in improved CAC performance with an overall decrease in ceiling panel thickness. CAC performance is a measure of soundproofing between adjacent room environments - it is expected that as thickness of the barrier between adjacent room environments decreases, so does CAC performance. Thus, positioning the sound attenuation layer in a free-floating relationship atop the upper major surface of the ceiling panel according to the present invention allows for improved CAC performance while decreasing the volume required for such ceiling panel.

CA 02976489 2017-08-11

WO 2016/144504

PCT/US2016/018650

[00162] While the invention has been described with respect to specific examples including presently preferred modes of carrying out the invention, those skilled in the art will appreciate that there are numerous variations and permutations of the above described systems and techniques. It is to be understood that other embodiments may be utilized and structural and functional modifications may be made without departing from the scope of the present invention. Thus, the spirit and scope of the invention should be construed broadly as set forth in the appended claims.