US 11,893,970 B2
Acoustic panels and methods for preparing them
David Shackleford, Framingham, MA (US); Sizhu You, Auburndale, MA (US); Steven Jacek, Boylston, MA (US); Phillip Evans, Littleton, MA (US); Alexis Rile, Cincinnati, OH (US); and Michael J. Lembo, Souderton, PA (US)
Assigned to CertainTeed Ceilings Corporation, Malvern, PA (US)
Filed by CertainTeed Ceilings Corporation, Malvern, PA (US)
Filed on Aug. 22, 2022, as Appl. No. 17/892,668.
Application 17/892,668 is a continuation of application No. 16/514,768, filed on Jul. 17, 2019, granted, now 11,423,871.
Claims priority of provisional application 62/699,570, filed on Jul. 17, 2018.
Prior Publication US 2023/0064323 A1, Mar. 2, 2023
This patent is subject to a terminal disclaimer.
Int. Cl. G10K 11/168 (2006.01); B05D 1/42 (2006.01)
CPC G10K 11/168 (2013.01) [B05D 1/42 (2013.01)] 21 Claims
OG exemplary drawing
 
1. An acoustic panel comprising
a base structure having one or more edges, an outward major surface having a total area, and an inward major surface opposing the outward major surface; and
a coating layer directly disposed on the outward major surface of the base structure, the coating layer being formed of an open-cell foam, the coating layer having an exterior major surface opposing the outward major surface of the base structure, the coating layer comprising
one or more foamable polymers, present in the coating layer in an amount within the range of about 20 wt. % to about 80 wt. %;
a dispersant, present in the coating layer in an amount within the range of about 0.1 wt. % to about 10 wt. %;
a coalescing agent, present in the coating layer in an amount within the range of about 0.1 wt. % to about 10 wt. % and
a foaming surfactant, present in the coating layer in an amount within the range of about 0.25 wt. % to about 15 wt. %.