ARMSTRONG WORLD INDUSTRIES, INC.

An acoustic structure includes a first core layer having a lattice structure between a first major surface and a second major surface, a first scrim coupled to the first major surface, a second scrim coupled to the second major surface, a second core layer having a lattice structure between a first major surface opposite a second major surface coupled to the second scrim, and a third scrim coupled to the second major surface of the second core layer. The acoustic structure has a bulk density of less than about 12 pounds per cubic foot.

Described herein is a coated building panel having a body and a surface coating atop the body, the surface coating comprising inorganic pigment and a polymeric dispersant comprising a polymer backbone and pendant side chains extending from the polymer backbone; wherein the surface coating comprises a liquid carrier in an amount less than about 1 wt. % based on the total weight of the surface coating.

A coating composition includes a crosslinking binder composition comprising crosslinking functional groups or crosslinker, a pigment composition, a flame retardant, a filler composition, and a biocide. A building panel includes a substrate having a first major surface opposite a second major surface and a side surface extending there-between, and a coating composition over at least one of the first major surface, the second major surface, and the side surface, the coating composition including a crosslinkable binder composition including a crosslinker and a binding agent, a pigment composition, a flame retardant, and a filler composition.

Described herein is a protected building panel comprising a substrate, a peelable film assembly comprising a film layer having a film thickness, the peelable film formed of a film composition comprising coextruded blend a first polyolefin comprising low-density polyethylene and a second polyolefin that is different from the first polyolefin, an adhesive layer having an adhesive thickness, wherein a ratio of the film thickness to the adhesive thickness ranges from about 3:1 to about 5:1, wherein the protected building panel comprising a plurality of perforations extending continuously through the peelable film assembly and the substrate.

A building panel includes a substrate having a first major surface opposing a second major surface. The substrate includes a composite body having a cellulosic matrix and a binder composition including magnesium sulfate and magnesium oxide, a first coating including sodium silicate, and a water-resistant coating including one or more of magnesium sulfate, paraffin, and silicone.

Described herein is a method of manufacturing a panel for a building wherein a wood-grain image is printed on a scrim, the scrim is joined to a panel body, and an edge portion of the panel body is coated. Panels manufactured according to this method may incorporate a variety of different wood-grain images, allowing an aesthetic appearance which matches the rest of the room in which the panel is installed. The image may be located on a printed layer which is on top of or penetrates into the scrim.

A method for determining a perforation matrix includes selecting a trial value for a number of matrix increments across a length and a width of a first major surface of a substrate, selecting a trial value for a number of rows and columns in the matrix, calculating a row spacing value and a column spacing value, comparing the calculated row spacing and column spacing to the target row spacing value and the target column spacing value in the matrix to determine if the values are within a predetermined tolerance of the target row spacing value and target column spacing value, if the values are not within the predetermined tolerance of the target spacing values, repeating, and, upon calculating values within the predetermined tolerance, selecting the lower of the row spacing value and the column spacing value as the final matrix spacing value of the perforation matrix.

A ceiling system is disclosed that comprises a grid frame and a ceiling panel. The grid frame comprises a first grid member and a second grid member. The ceiling panel comprises a top side, a bottom side, a first lateral edge, a second lateral edge, a corner defined between the first lateral edge and the second lateral edge, and a registration guide mounted to the top side comprising a first projection extending from a first side of the corner adjacent the first lateral edge and a second projection extending from a second side of the corner adjacent the second lateral edge, wherein the first projection comprises a first registration face adjacent the first lateral edge configured to engage the first grid member, and wherein the second projection comprises a second registration face adjacent the second lateral edge configured to engage the second grid member.

Described herein is a method of smelting to form an inorganic fiber, the method comprising: a) introducing a silicomanganese slag and a smelting additive into a furnace, the smelting additive comprising biochar; b) smelting the silicomanganese slag in the presence of the smelting additive into a silicomanganese metal and a smelting byproduct; and c) flowing the smelting byproduct from the furnace from a first outlet to a fiber spinning apparatus; and step d) processing the smelting byproduct by the fiber spinning apparatus to form the inorganic fiber.

Described herein is an acoustic building panel having a first major exposed surface opposite a second major exposed surface and a side exposed surface extending there between, the acoustic ceiling panel comprising: a body comprising a first major surface opposite a second major surface and a side surface extending between the first and second major surfaces, the body being air-permeable; and an attenuation coating applied to the first major surface of the body; wherein a first portion of the second major exposed surface of the acoustic building panel is formed by the first major surface of the body and a second portion of the second major exposed surface of the acoustic building panel is formed by the attenuation coating.