DURABLE ACOUSTICAL PANEL AND METHOD OF MAKING THE SAME

• Main Authors: GANSE, ROBERT G, JANCZURA, JOHN J, LOKEY, JAMES R, PARKS, LARRY R, FOSTER, ROBERT E, FELEGI, JOHN JR, BUHAY, BARRY, CHAMBERLAIN, WALTER W
• Format: Patent
• Language: English; French
• Published: 24.11.2001
• Edition: 7
• Subjects: ARTIFICIAL STONE; BUILDING; CEILINGS; CEMENTS; CERAMICS; CHEMISTRY; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDINGMATERIALS; CONCRETE; DECORATIVE ARTS; FIBREBOARD; FIXED CONSTRUCTIONS; FLOORS; GENERAL BUILDING CONSTRUCTIONS; IMPREGNATING OR COATING OF PAPER; INSULATION OR OTHER PROTECTION OF BUILDINGS; LIME, MAGNESIA; MANUFACTURE OF ARTICLES FROM CELLULOSIC FIBROUS SUSPENSIONS ORFROM PAPIER-MACHE; METALLURGY; METHODS OF PRODUCING PAPER THEREON; MOSAICS; PAPER NOT OTHERWISE PROVIDED FOR; PAPER-MAKING; PAPER-MAKING MACHINES; PAPERHANGING; PERFORMING OPERATIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; PRODUCING DECORATIVE EFFECTS; PRODUCTION OF CELLULOSE; PULP COMPOSITIONS; REFRACTORIES; ROOFS; SLAG; TARSIA WORK; TEXTILES; TRANSPORTING; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; TREATMENT OF NATURAL STONE; WALLS, e.g. PARTITIONS

An acoustical panel has a fiberboard which includes a fibrous filler and a base binder, and a nodulated overlay disposed on the fiberboard, wherein the overlay includes nodulated wool and an overlay binder and has a substantially smooth surface. In one embodiment of the present invention, the fibrous filler is mineral wool and the base binde r is granular starch. In an another embodiment of the present invention, the nodulated wool is nodulated mineral wool and the overlay binder is cooked pearl cornstarch. A method of making the durable acoustical panel in accordance with the prese nt invention is disclosed. Initially, an aqueous slurry comprising a fibrous filler, a base binder, and water is formed. The aqueous slurry is deposited onto a moving foraminou s support wire to form an aqueous felt, thereby creating a continuous process. Thereafter, the aqueous felt is de-watered to form a wet felt. The wet felt is coated with an aqueous overla y comprising nodulated wool, overlay binder, and water and has a substantially smooth surface. Finally, the wet felt and aqueous overlay are dried to form the ceiling panel.