US Patent:
20020096278, Jul 25, 2002
Inventors:
Robert Foster - Enon Valley PA, US
Larry Parks - Rochester PA, US
James Lokey - Beaver Falls PA, US
John Janczura - Beaver Falls PA, US
Robert Ganse - Lancaster PA, US
Barry Buhay - Lancaster PA, US
Walter Chamberlain - Lancaster PA, US
John Felegi - Lancaster PA, US
Assignee:
ARMSTRONG WORLD INDUSTRIES, INC.
International Classification:
D21H013/00
D21H013/40
D21H013/02
US Classification:
162/141000, 162/143000, 162/157100
Abstract:
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 binder 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 present 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 foraminous 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 overlay 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.
