Durable acoustical panel and method of making the same

Details Durable acoustical panel and method of making the same Durable acoustical panel and method of making the same

E - Fixed Constructions

04

B

E04B 1/86 (2006.01) B44C 5/04 (2006.01) C04B 26/02 (2006.01) D21F 9/00 (2006.01) D21H 27/38 (2006.01) D21J 1/08 (2006.01) D21J 1/16 (2006.01) E04B 9/00 (2006.01) E04B 9/04 (2006.01) E04C 2/16 (2006.01)

Patent

CA 2348326

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.

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