U.S. patent number 3,583,522 [Application Number 04/041,732] was granted by the patent office on 1971-06-08 for decorative acoustical panel construction.
This patent grant is currently assigned to Johns-Manville Corporation. Invention is credited to George J. Hannes, Theodore Richard Rohweder.
United States Patent |
3,583,522 |
Rohweder , et al. |
June 8, 1971 |
DECORATIVE ACOUSTICAL PANEL CONSTRUCTION
Abstract
A porous acoustical-type panel having improved appearance and
decorative value comprising a laminated structure of a combination
of a substantially rigid fibrous body bonded with a translucent
resin and adhered thereto a facing mat impregnated with a
translucent resin and coloring pigment.
Inventors: |
Rohweder; Theodore Richard
(Toledo, OH), Hannes; George J. (Maumee, OH) |
Assignee: |
Johns-Manville Corporation (New
York, NY)
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Family
ID: |
21918035 |
Appl.
No.: |
04/041,732 |
Filed: |
June 1, 1970 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
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779748 |
Nov 29, 1968 |
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Current U.S.
Class: |
181/290; D25/159;
428/113; 442/326 |
Current CPC
Class: |
E04C
2/16 (20130101); E04B 1/8409 (20130101); E04C
2/32 (20130101); Y10T 428/24124 (20150115); E04B
2001/8442 (20130101); Y10T 442/59 (20150401) |
Current International
Class: |
E04B
1/84 (20060101); E04C 2/16 (20060101); E04C
2/32 (20060101); E04C 2/10 (20060101); E04b
001/84 (); B32b 005/12 (); B32b 005/22 () |
Field of
Search: |
;181/33,33.1,33.11
;161/59,155,157 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
Primary Examiner: Ward, Jr.; Robert S.
Parent Case Text
This application is a continuation of copending application Ser.
No. 779,748, which was filed Nov. 29, 1968 and which is now
abandoned.
Claims
We claim:
1. A decorative, porous vaulted panel having sound dampening
acoustical properties consisting essentially of a composite
laminated structure of deep concave configuration composed of a
substantially rigid self-supporting body of generally random felted
mineral fiber bonded with at least one thermosetting translucent
resin selected from the group consisting of melamine formaldehyde,
ureaformaldehyde and polyester, and having a facing mat
superimposed conterminously with one major surface of the said
substantially rigid self-supporting body of felted fiber and
adhered thereto, said facing mat being composed of mineral
filaments lying generally transverse to each other and impregnated
with at least one thermosetting translucent resin selected from the
group consisting of melamine formaldehyde, ureaformaldehyde and
polyester.
2. The porous acoustical vaulted panel product of claim 1, wherein
the facing mat superimposed conterminously with and adhered to the
said rigid body of felted mineral fibers is impregnated with a
combination of translucent resin and pigment in a ratio of about 30
to 100 percent by weight of resin to about 0 to 70 percent by
weight of pigment.
3. The porous acoustical vaulted panel product of claim 2, wherein
the said impregnating composition of the facing mat comprises
approximately 30 to 50 percent by weight of resin and approximately
0 to 70 percent by weight of pigments.
4. The porous acoustical vaulted panel product of claim 2, wherein
the pigment comprises at least one white pigment selected from the
group consisting of titanium dioxide, zinc oxide, white lead, and
clay.
5. The porous acoustical vaulted panel product of claim 4, wherein
the thermosetting resin bond for the substantially rigid body of
generally random felted mineral fiber is melamine formaldehyde
resin.
6. The porous acoustical vaulted panel product of claim 5, wherein
the thermosetting resin of the impregnate for the facing mat of
mineral filaments lying generally transverse to each other is
melamine formaldehyde resin.
7. The porous acoustical vaulted panel product of claim 6, wherein
the white pigment is titanium dioxide.
8. The porous acoustical vaulted panel product of claim 7, wherein
the impregnating combination for the facing mat comprises
approximately 40 percent by weight of the resin and approximately
60 percent by weight of the white pigment.
9. The porous acoustical vaulted panel product of claim 8, having a
porous coating of paint on the exposed surface of the facing
mat.
10. The porous acoustical vaulted panel product of claim 9, wherein
the facing mat of mineral filaments lying generally transverse to
each other in a nonwoven fabric.
11. The porous acoustical vaulted panel product of claim 10,
wherein the nonwoven fabric facing mat of mineral filaments lying
generally transverse to each other is an open scrim having a weight
of approximately 2 to 3 grams per square foot.
12. The porous acoustical vaulted panel product of claim 1, wherein
the substantially rigid body of generally random felted mineral
fiber bonded with thermosetting resin is composed of a plurality of
sections with at least the section adjacent to the facing mat being
bonded with a thermosetting translucent resin.
Description
BACKGROUND OF THE INVENTION
Acoustical products such as ceiling or wall tiles and panels etc.,
must, for effective sound dampening--their prime function--be of a
highly porous or open structure and in particular in their exposed
functional surface. This essential open or discontinuous surface
and porous structure of acoustical materials presents a significant
obstacle in enhancing appearance or producing decorative effects,
as for example the application of paint films, in products such as
typical acoustical ceiling tiles. For instance, paint in sufficient
amount to effectively hide the underlying surface and thus decorate
the product significantly reduces the openings of the surface
thereby blocking off the internal porous structure from its
effective sound-reducing function. In addition to the old means of
coloring the entire or a substantial portion of the material
throughout its composition, a technique which although normally
very effective in decorative aspects is unduly expensive, because
of the usually high cost of pigments and amounts required, numerous
other schemes have been proposed to improve the appearance of
open-faced and porous acoustical products including for example
surfacing with perforated metal or plastic sheets or of other
materials, covering with plastic films either imperforate or
perforated, etc. However, these means inevitably diminish the sound
dampening qualities of the product and frequently detract from
appearance and are often costly to manufacture or in materials.
SUMMARY OF THE INVENTION
This invention comprises a unique laminated structure and
composition amenable to the manufacture of conventional-type
fibrous acoustical panels, such as common resin-bonded glass and/or
other mineral fiber acoustical ceiling tile, etc., which by itself
provides a decorative facing surface, or one which may be
effectively decorated as by the application of paint in such
amounts as to retain the porous and open surface essential to sound
abatement while providing an appealing, highly uniform
appearance.
The laminated structure and composition of the invention
essentially includes a facing mat of open construction impregnated
with a translucent resin binder and coloring pigment which is
applied over the major and functional surface of the substantially
rigid body of mineral fibers which may be of conventional structure
and composition except for including a translucent thermosetting
resin as the binder.
It is the primary object and advantage of this invention to provide
an acoustical product having integral therewith a highly porous and
open surface of good appearance itself and of effective sound
dampening properties, which surface additionally is amenable to
painting if desired to enhance or revitalize the decorative effect
without effectively diminishing the porosity and acoustical values
attributable thereto, and also enables the easy application of
paint to contribute to or modify the decorative appearance of
acoustical tiles and panels which is especially applicable to
deeply concave domed or vaulted three-dimensional-type panels with
steeply sloping sides.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a perspective view of a typical high-vaulted
three-dimensional-type acoustical tile product with a cutout
section illustrating the construction of this invention; and,
FIG. 2 is an exaggerated sectional view of the construction of the
product illustrated in FIG. 1 taken along lines 2-2.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The decorative and porous sound dampening acoustical panel products
of this invention essentially comprise a two-component laminated
structure of a substantially rigid or self-supporting body of
generally random felted mineral fibers bonded with a translucent
resin, and having adhered to the major functional surface thereof
which is to be decorated, a facing mat of mineral filaments lying
generally transverse to each other and impregnated with a
combination of translucent resin and particulate pigments of the
color desired. This combination of the translucent resin bonded
rigid mineral fiber body and facing thereon of open mat containing
translucent resin binder and pigment produces a composite structure
which is both highly porous and open in the exposed functional
surfaces and continuing at least partly through the body thereof,
and yet presents a pleasing color decorated surface finish, thereby
rendering it well suitable for the manufacture of acoustical tiles
and panels for ceiling, walls, partitions, and the like covering
finishes. Moreover, when desired or fitting to paint the surface of
the product, either initially in conjunction with manufacture, or
subsequently to restore or change appearance, the exposed
functional surface is more amenable to painting in that a
decorative and effective hiding application with paint can be
achieved with minimal amounts without closing or blocking the open
and porous surface, thus maintaining acoustical values.
The substantially rigid or self-supporting body portion in the
laminated structure of this invention comprises common mineral
fibers, in particular including fibers composed basically of
siliceous or silicate compositions such as typical glass fibers, or
the wools or fibers derived from rock or other siliceous and
argillaceous material, or metallurgical slags which are well known
in the industry and have long heretofore been employed in
acoustical panel or tile products. Fibers can be produced and
collected in accordance with the common manufacturing procedures
for glass fibers and related mineral compositions, for example, as
illustrated in U.S. Pat. Nos. 2,663,906, 2,814,657, and 2,863,176,
each to Labino, wherein the formed fine diameter fibers (about 1 to
5 microns) are collected from their dispersed state within a
gas-suspending medium in a generally random or haphazardly arranged
felted mass, including appropriate resin binder which is normally
and preferably applied to the fiber while suspended substantially
individually in the gas medium prior to their collection. The
thermosetting resin binder for the purpose of this invention should
consist of one which is translucent upon curing, such as melamine
formaldehyde, ureaformaldehyde, polyester, and the like colorless
or translucent synthetic materials.
However, to reduce cost, the generally rigid or self-supporting
body component may be formed of two or more sections with only that
section of the total body providing the outer functional surface to
be faced with the mat, being necessarily bonded with the
translucent resin whereby the back section or sections can employ
substantially any thermosetting resin as a binder regardless of its
color.
The facing mat consists of a scrim-type fabric either woven or
nonwoven intercrossed strands of a highly open construction, and
particularly mats of mineral filaments lying transverse to each
other comprising the multilayered intercrossed filament product
formed according to the processes and/or means of U.S. Pat. No.
2,574,221, 2,609,320, 2,729,582, 2,913,037, and 2,964,439, each to
Modigliani, and Nos. 2,996,102, and 3,220,811 to Schuller.
Continuous glass or other mineral filaments constitute the optimum
material, but twisted textile strands of staple mineral fibers
generally may serve.
The facing mat is impregnated with a combination comprising an
admixture of translucent thermosetting resin and pigment, with the
resin, as in the case of at least the adjoining section of the
rigid or self-supporting felted fiber body, being of a translucent
material such as melamine formaldehyde, ureaformaldehyde, or
polyester resin. Panels for ceiling tile being generally white or
off white, the pigment should be white comprising for example,
titanium dioxide, zinc oxide, white lead, or a white clay and
preferably titanium dioxide because of its substantially greater
hiding capacity and absence of toxicity. Nevertheless, a colored
pigment can be utilized to achieve a particular color but such use
is restrictive insofar as the advantageous color versatility of the
product. Moreover, a flat white background such as provided with
these pigments presents an optimum surface for the application of
very light pastel paints of any color as well as white paint,
comprising the most appropriate color schemes for ceilings and
permits the application of such light-toned paint in rather thin
and substantially discontinuous coatings which do not obstruct the
porous structure of the facing mat but aptly transmit the color
effect. Apt proportions of resin to pigment comprise approximately
30 to 100 percent by weight of resin to approximately 0 to 70
percent by weight of pigment, and preferably of ratios of about 30
to 50 percent by weight of resin to about 50 to 70 percent by
weight of pigment, but, of course, depending upon the density of
given pigments, the ratios can be varied. The inclusion of pigment
is not entirely essential, particularly when the product is to be
painted.
Referring to the drawings, numeral 10 designates a ceiling
acoustical tile product of the common three-dimensional and
high-domed or vaulted construction comprising a generally rigid
body section 11 composed of a mat of felted glass fibers bonded
with melamine formaldehyde resin which is translucent upon curing.
Facing mat 12 is superimposed over the functional or front major
surface of fiber body 11 of tile 10 and adhered thereto during
manufacturing by means of the melamine resin binder content of the
body section 11 and of the facing mat itself. Mat 12 contains a
mixture of translucent melamine formaldehyde resin and titanium
dioxide white pigment which provides a flat white and porous
surface having good acoustical properties and which provides a
pleasing uniform white appearance itself without the application of
paint. The construction of the invention is thus especially
advantageous in the manufacture of high domed or vaulted
three-dimensional panels having steeply sloped side portions such
as in the product illustrated because due to the deep concave
configuration and the steeply sloped sides of the product it is
especially advantageous in the manufacture of high domed or vaulted
three-dimensional panels having steeply sloped side portions such
as in the product illustrated because due to the deep concave
configuration and the steeply sloped sides of the product it is
especially difficult to apply paint uniformly over the article with
usual factory equipment and methods and achieve a consistent
overall color tone.
A typical product of this invention for use as an acoustical
ceiling tile can be produced by means of the following exemplary
procedure. A loose felt or mass of glass fiber of a thickness of
about 1 inch and a density of about 1.5 pounds per cubic foot of a
type commonly used in thermal insulations and related products,
containing substantially uniformly distributed throughout about 15
percent by weight thereof of "B" stage melamine formaldehyde resin,
is placed in a press mold with dyes of appropriate configuration
design. Superimposed thereon is a facing mat of continuous glass
filaments consisting of a plurality of layers oriented to lie
generally transverse to each other as provided by the procedure of
the aforesaid patents to Modigliani or Schuller, weighing
approximately 2.5 grams per square foot and containing therethrough
about 2.0 grams per square foot of a mixture 60 percent by weight
titanium dioxide and 40 percent by weight of melamine formaldehyde
resin in the "B" stage. The mold is closed upon the composite body
of random fibers and facing mat of intercrossed filaments and the
said contents compressed and subject to a temperature of about
420.degree. F. for 40 seconds, whereupon the melamine formaldehyde
resin content of the fibrous body and the facing mat is
substantially cured, bonding the fibers of the loose felt to a
rigid body of about 11.0 pcf, and securing the titanium dioxide
pigment within and about the facing mat while at the same time
adhering the facing mat to the rigid body forming a composite
laminate of sufficient structural integrity to be substantially
self-supporting.
The resulting formed and cured panel product exhibited a uniformly
white surface for exposure having a flat or mat surface of good
appearance. The product is decorative and useful without painting
or other surface treatment. However, upon the spray application of
white or light pastel color paint by means of a usual factory
reciprocating spray gun, coverage is entirely adequate including
the steep side slopes of deeply concave or vaulted
three-dimensional tile. The openness of the facing mat causes the
paint film to open up into many small pores producing a
discontinuous coating effectively preserving the good acoustical
properties attributable to the original unpainted product and yet
exhibiting a good appearance of uniform coloring.
* * * * *