U.S. patent number 3,920,872 [Application Number 05/528,003] was granted by the patent office on 1975-11-18 for carpet-faced wallboard.
This patent grant is currently assigned to Armstrong Cork Company. Invention is credited to James C. Ollinger.
United States Patent |
3,920,872 |
Ollinger |
November 18, 1975 |
Carpet-faced wallboard
Abstract
A carpet material is applied to a fiberboard which has been
provided with acoustical openings. The carpet is adhesively bonded
to the fiberboard in such a manner as to prevent the obstruction of
the entrances of the acoustical openings in the fiberboard. The
carpet-covered fiberboard is utilized as a wallboard.
Inventors: |
Ollinger; James C. (Lancaster,
PA) |
Assignee: |
Armstrong Cork Company
(Lancaster, PA)
|
Family
ID: |
26974621 |
Appl.
No.: |
05/528,003 |
Filed: |
November 29, 1974 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
|
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305471 |
Nov 10, 1972 |
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Current U.S.
Class: |
428/95; D25/138;
181/284; 428/138; 428/198; 181/207; 428/96; 428/196; 428/201 |
Current CPC
Class: |
B32B
3/02 (20130101); E04F 13/16 (20130101); E04B
1/86 (20130101); B32B 3/30 (20130101); B32B
7/14 (20130101); B32B 21/02 (20130101); B32B
19/06 (20130101); B32B 21/10 (20130101); Y10T
428/23986 (20150401); E04B 2002/7485 (20130101); E04B
2001/848 (20130101); Y10T 428/2481 (20150115); E04B
2001/8476 (20130101); B32B 2307/102 (20130101); Y10T
428/23979 (20150401); E04B 2001/8461 (20130101); Y10T
428/24851 (20150115); B32B 2315/14 (20130101); Y10T
428/24331 (20150115); Y10T 428/24826 (20150115) |
Current International
Class: |
E04B
1/86 (20060101); E04B 1/84 (20060101); E04F
13/16 (20060101); E04B 2/74 (20060101); D04H
011/00 (); D05C 017/00 () |
Field of
Search: |
;428/85,94,95,96,196,198,200,201,304,317,137,138 ;181/33G,336A |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: McCamish; Marion E.
Parent Case Text
CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation of application Ser. No. 305,471,
filed Nov. 10, 1972 by James C. Ollinger and entitled "Carpet-Faced
Wallboard" and now abandoned.
Claims
What is claimed is:
1. A wallboard structure which is composed of a rigid fiberboard
base having on one surface thereof a plurality of perforations
therein, an adhesive coating applied at a very low application rate
to the surface of the fiberboard in such a manner as to not close
over any of the perforation openings in the fiberboard, and a
carpet material which is approximately 1/8 inch thick and which is
composed of a plurality of needle-bonded fibers, the back surface
of the carpet material, which is placed adjacent the
adhesive-coated surface of the fiberboard, being an irregular
surface and having a discontinuous coating of latex adhesive
applied thereto in the form of dots of adhesive, said latex-coated
surface of the carpet material being placed adjacent the adhesive
coating of the fiberboard structure whereby the latex coating on
the carpet and the adhesive coating on the fiberboard bond the
carpet material to the fiberboard, the perforations of the
fiberboard in the fiberboard-carpet material combination not having
their openings bridged by either the adhesive coating of the
fiberboard or the latex coating of the carpet so as to close off
these openings which provide the carpet-covered fiberboard
structure with good acoustical properties.
2. The structure of claim 1 wherein the composite structure is
composed of a fiberboard base, a carpet material and therebetween
an adhesive bond which is in two parts, the one part of the
adhesive bond being dots of latex adhesive adhering to the
irregular back of the carpet surface and the second part of the
adhesive bond, and the second part of the adhesive bond being a
film of adhesive fastening the rigid fiberboard to the dots of
latex adhesive.
3. A wallboard structure as set forth in claim 2 wherein the
perforations in one surface of the rigid fiberboard extend from one
surface into the board structure, but not through the board
structure.
4. The wallboard structure of claim 3 wherein the carpet material
is wrapped partly around the end of the rigid fiberboard.
Description
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention herein is directed to a carpet-faced fiberboard and,
more particularly, to an acoustical wallboard which is covered with
a carpet facing.
2. Description of the Prior Art
Installation of carpet material to walls or ceilings requires
complicated techniques by specialized craftsmen. It would be
desirable to make carpeting available as a wallboard material of
the same dimension as presently marketed gypsum wallboard so that
it could be substituted directly for gypsum wallboard in wall and
ceiling systems. Application to solid walls or studs could be by
means of an adhesive system.
It is not unusual in many countries to use carpeting as a covering
for walls. The carpeting would either be hung on the wall or
permanently affixed to the wall.
U.S. Pat. Nos. 2,369,658 and 2,839,442 disclose panel structures
wherein a carpet-like structure is placed upon a panel
structure.
The invention herein is directed to the use of a carpet on a
perforated acoustical fiberboard which will provide a wallboard
structure of improved sound absorption characteristics. The carpet
is carefully mounted on the perforated fiberboard so as not to
obstruct the perforation openings in the fiberboard to maintain the
sound absorbing ability of the fiberboard structure.
SUMMARY OF THE INVENTION
A conventional fiberboard structure is utilized as the base for the
wallboard invention herein. This fiberboard structure may be any of
the conventional mineral wool or wood fiber panel structures which
are currently available on the open market. The base structure is
provided with a perforated surface wherein the perforations in the
surface provide acoustical pockets to increase the sound absorption
ability of the base structure surface. An adhesive coating is
placed upon the perforated surface in such a manner as not to close
over the perforation openings on the base surface. A carpet
material is provided with a latex tie coat on the back surface
thereof. The latex tie coat is placed on the carpet surface to
provide a discontinuous film on the back of the carpet surface. The
carpet material is applied to the perforated surface of the base
material, and the adhesive on the base material and the tie coat on
the carpet backing bond the base material and carpet facing
together to form the carpet-faced fiberboard which is now capable
of being used as a wallboard.
There is provided a wallboard structure with improved sound
absorption features over conventional gypsum or wood wallboards.
The board structure is provided with a very pleasing decorative
effect and is quite capable of being mounted directly to a wall
structure or being used as a free-standing dividing wall.
BRIEF DESCRIPTION OF THE DRAWING
FIG. I is a perspective view of the wallboard invention herein;
and
FIG. II is a cross-sectional view of a portion of the wallboard
structure of FIG. I.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The invention herein is directed to a wallboard structure 2 which
is composed of a base structure or board 4, which is a fiberboard
structure, and a carpet facing 6 placed on the surface of the board
4.
The fiberboard or base board material can be any conventional
fiberboard structure made of either mineral wool or wood fiber
material. The fibers of the board are bound together by appropriate
binder material. Typical of the boards which could be used are the
boards which are sold under the Armstrong trademarks "Minaboard" or
"Trilon." These are fiberboard structures of approximately 1/2 inch
in thickness and are of relatively dense fiberboard material with a
substantial degree of rigidity. Almost any base material could be
used including plywood. The base material 4 is provided with a
plurality of acoustical perforations 8. These perforations extend
from one surface 10 of the board structure into the board
structure. The perforations act as sound pockets for absorbing
sound which is directed against the surface 10 of the board. The
board shown with its perforations is exactly the same as the
conventional acoustical ceiling boards which are installed in many
building structures, particularly in suspended ceilings.
The carpet material is a nylon or like-type carpet material which
is composed of a plurality of fibers which have been needled
together by the conventional needle-bonded technique which is used
for forming the so-called indoor-outdoor carpeting which was
initially made famous by the Ozite Corporation. The carpet material
is approximately 1/8-inch thick and is very similar in nature to a
heavy felted material.
The surface 10 of the base material board is roll coated with an
adhesive which is placed on the surface 10 at a very low
application rate so that the adhesive 12 does not bridge the
openings of the perforations 8. Consequently, after the application
of the adhesive 12 to the surface 10 of the base material 4, the
perforations will still all be exposed to view and will be
unobstructed by an adhesive. The back of the carpet material is
sprayed with a conventional latex tie coat which is normally
applied to carpet materials to bond the needle-bonded carpet
material to an appropriate backing material. The tie coat is
sprayed on the carpet to provide a very light application of the
tie coat to the carpet as a discontinuous coating to the back of
the carpet; that is, continuous film of tie coat material is not
applied to the back of the carpet. The carpet is actually sprayed
with dots of adhesive to provide a discontinuous coating 14 on the
back of the carpet 6.
A continuous length of carpet having a tie coat applied on the back
thereof is applied to sheets of fiberboard 4 which are fed under
the carpet material. The back of the carpet material containing the
tie coat 14 is pressed against the adhesive-coated surface 10 of
the fiberboard 4 to bond the carpet to the fiberboard 4. Normally
the carpet is wrapped partly around the edge of the fiberboard to
give a neat edge to the finished product. The carpet is cut off
from the continuous length of carpet at the end of each fiberboard
to provide panel structures which are normally 4 feet by 8 feet in
size. Due to the discontinuous nature of the tie coat 14 and the
adhesive coat 12, the perforations 8 are open to the back of the
carpet fabric 6. Consequently, sound waves impinging against the
surface of the carpet will be transmitted through the carpet to the
perforations in the base board. This will result in not only
absorption of sound within the carpet structure, but also
absorption of sound by the perforations within the base structure
4.
Consequently, there is provided a decorative board structure having
very good absorption and low sound transmission. The structure is
quite capable of being mounted directly upon a wall structure, or
it could be used as a free-standing wall divider.
The adhesive coating which is applied to the carpet back is a
conventional latex tie coat such as is used in the carpet industry.
A conventional tie coat material is as follows:
Parts by weight Carboxylated Styrene Butadiene Rubber latex 500
Tetrasodium Pyrophosphate dispersant 2 Paragum 104 thickener,
sodium polyacrylate 10 Aluminum Trihydrate fire retardant 500 Water
500
This material is mixed to a viscosity of approximately 150 to 200
cps and is spray coated on the carpet back at a coverage rate of
about 3 to 5 ounces per square yard.
The adhesive coating for the fiberboard is a conventional neoprene
latex sold by Armstrong Cork Company under the trade name "LD 780."
Any conventional latex adhesive could be utilized, but the above
particular latex has been found to be particularly useful. Its
formulation is as follows:
Parts by Weight Solvent-toluol 148 Resin-Hercules Polypule
10--glycerol ester of polymerized rosin 220 Resin-Diamond alkali
Chloroway 70--Chlorinated paraffin 220 Neoprene-Du
Pont-polychloroprene (58% solids) 763 Anti-oxidant-Du Pont Neozone
D-N-phenyl-beta- naphthylamine 13 Water 340
This is applied to the board structure by either roll coating or
spraying at a coverage rate of about 10 grams per square foot.
As is obvious from FIG. I and FIG. II of the drawing, the base
material 4 has a flat surface 10 on which the adhesive 12 is
applied as a film. However, the carpet 6, as clearly shown in FIG.
II, does not have a flat back, but has an irregular or rough back
surface.
* * * * *