Armstrong World Industries, Inc.

Awi Licensing Company

Barry Buhay

Walter W Chamberlain

John Felegi, Jr

Donald F Claussen

Robert G Ganse

James R Lokey

Robert E Foster

John J Janczura

Larry R Parks

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.

Durable acoustical panel and method of making the same

The invention is a ceiling board with a factory cut aperture therein. The edges of the ceiling board and/or the edges of a design cut in the face of the board are of the same or compatible design to that of the edge(s) of the aperture.

Ceiling board aperture

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Lancaster, PA, United States of America

Barry Buhay