Foam coated ceiling board facing and method of making the same

A process for manufacturing a cellular foam coated, sculptured, nubby fabric useful as a ceiling board facing and the like, consisting of:

• forming on at least one face of a nubby textured fabric a uniform layer of foamed cellular latex containing vinyl chloride polymer, a cell producing surfactant, a white powdered pigment, and a flame retardant,
• passing said nubby textured fabric coated with a uniform layer of cellular foamed latex between gapped means for removing foam and sculpturing said uniform layer of cellular foamed latex, the gap of said gapped means being adjusted to leave sufficient foam on the fabric to provide extra depth and nubbiness to said fabric face without hiding completely the original fabric pattern and without crushing said cellular foam, and
• drying and curing said cellular foam coated, sculptured, nubby fabric.

A cellular foam coated, sculptured, nubby fabric useful as a ceiling board facing manufactured by the process of:

• forming on at least one face of a nubby textured fabric a uniform layer of cellular foamed latex containing vinyl chloride polymer, a cell producing surfactant, a white powdered pigment, and a flame retardant,
• passing said nubby textured fabric coated with a uniform layer of cellular foamed latex between gapped means for removing foam and sculpturing said uniform layer of cellular foamed latex, the gap of said gapped means being adjusted to leave sufficient foam on the fabric to provide extra depth and nubbiness to said fabric face without hiding completely the original fabric pattern and without crushing said cellular foam, and
• drying and curing said cellular foam coated, sculptured nubby fabric.

A cellular foam coated, sculptured, nubby fabric useful as a ceiling board facing manufactured by the process of:

• forming on at least one face of a nubby textured fabric a uniform layer of a cellular foamed latex containing vinyl chloride polymer, a cell producing surfactant, a white powdered pigment, and a flame retardant, passing said nubby textured fabric coated with a uniform layer of cellular foamed latex between gapped pad rolls, gapped between about 10 mils and about 100 mils, removing foam and sculpturing said uniform layer of cellular foamed latex to provide extra depth and nubbiness to said fabric face without hiding completely the original fabric pattern of said fabric face without crushing said cellular foam, and
• drying and curing said cellular foam coated, sculptured, nubby fabric.