# US 4,397,894 A · Vinyl faced wallboard

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- Number: US 4,397,894 A
- Document ID: US4397894A
- Status: Granted
- Kind: A
- Application number: 06/360,786
- Filed: 1982-03-22
- Granted: 1983-08-09
- Earliest claimed: 1982-03-22
- Assignees: Armstrong World Industries, Inc.
- Inventors: Charles Haines, Jr.; Raymond C. Kent
- Web page: https://patentgrep.com/patent/US4397894A

## CPC

- B32B 3/26: characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids {(foam layer B32B5/18; layer of synthetic resin characterised by fillers that create voids or cavities B32B27/205); characterised by an apertured layer}
- B32B 7/12: using interposed adhesives or interposed materials with bonding properties
- B32B 27/12: next to a fibrous or filamentary layer
- E04C 2/246: {combinations of materials fully covered by E04C2/16 and E04C2/20}
- E04F 13/0867: {having acoustic absorption means on the visible surface}
- B32B 2607/00: Walls, panels
- Y10T 428/24331: including nonapertured component
- Y10T 428/24992: Density or compression of components
- Y10T 428/31895: Paper or wood
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- E04C: STRUCTURAL ELEMENTS; BUILDING MATERIALS (for bridges E01D; specially designed for insulation or other protection E04B; elements used as building aids E04G; for mining E21; for tunnels E21D; structural elements with broader range of application than for building engineering F16, particularly F16S)
- E04F: FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS (windows, doors E06B)
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

The invention is directed to a wallboard structure which is first composed of a base sheet having a dense upper surface region. Over the dense surface region there is placed a vinyl sheet. Perforations are placed through the vinyl sheet and through the dense surface region and partly into the base region so there is formed an acoustical vinyl faced wallboard.

## Claims

### Claim 1

A wallboard comprising:
(a) a base sheet composed of two regions, the upper region being of a greater density than the lower region
(b) a vinyl sheet positioned over the surface of the denser region and fastened thereto, and
(c) small perforations extending through the vinyl sheet, the denser upper region of the base sheet and partly into the less dense lower region of the base sheet.

### Claim 2 (depends on 1)

The wallboard panel of claim 1 wherein the base sheet is a mineral fiber board and has a density of about 2.40 pounds per board foot for the upper region and a density of 2.00 pounds per board foot for the lower region.

### Claim 3 (depends on 2)

The wallboard panel of claim 2 wherein the denser upper region is 33% of the overall thickness of the board.

### Claim 4 (depends on 1)

The wall panel of claim 1 wherein the perforations are approximately 0.075 mils in diameter.

### Claim 5 (depends on 1)

A wall panel set forth in claim 1 wherein the vinyl sheet is 20 mils thick.

### Claim 6 (depends on 1)

A wall panel set forth in claim 1 wherein the perforations which extend through the vinyl sheet, the denser upper layer and the less denser lower region are all of the same diameter and are in register one above the other.