Acoustically porous building materials
AssigneeArmstrong World Industries, Inc.
InventorsJohn S. Forry, Karl B. Himmelberger
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Abstract
The present invention relates to acoustically porous building materials which are produced by disposing an aggregate material on the surface of a dry-formed web comprising a fibrous material and an organic binder, and consolidating the composite material such that the aggregate material is embedded in the web. The resulting product is acoustically porous but, in one preferred embodiment, the embedding process provides a substantially planar surface which is relatively non-friable.
Claims46
A process for preparing an acoustically porous composite, said process comprising the steps of:
- providing a dry-formed web comprising substantially fibrous material and organic binder;
- interfacing a layer of aggregate material with said web such that the majority of said particles are in contact with said web, the compressibility of said aggregate material relative to the compressibility of said web being such that said aggregate can be embedded in said web;
- and
- consolidating and curing the layered composite, whereby substantially all of said aggregate material is at least partially embedded in said web, the surface of the cured structure possesses the contour of the consolidation means, and the cured structure is acoustically porous.
A process for preparing an acoustically porous composite, said process comprising the steps of:
- providing a dry-formed web comprising substantially fibrous material and organic binder;
- interfacing a layer of a surfacing mixture comprising an aggregate material and an organic binder with said web, the compressibility of said web being such that said aggregate can be embedded therein;
- and
- consolidating and curing the layered composite, whereby said aggregate material adjacent said web is at least partially embedded therein, the surface of the cured structure possesses the contour of the consolidation means, and the cured structure is acoustically porous.
An acoustically porous composite comprising an aggregate surfacing material on a dry-formed web comprising substantially fibrous material and organic binder, said web having the majority of said aggregate material at least partially embedded therein, the surface of said composite possessing the contour of the means used to effect consolidation.
A consolidated acoustically porous composite comprising a surfacing material comprising a mixture of aggregate material and an organic binder on a dry-formed web comprising a substantially fibrous material and organic binder, said web having the aggregate material adjacent thereto at least partially embedded therein, the surface of said composite possessing the contour of the means used to effect consolidation.
Dependencies are inferred from the claim text.