Acoustical panel
AssigneeNational Gypsum Company
InventorsRobert J. Menchetti, Andrew E. Heuer
Life of this patent
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Abstract
An acoustical panel, for ceilings or for area separation, and the method of making such panels, wherein the panel consists essentially of a unitary frame consisting of four sides, each with an inwardly opening channel, an outwardly opening rebend and a downwardly extending flange, the panel further including a rigid gypsum board with edges filling the frame channel, a low density sound absorbing mat within the confines of the downwardly extending flanges, and a porous fabric facing concealing the acoustical mat and affixed to the frame by disposing the fabric edges in the outwardly opening rebends and crimping the rebends tightly closed.
Claims16
An acoustical panel comprising a thin unitary, four-sided frame, a rigid board, at least one low density sound absorbing mat and at least one porous fabric facing, said frame having in each of four sides an inwardly directed channel, said rigid board having four side edges, said four side edges being disposed within and substantially completely filling said frame channel, said frame having, in each side, at least one outwardly opening rebend adjacent said channel and a flange adjacent said rebend extending away from said channel, said flanges of said frame four sides forming a space therewithin wherein said low density mat is disposed, said fabric facing having four edges, said facing four edges being disposed and tightly held within said rebends of said frame four sides, said facing extending over said flanges and over said low density mat, retaining said low density mat within the confines of said four flanges.
The method of making an acoustical panel comprising the steps of forming an elongate frame element with a sidewardly directed channel, an oppositely directed, sidewardly directed rebend immediately below said channel and a downwardly directed flange immediately below said rebend, severing said channel at at least three spaced positions along said elongate element and indenting a fold line across said flange below said severance of said channel, forming a 90.degree. fold at said fold lines to form a four-sided frame, with said channel opening inwardly of said frame, disposing the four edges of a rigid four-sided board in said channel with said board edges substantially completely filling said channel, disposing a low density acoustical mat within the confines of said flanges of said frame four sides, and affixing a porous fabric facing under said acoustical mat and upward over the outer sides of said flanges and into said frame rebends, by crimping said rebends with the edges of said fabric disposed therewithin.
Dependencies are inferred from the claim text.