GB2058664A - Fabric-covered wallboard - Google Patents

Fabric-covered wallboard Download PDF

Info

Publication number
GB2058664A
GB2058664A GB8030396A GB8030396A GB2058664A GB 2058664 A GB2058664 A GB 2058664A GB 8030396 A GB8030396 A GB 8030396A GB 8030396 A GB8030396 A GB 8030396A GB 2058664 A GB2058664 A GB 2058664A
Authority
GB
United Kingdom
Prior art keywords
fibreboard
adhesive
carpet material
carpet
board
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
GB8030396A
Other versions
GB2058664B (en
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Armstrong World Industries Inc
Original Assignee
Armstrong World Industries Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Armstrong World Industries Inc filed Critical Armstrong World Industries Inc
Publication of GB2058664A publication Critical patent/GB2058664A/en
Application granted granted Critical
Publication of GB2058664B publication Critical patent/GB2058664B/en
Expired legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B21/00—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board
    • B32B21/10—Next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form 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 ; characterised by an apertured layer
    • B32B3/266—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form 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 ; characterised by an apertured layer characterised by an apertured layer, the apertures going through the whole thickness of the layer, e.g. expanded metal, perforated layer, slit layer regular cells B32B3/12
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form 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 ; characterised by an apertured layer
    • B32B3/30—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form 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 ; characterised by an apertured layer characterised by a layer formed with recesses or projections, e.g. hollows, grooves, protuberances, ribs
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/06—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer characterised by a fibrous or filamentary layer mechanically connected, e.g. by needling to another layer, e.g. of fibres, of paper
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • B32B7/14—Interconnection of layers using interposed adhesives or interposed materials with bonding properties applied in spaced arrangements, e.g. in stripes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2317/00—Animal or vegetable based
    • B32B2317/16—Wood, e.g. woodboard, fibreboard, woodchips

Landscapes

  • Life Sciences & Earth Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Wood Science & Technology (AREA)
  • Floor Finish (AREA)
  • Building Environments (AREA)
  • Laminated Bodies (AREA)
  • Finishing Walls (AREA)
  • Soundproofing, Sound Blocking, And Sound Damping (AREA)

Abstract

A carpet material is applied to a fibreboard which has been provided with acoustical openings. The carpet is adhesively bonded to the fibreboard in such a manner as to prevent the obstruction of the entrances of the acoustical openings in the fibreboard by the adhesive bonding the carpet to the fibreboard. The surface of the fibreboard is provided with an embossed configuration, and the adhesive on the surface of the fibreboard coats only the raised areas of the embossed surface. <IMAGE>

Description

SPECIFICATION Fabric-covered wallboard The invention relates to a carpet-faced fibreboard and especially to an acoustical wallboard which is covered with a carpet facing.
The installation of carpet material on walls or ceilings requires the use of complicated techniques by specialized craftmen. It would be desirable to make carpeting available as a material for wallboards of the same dimensions as the gypsum wallboards marketed at present so that it could be substituted directly for gypsum wallboard in wall and ceiling systems. Application to ceiling walls or studs could be by means of an adhesive system.
It is not unusuai in many countries to use carpeting as a covering for walls. The carpeting may be either hung on the wall or permanently affixed to the wall.
United States Patent Specifications Nos.
2,369,658 and 2,839,442 disclose structures wherein a carpet-like structure is placed upon a panel structure.
British Patent Specification No. 1 453 445 discloses a carpet-faced wallboard.
The invention herein is directed to the use of an embossed surface on the fibreboard and the application of the adhesive on the fibreboard surface to only the raised areas of the fibreboard so that the adhesive coating applied to the fibreboard is a discontinuous coating.
The invention provides a structure which comprises a substantially rigid base having a plurality of perforations through one face thereof which face has areas that are raised and depressed relative to each other, an adhesive coating applied only to the raised areas of the said face of the base, and a carpet material placed with the back surface of the carpet material bonded to the base by bonding means comprising the said adhesive coating.
In accordance with the invention, a wallboard structure may be constructed which is composed of a rigid fibreboard base having on one surface thereof a plurality of perforations extending into, and stopping short within, the fibreboard. An adhesive coating is applied to parts of the surface of the fibreboard in such a manner that at least some of the perforations in the fibreboard are not closed over. The adhesive is applied to only parts of the fibreboard surface because the surface of the fibreboard has been provided with an embossed effect so that it has raised and depressed areas. The adhesive is applied only to the raised areas of the fibreboard surface, and thus provides a discontinuous coating on the surface of the fibreboard. The perforations may be concentrated in the depressed areas so as to reduce the proportion of the perforations that are closed by the adhesive coating.A carpet material which is approximately 1/8 of an inch (3 mm) thick and which is composed of a plurality of needle bonded fibres has adhesive adjacent to the back surface thereof.
The adhesive coated surface of the carpet material is placed in contact with the adhesive covered surface of the fibreboard structure so that the adhesive coatings on the carpet and fibreboard bond the carpet material to the fibreboard, and the perforations of the fibreboard have not been bridged by the adhesive coating of the fibreboard so as to close off the openings in the fibreboard which provide the carpet-covered fibreboard structure with good acoustical properties.
One form of wallboard constructed in accordance with the invention will now be described by way of example with reference to the accompanying drawing, the single figure of which is a cross-sectional view of the wallboard structure.
Referring to the accompanying drawing, a wallboard structure 2 is composed of a base structure or board 4, which is a fibreboard structure, and a carpet facing 6 having an irregular back surface placed on the surface of the board 4.
The board 4 and the facing 6 are held together by an adhesive coating 8 which in part is applied to the face of the board 4 which receives the carpeting, and the carpeting is provided with an adhesive coating also on its surface which engages the board 4. The structure of the fibreboard 4, the carpet facing 6 and the composition of the two adhesive coatings are the same as that set forth in British Patent Specification No. 1 453 445, and that Specification is incorporated by reference into this application.
In accordance with the invention, the adhesive coated surface of the board 4 is provided with an embossed effect so that it contains both raised and depressed areas. This embossed effect can be produced by actually mechanically embossing the surface of the finished board to provide it with raised and depressed areas or by forming the board in either a wet-laid or dry-laid manner with a screen being placed against the surface of the board and this screen thus leaves the board with an embossed effect once the board has been formed on the screen. The board is provided with raised and depressed areas which are spaced apart with about 3/8 inch (9 mm) spacing between each adjacent raised and depressed area and the height of the raised areas above the depressed areas is approximately 1/1 6 inch (1.5 mm). The adhesive coating is applied to the fibreboard by roll coating.The adhesive is maintained at a high enough viscosity and applied at a light enough pressure, as is conventional in the art, that the adhesive is applied only to the raised areas of the embossed surface and to the depressed areas and does not fill in the depressed areas of the board. Since the adhesive coating is applied only to the raised areas of the board and exists only on these raised areas, and the raised areas are basically surrounded by depressed areas, there is formed a discontinuous coating of adhesive.
Since it is thus not necessary to apply a very thin coating of adhesive which will not bridge over the perforations in a flat board surface such as that described in British Patent Specification No.
1 453 445, increased amounts of adhesive can be provided on those areas of the board where the adhesive is applied. That is to say, the amount of adhesive that can be provided on a raised area of the board is greater than the amount of adhesive that could be provided on a comparable area of a flat board such as that described in British Patent Specification No. 1 453 445.
It has been found that, because the adhesive on the board has not totally sealed the board surface, and especially the perforations therein, the recessed areas of the board surface allow for a greater sound absorption rating for the board than may have existed with the board described in British Patent Specification No. 1 453 445.
Finally, it is found that the technique of the present invention is especially useful with fibreboards which are made by a dry-laid process over board structures which were previously made with a conventional wet-laid process for forming the boards.

Claims (10)

1. A structure which comprises a substantially rigid base having a plurality of perforations through one face thereof which face has areas that are raised and depressed relative to each other, an adhesive coating applied only to the raised areas of the said face of the base, and a carpet material placed with the back surface of the carpet material bonded to the base by bonding means comprising the said adhesive coating.
2. A structure as claimed in claim 1, wherein the adhesive coating is discontinuous.
3. A structure as claimed in claim 1 or claim 2, wherein the carpet material is composed of a plurality of needle-bonded fibres.
4. A structure as claimed in any one of claims 1 to 3, wherein the back surface of the carpet material is an irregular surface.
5. A structure as claimed in any one of claims 1 to 4, wherein the carpet material is bonded to the base by bonding means comprising an adhesive bond in two parts, one part being an adhesive adhering to the back surface of the carpet material and the other part being the said adhesive coating on the base.
6. A structure as claimed in claim 5, wherein the adhesive adhering to the carpet material is a latex adhesive.
7. A structure as claimed in claim 5 or claim 6, wherein the adhesive adhering to the carpet material is in discrete dots.
8. A structure as claimed in any one of claims 1 to 7, wherein the base is fibreboard.
9. A structure as claimed in claim 8, wherein the fibreboard is a dry laid fibreboard.
10. A structure as claimed in claim 1 and substantially as hereinbefore described with reference to, and as shown in, the accompanying drawings.
GB8030396A 1979-09-21 1980-09-19 Fabric-covered wallboard Expired GB2058664B (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
US7757379A 1979-09-21 1979-09-21

Publications (2)

Publication Number Publication Date
GB2058664A true GB2058664A (en) 1981-04-15
GB2058664B GB2058664B (en) 1983-05-05

Family

ID=22138866

Family Applications (1)

Application Number Title Priority Date Filing Date
GB8030396A Expired GB2058664B (en) 1979-09-21 1980-09-19 Fabric-covered wallboard

Country Status (8)

Country Link
JP (1) JPS5655654A (en)
BE (1) BE885316A (en)
DE (1) DE3029938C2 (en)
FR (1) FR2465590A1 (en)
GB (1) GB2058664B (en)
IT (2) IT8022868V0 (en)
LU (1) LU82783A1 (en)
NL (1) NL8004864A (en)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5344681A (en) * 1991-09-12 1994-09-06 Minnesota Mining And Manufacturing Company Patterned pressure sensitive adhesive transfer tape

Families Citing this family (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE3242940A1 (en) * 1982-11-20 1984-05-24 Hans Julius 6303 Hungen Schmitt ACOUSTICALLY EFFECTIVE COMPONENT
DE3643481A1 (en) * 1986-05-14 1987-11-19 Pape Hans SOUND ABSORPTION COATING OF AN ACOUSTIC WALL OR ACOUSTIC CEILING
DE3800779A1 (en) * 1987-08-21 1989-03-02 Dura Tufting Gmbh DEFORMABLE TEXTILE SURFACE FOR LINING NOISED ROOMS AND METHOD FOR THE PRODUCTION THEREOF
JPH078662Y2 (en) * 1988-11-02 1995-03-06 日本板硝子株式会社 Sound absorbing panel

Family Cites Families (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE469077C (en) * 1925-08-12 1928-12-01 Johann Palmen Fabric for covering walls and methods of making the same
GB1065449A (en) * 1964-10-23 1967-04-12 Herbert Freudenheim Improvements relating to wall coverings
CA991375A (en) * 1972-11-10 1976-06-22 James C. Ollinger Carpet-faced wallboard

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5344681A (en) * 1991-09-12 1994-09-06 Minnesota Mining And Manufacturing Company Patterned pressure sensitive adhesive transfer tape
US5449540A (en) * 1991-09-12 1995-09-12 Minnesota Mining And Manufacturing Company Patterned pressure sensitive adhesive transfer tape

Also Published As

Publication number Publication date
LU82783A1 (en) 1980-12-15
BE885316A (en) 1981-01-16
IT8022868V0 (en) 1980-09-19
FR2465590A1 (en) 1981-03-27
JPS5655654A (en) 1981-05-16
IT1133113B (en) 1986-07-09
GB2058664B (en) 1983-05-05
DE3029938A1 (en) 1981-04-02
FR2465590B1 (en) 1984-04-06
NL8004864A (en) 1981-03-24
IT8024756A0 (en) 1980-09-19
DE3029938C2 (en) 1982-08-12

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Legal Events

Date Code Title Description
PCNP Patent ceased through non-payment of renewal fee