Patent ID: 6616804
Filing Date: 2003-09-09
Classification: B44C,C04B,D21F,D21H,D21J,E04B,Y02W,Y10T

Abstract:
A method of making a durable acoustical panel comprising:(a) forming an aqueous slurry comprising a fibrous filler, a base binder, and water; (b) depositing the aqueous slurry onto a moving foraminous support wire to form an aqueous felt; (c) de-watering the aqueous felt to form a wet felt; (d) coating the wet felt with an aqueous overlay comprising nodulated wool, overlay binder, and water, wherein the aqueous overlay has a substantially smooth surface; and (e) drying the aqueous overlay coated wet felt at a temperature from about 400Â° F. to about 750Â° F. to form the panel.