Abstract: The present invention relates to laminated acoustical tile products which are derived from compositions that are suitable to provide rigid, water-resistant phosphate ceramic materials. The tile products comprise a decorative facing comprising a substantially open-celled character and a backing layer of higher density, the backing layer and edges of the tile comprising substantially closed-celled facing characteristics. The backing layer provides structural strength and dimensional stability to the tile product whereas the decorative, open-celled facing provides access by sound waves to the interior regions of the board. The resulting composite material provides good acoustical performance, yet is capable of withstanding conventional handling stresses.

Abstract: The present invention relates to a curtain coating apparatus by which a foamable or foaming material is conveyed from a mixing apparatus through a distributor comprising a plurality of conveying tubes to a curtain coating slot. The apparatus comprises homogenization means for agitating the mixture such that the merging streams of foamable or foaming material are intermixed so as to provide a substantially uniform material which emerges from the curtain coating slot.

Abstract: The present invention relates to a curtain coating apparatus by which a foamable or foaming material is conveyed from a mixing apparatus through a distributor comprising a plurality of conveying tubes to a curtain coating slot. The apparatus comprises homogenization means for agitating the mixture such that the merging streams of foamable or foaming material are intermixed so as to provide a substantially uniform material which emerges from the curtain coating slot.

Abstract: The present invention relates to laminated acoustical tile products which are derived from compositions that are suitable to provide rigid, water-resistant phosphate ceramic materials. The tile products comprise a decorative facing comprising a substantially open-celled character and a backing layer of higher density, the backing layer and edges of the tile comprising substantially closed-celled facing characteristics. The backing layer provides structural strength and dimensional stability to the tile product whereas the decorative, open-celled facing provides access by sound waves to the interior regions of the board. The resulting composite material provides good acoustical performance, yet is capable of withstanding conventional handling stresses.

Abstract: The present invention relates to a method by which a composition which will provide a foamed phosphate ceramic material is cast upon a support surface comprising regions having a substantially smooth character, being of relatively low surface energy, and having the ability to release from the cured phosphate material. In those regions where the smooth coating contacts the phosphate open cells will result, whereas in other regions closed cells will result. One preferred substrate against which the phosphate material can be cast is a wax material.