Abstract: Disclosed is both a method and apparatus related to coated panels. The panels are coated with an ultra thin coating of fluoropolymer. The coating imparts resistance to staining, washability, scrubbability, and soiling, as well as long durability. Furthermore, excellent adhesion is obtained with the ultra thin fluoropolymer when applied to panels.

Abstract: The present invention provides for both a composition and method for producing a scratch resistant coating applied to an acoustical panel. The coating primarily comprises binder, filler and mica and is typically applied as a spray. The coating can be characterized as a discontinuous film, whereby sound can pass through the coating to the panel for attenuating sound. The coating is thus enabled to provide a finish and color without compromising the acoustical performance of the substrate. The process primarily comprises combining and mixing the dry components of filler, binder and mica and then combining the same with water and mixing to create an aqueous mix that can be applied to the acoustical panel and dried.

Abstract: An aqueous, two component system for coating a substrate includes either a filler incorporated in both components prior to combining the components or an elevated amount of a filler, such as 50% by dry volume, in either component. The filler is preferably calcium carbonate, but may also be selected from titanium dioxide, sand, clay, mica, dolomite, silica, talc, perlite, gypsum, wallastonite, aluminum trihydrate, zinc oxide, barium sulfate, zinc sulfate, and combinations thereof. The first component includes a first polymer containing hydroxyl functional groups or amine functional groups and, optionally, a catalyst, preferably an organotin catalyst. The first polymer is selected from a polyester polyol, an acrylic polyol, a urethane polyol, a polyether polyol, a polyamine, an aldimine, a short oil alkyd, a silicone polyol, a cellulose ester, a vinyl polyol, and combinations thereof and preferably is a polyaspartic ester.

Abstract: A ceiling board coating composition includes water, a binder and a filler, said filler having large particles with an average particle size of a minimum of about 50 microns, medium particles with an average particle size in the range of from about 1.2 to about 30 microns, and small particles which have an average particle size in the range of from about 0.1 to about 1.0 microns.

Abstract: Using a combination of relatively coarse filler and latex binder, a very high solids coating (about 85% or higher) can be produced with a relatively low working viscosity. These very high solids coatings can be applied in thick single layers and oven cured without cracking. They maintain more than 80% of their original wet thickness. The resulting coating provides an extremely hard and durable surface, even on relatively soft mineral fiber board ceiling tiles or wall panels.

Abstract: A novel fabric-covered wall- or ceiling-board of improved abrasion resistance is disclosed. The fabric is composed of fibers of at least two different melting temperatures. The product is manufactured by heating the fabric to a temperature to soften one fiber but not the other and bonding the fabric to the board.

Abstract: A method and apparatus is set forth to form a flannel-like product. A non-woven web of fibers of two contrasting shades of color are needled twice to form a non-woven fabric with the coloration of woven flannel material. A calendar roll smooths the fabric to remove the appearance of the needling operations and get a non-woven flannel-like product.

Abstract: A method and apparatus is set forth to form a flannel-like product. A non-woven web of fibers of two contrasting shades of color are needled twice to form a non-woven fabric with the coloration of woven flannel material. A calendar roll smooths the fabric to remove the appearance of the needling operations and get a non-woven flannel-like product.

Abstract: A method of forming a fabric covered end on a wallboard spline structure is disclosed herein. A fixture is provided with a series of recesses to position the fabric and the spline in a desired relationship. An adhesive is provided on a portion of the vertical web of the spline and the inserting of the fabric and the spline into the fixture positions the fabric on the desired portion of the spline.

Abstract: A non-woven material is applied to the surface of a woven scrim. The non-woven material is needle-bonded to the scrim. The composite structure is then embossed, and during the embossing operation, a uniform coloring is provided in the areas of the embossing. The embossed pattern is placed by a heated embosser on the composite structure and in the embossed areas, the heat of embossing causes the non-woven material to partially melt and assume a textured effect which mirrors the texture of the woven scrim.