Building materials comprising non-woven webs

Claim 2

A building board comprising a composite of a core material covered with non-woven webs, said board being obtained by aerodynamically forming two generally uniform non-woven webs consisting essentially of organic binder and mineral wool; disposing a core mixture comprising organic binder and filler between said webs; consolidating said webs and said core mixture to provide a composite structure; and compressing and curing said structure.

Claim 3

The invention as set forth in claim 1 hereof wherein said core mixture comprises perlite.

Claim 4

The invention as set forth in claim 2 hereof wherein not more than about 15% by weight of said perlite has a mesh size smaller than about 50 mesh U.S. Standard.

Claim 5

The invention as set forth in claim 3 hereof wherein not more than about 5% of said perlite is smaller than 50 mesh.

Claim 6

The invention as set forth in claim 2 hereof wherein said board has an NRC value in excess of 50 without being acoustically perforated.

Claim 7

The invention as set forth in claim 1 hereof wherein said composite structure is sequentially cured.

Claim 8

The invention as set forth in claim 6 hereof wherein said core mixture is cured at a temperature at which the binder in said non-woven webs remains essentially uncured.

Claim 9

The invention as set forth in claim 6 hereof wherein the binder in said non-woven webs lacks a curing component, said webs remaining uncured when said core mixture is cured, the curing component for said webs being subsequently added prior to curing said webs.

Claim 10

The invention as set forth in claim 6 hereof wherein said structure is differentially densified.

Claim 11

A groove molded building board comprising a composite of a core material covered with aerodynamically formed generally uniform non-woven webs, said board having dimensions, edge detail, and optionally embossed features obtained by the simultaneous compression, grooving, curing and optional embossing of the uncured composite, said core comprising organic binder and filler and said webs consisting essentially of organic binder and mineral wool.

Claim 12

A groove molded building board comprising a composite of a core material covered with aerodynamically formed generally uniform non-woven webs, said board having dimensions, edge detail, and optionally embossed features obtained by the simultaneous compression, grooving, curing and optional embossing of the uncured composite, said core comprising organic binder and filler and said webs consisting essentially of organic binder and mineral wool.

Claim 13

The invention as set forth in claim 10 hereof wherein the upper facing web is of sufficient thickness that it has stretched to cover the entire grooved and contoured surface.

Claim 14

The invention as set forth in claim 10 hereof wherein said core material comprises perlite and starch.

Claim 15

The invention as set forth in claim 12 hereof wherein not more than about 15% by weight of said perlite has a mesh size smaller than about 50 mesh U.S. Standard.

Claim 16

The invention as set forth in claim 13 hereof wherein not more than about 5% of said perlite is smaller than 50 mesh.

Claim 17

The invention as set forth in claim 12 hereof wherein said board has an NRC value in excess of 50 without being acoustically perforated.

Claim 18

The invention as set forth in claim 10 hereof wherein said board comprises a decorative edge.

Claim 19

The invention as set forth in claim 10 hereof wherein the groove molded edge of said board has an edge angle of from about 45 to about 76 degrees.

Claim 20

A process for forming a groove molded building board, said process comprising the steps of aerodynamically forming two generally uniform non-woven webs consisting essentially of organic binder and mineral wool; disposing a core mixture comprising organic binder and filler between said webs; consolidating said webs and said core mixture to provide a composite structure; optionally, preheating said composite; simultaneously compressing, grooving, curing, and optionally embossing said structure, thereby providing a groove molded board comprising at least one board segment; and separating said board segment from the board scrap and from any adjacent board segments, said grooving being sufficient to provide edge detail to said board segment and to provide lines of demarcation between said board or board segments and said scrap without causing premature separation along said lines.

Claim 21

A process for forming a groove molded building board, said process comprising the steps of aerodynamically forming two generally uniform non-woven webs consisting essentially of organic binder and mineral wool; disposing a core mixture comprising organic binder and filler between said webs; consolidating said webs and said core mixture to provide a composite structure; optionally, preheating said composite; simultaneously compressing, grooving, curing, and optionally embossing said structure, thereby providing a groove molded board comprising at least one board segment; and separating said board segment from the board scrap and from any adjacent board segments, said grooving being sufficient to provide edge detail to said board segment and to provide lines of demarcation between said board or board segments and said scrap without causing premature separation along said lines.

Claim 22

The invention as set forth in claim 18 hereof wherein the groove molded board prior to the separation step comprises a plurality of board segments.

Claim 23

The invention as set forth in claim 18 hereof wherein the upper facing web is of sufficient thickness that it stretches to cover the entire grooved and contoured surface during the simultaneous compression, grooving, curing and optional embossing of said structure.

Claim 24

The invention as set forth in claim 18 hereof wherein said core material comprises perlite and starch.

Claim 25

The invention as set forth in claim 21 hereof wherein not more than about 15% by weight of said perlite has a mesh size smaller than about 50 mesh U.S. Standard.

Claim 26

The invention as set forth in claim 22 hereof wherein not more than about 5% of said perlite is smaller than 50 mesh.

Claim 27

The invention as set forth in claim 18 hereof wherein said board is provided with a decorative edge.

Claim 28

The invention as set forth in claim 18 hereof wherein said board is provided with a groove molded edge having an edge angle of from about 45 to about 76 degrees.

Claim 29

The invention as set forth in claim 18 hereof wherein the trim edge is compressed more completely than the non-embossed inboard portions of said board, whereby lateral movement of said trim edge is prevented during the simultaneous compression, grooving, curing and optional embossing of said structure.

Claim 30

The invention as set forth in claim 18 hereof wherein the thickness of the material remaining along said lines of demarcation prior to the separation step is from about 0.015 to about 0.03 inch.

Claim 31

A composite suitable to provide a groove molded building board, said composite comprising a core material comprising organic binder and filler, said core material being covered by aerodynamically formed generally uniform webs consisting essentially of organic binder and mineral wool, the components of said webs and said core material being selected such that, when said composite is subjected to conditions which will induce simultaneous comprssion, grooving, curing and optional embossing, said webs will stretch and move so as to accommodate the contours which are impressed into their respective surfaces, and said underlying core material will similarly flow to adopt said contours.

Claim 32

A composite suitable to provide a groove molded building board, said composite comprising a core material comprising organic binder and filler, said core material being covered by aerodynamically formed generally uniform webs consisting essentially of organic binder and mineral wool, the components of said webs and said core material being selected such that, when said composite is subjected to conditions which will induce simultaneous comprssion, grooving, curing and optional embossing, said webs will stretch and move so as to accommodate the contours which are impressed into their respective surfaces, and said underlying core material will similarly flow to adopt said contours.

Claim 33

The invention as set forth in claim 28 hereof wherein the upper facing web is of sufficient thickness that it will stretch to cover the entire contour of the resulting structure.

Claim 34

The invention as set forth in claim 28 hereof wherein said core material comprises perlite and starch.

Claim 35

The invention as set forth in claim 30 hereof wherein not more than about 15% by weight of said perlite has a mesh size smaller than about 50 mesh U.S. Standard.

Claim 36

The invention as set forth in claim 31 hereof wherein not more than about 5% of said perlite is smaller than 50 mesh.