US4711685A
Expired / Lapsed
US
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Soft textured reveal edge ceiling board and process for its manufacture
Assignee: USG Interiors LLC
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Filing: 1986-10-30
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Granted: 1987-12-08
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Expires: 2006-10-30
Abstract
Abstract A fabric-surfaced fiber board having pressed and non-pressed portions. The board includes a low density fiber board composition having a re-activatable binder therein and having a fabric bonded thereto to form a laminate therewith. The laminate has peripheral portions wherein said fiber board composition has been compressed and reformed to have a reduced height, a higher density and a greater strength as compared to the non-pressed portion of the board.
Inventors
- 👤 Theodore E. Hillman
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-05 11:29
CPC Classifications
B; B32; B32B; B32B3/00; B32B3/02; B32B5/00; B32B5/02; B32B5/024; B32B5/22; B32B5/24; B32B5/26; E; E04; E04B; E04B9/00; E04B9/04; E04B9/045; E04B9/0471; E04F; E04F13/00; E04F13/07; E04F13/08; E04F13/0867; B32B38/00; B32B2038/0052; B32B2038/0056; B32B2262/00; B32B2262/10; B32B2262/105; B32B2419/00; B32B2419/06; Y; Y10; Y10T; Y10T156/00; Y10T156/10; Y10T156/1002; Y10T156/1039; Y10T156/1041; Y10T156/1043; Y10T156/1044; Y10T428/00; Y10T428/24; Y10T428/24777; Y10T428/24942; Y10T428/24992
Claims Analysis
Total Claims: 18
Claim 1
Independent Claim
114 words
A process for manufacturing a reveal edge fabric surfaced ceiling board having pressed and non-pressed portions comprising the steps of: (a) bonding a fabric to one face of a preformed ceiling board, said ceiling board comprising wood fibers or mineral fibers and a re-activatable binder to form a laminate of said fabric and said preformed ceiling board; and (b) simultaneously heating and pressing the periphery portion of the ceiling board while said reactivatable binder in said periphery portion is in a reactivatable condition to form a reveal edge ceiling board, said reveal edge being a portion of reduced height, higher density and greater strength as compared to a non-pressed portion of the ceiling board.
Claim 2
Dependent Claim
114 words
A process for manufacturing a reveal edge fabric surfaced ceiling board having pressed and non-pressed portions comprising the steps of: (a) bonding a fabric to one face of a preformed ceiling board, said ceiling board comprising wood fibers or mineral fibers and a re-activatable binder to form a laminate of said fabric and said preformed ceiling board; and (b) simultaneously heating and pressing the periphery portion of the ceiling board while said reactivatable binder in said periphery portion is in a reactivatable condition to form a reveal edge ceiling board, said reveal edge being a portion of reduced height, higher density and greater strength as compared to a non-pressed portion of the ceiling board.
Claim 3
Dependent Claim
22 words
The process of claim 1 further comprising the step of applying a thermosetting resin to the other face of the ceiling board.
Claim 4
Dependent Claim
27 words
The process of claim 1 wherein the step of heating is carried out at a temperature within the range of about 275° F. to about 500° F.
Claim 5
Dependent Claim
19 words
The process of claim 1 wherein the applied pressure in the pressing step is greater than about 50 pounds.
Claim 6
Dependent Claim
33 words
The process of claim 1 wherein the reactivatable binder in the laminate is placed in reactivatable condition by wetting at least a portion of the laminate with aliquid capable of reactivating the binder.
Claim 7
Dependent Claim
17 words
The process of claim 1 or 5 wherein the binder comprises starch and the liquid is water.
Claim 8
Dependent Claim
40 words
The process of claim 6 wherein said water is sprayed at a rate in the range of about 6 grams per square foot of surface to be wetted to about 10 grams per square foot of surface to be wetted.
Claim 9
Dependent Claim
13 words
The process of claim 1 wherein said fabric is a needle-punched carpet fabric.
Claim 10
Dependent Claim
12 words
The process of claim 1 wherein said fabric is a woven fabric.
Claim 11
Dependent Claim
90 words
A process for manufacturing a fabric surfaced mineral fiber board comprising the steps of bonding a fabric to a preformed low density mineral fiber board having a re-activatable binder to form a laminate of said fabric and said preformed low density mineral fiber board; placing the re-activatable binder in the periphery portion of the laminate into a reactivatable condition; simultaneously heating and pressing said periphery portion for compressing and reforming said periphery portion to have reduced height and higher density as compared to the non-peripheral portion of the ceiling board.
Claim 12
Dependent Claim
90 words
A process for manufacturing a fabric surfaced mineral fiber board comprising the steps of bonding a fabric to a preformed low density mineral fiber board having a re-activatable binder to form a laminate of said fabric and said preformed low density mineral fiber board; placing the re-activatable binder in the periphery portion of the laminate into a reactivatable condition; simultaneously heating and pressing said periphery portion for compressing and reforming said periphery portion to have reduced height and higher density as compared to the non-peripheral portion of the ceiling board.
Claim 13
Dependent Claim
75 words
The process of claim 10 wherein the composition by weight of the mineral fiber board is within the range mineral fibers--from about 20% to about 85% perlite--from 0% to about 50% other mineral materials--from 0% to about 10% binders, including a re-activatable binding agent--from about 15% to about 25%, and the density of said mineral fiber board prior to reformation is within the range of from about 141/2 to about 16 pounds per cubic foot.
Claim 14
Dependent Claim
112 words
A fabric surface fiber board laminate having pressed and non-pressed portions manufactured in accordance with the following process: (a) bonding a fabric to one face of a preformed ceiling board, said ceiling board comprising wood fibers or mineral fibers and a re-activatable binder to form a laminate of said fabric and said preformed ceiling board; and (b) simultaneously heating and pressing the periphery portion of the ceiling board while said reactivatable binder in said periphery portion is in a reactivatable condition to form a reveal edge ceiling board, said reveal edge being a portion of reduced height, higher density and greater strength as compared to the non-pressed portion of the ceiling board.
Claim 15
Dependent Claim
112 words
A fabric surface fiber board laminate having pressed and non-pressed portions manufactured in accordance with the following process: (a) bonding a fabric to one face of a preformed ceiling board, said ceiling board comprising wood fibers or mineral fibers and a re-activatable binder to form a laminate of said fabric and said preformed ceiling board; and (b) simultaneously heating and pressing the periphery portion of the ceiling board while said reactivatable binder in said periphery portion is in a reactivatable condition to form a reveal edge ceiling board, said reveal edge being a portion of reduced height, higher density and greater strength as compared to the non-pressed portion of the ceiling board.
Claim 16
Dependent Claim
81 words
A fabric-surfaced fiber board having pressed and non-pressed portions comprising a low density fiber board composition with a density of from about 10 to about 30 pounds per cubic foot including a re-activatable binder therein and having a fabric bonded thereto to form a laminate therewith, said laminate having peripheral portions wherein said fiber board composition has been compressed and reformed to have reduced height, a higher density and greater strength as compared to the non-pressed portion of the ceiling board.
Claim 17
Dependent Claim
81 words
A fabric-surfaced fiber board having pressed and non-pressed portions comprising a low density fiber board composition with a density of from about 10 to about 30 pounds per cubic foot including a re-activatable binder therein and having a fabric bonded thereto to form a laminate therewith, said laminate having peripheral portions wherein said fiber board composition has been compressed and reformed to have reduced height, a higher density and greater strength as compared to the non-pressed portion of the ceiling board.
Claim 18
Dependent Claim
22 words
The fabric-surfaced fiber board of claim 13 wherein said fiber board is a mineral fiber board including starch as the re-activatable binder.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1990-12-07 | 1991-06-08 | 1991-12-08 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1994-12-07 | 1995-06-08 | 1995-12-08 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1998-12-07 | 1999-06-08 | 1999-12-08 | $7700.00 | Window Closed / Lapsed |