Acoustical panel coating and process of applying same

Abstract

A coating composition and process of applying the coating to a substrate are provided herein. The coating composition includes filler particles, binder and a liquid carrier, such as water. The filler particles have an average particle size in the range from about 100 to about 600 microns and preferably in the range from about 200 to about 450 microns. The coating composition comprises from about 15% to about 50% by weight liquid carrier and from about 35% to about 90% by dry solids weight filler particles. The coating composition preserves the acoustic performance characteristics of the substrate to which it is applied, while imparting a textured appearance to the substrate, making the substrate virtually indistinguishable from surrounding panels.

Description

CROSS REFERENCE TO RELATED APPLICATION [0001] This application claims the benefit under 35 U.S.C. § 119(e) of U.S. provisional application Ser. No. 60 / 414,950, filed Sep. 30, 2002.BACKGROUND [0002] The present invention relates generally to ceiling systems having acoustical panels and more particularly to coatings for acoustic scrims of flat panel sound radiators and acoustical panels and a method for applying these coatings. [0003] As the service sector of the economy grows, more and more workers find themselves in offices rather than in manufacturing facilities. The need for flexible, reconfigurable space has resulted in open plan workspaces, large rooms with reduced height, moveable partitions, and suspended ceiling systems. Workstation density also is increasing, with more workers occupying a given physical space. Additionally, speakerphones, conferencing technologies, and multimedia computers with large sound reflecting screens and voice input tend to increase the noise level o...

AI Technical Summary

Benefits of technology

The present invention provides a coating composition that can be applied to a substrate, such as an acoustical panel, to preserve its acoustical performance and give it a textured appearance that is visually indistinguishable from surrounding panels in a wall or suspended ceiling system. The coating composition contains filler particles, a binder, and a liquid carrier. The resulting coated substrate has an airflow resistance and texture value within certain ranges. The invention also provides a method for applying the coating, a coated scrim that exhibits an airflow resistance and texture value within certain ranges, and a suspended ceiling system with coated scrim and acoustical panels that appear monolithic.

Problems solved by technology

Additionally, speakerphones, conferencing technologies, and multimedia computers with large sound reflecting screens and voice input tend to increase the noise level of the workplace.

Unfortunately, many loudspeaker systems do not integrate visually into the ceiling system and, as a result, interrupt the desired monolithic appearance of the ceiling.

By way of example, many speaker systems, when installed, protrude below the plane of the acoustical panels, thus interrupting the planar surface of ceiling.

Such a speaker grill, while effective, nevertheless interrupts the monolithic appearance of the ceiling and is considered unsightly by some.

However, existing flat panel sound radiators generally are detectable because the coloring and texture of the facing does not match precisely the surrounding ceiling tiles.

Thus, these flat panel radiators still are considered by some to present an unacceptable appearance.

However, it has proven difficult to formulate a coating and a process for its application which provides the facing material with the proper appearance and texture while continuing to provide the desired acoustic transparency.

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