Acoustic wall panels, wall covering systems, and methods for making the same

Abstract

A method for forming a wall covering system includes positioning a first substrate adjacent a second substrate such that a seam is defined between the first acoustic wall panel and the second acoustic wall panel, applying a seam-filling material to the seam, applying a coating composition over the first substrate, the second substrate, and the seam-filling material to define a first major exposed surface, and perforating at least a portion of the first major exposed surface.

Description

ACOUSTIC WALL PANELS, WALL COVERING SYSTEMS, AND METHODS FORMAKING THE SAMECROSS-REFERENCE TO RELATED APPLICATION

[0001] This application is a PCT International Application that claims the benefit of United States Provisional Patent Application No. 63 / 632,264, filed on April 10, 2024, the disclosure of which is incorporated herein by reference.FIELD OF DISCLOSURE

[0002] The present disclosure relates to acoustic building panels and surface covering systems including acoustic building panels, and more particularly to microperforated acoustic wall systems and perforation roller tools for microperforating acoustic wall and ceiling systems.BACKGROUND

[0003] Building materials, such as planks and panels for ceiling and wall systems, may be designed balance interests with respect to aesthetics, material cost, structural integrity, acoustics, and environmental impact.

[0004] Accordingly, those skilled in the art continue research and development in the field of acoustic wall panels, acoustic wall systems, and tools for microperforating acoustic wall systems.BRIEF SUMMARY

[0005] This summary is intended merely to introduce a simplified summary of some aspects of one or more implementations of the present disclosure. Further areas of applicability of the present disclosure will become apparent from the detailed description provided hereinafter. This summary is not an extensive overview, nor is it intended to identify key or critical elements of the present teachings, nor to delineate the scope of the disclosure. Rather, its purpose is merely to present one or more concepts in simplified form as a prelude to the detailed description below.

[0006] The present disclosure offers a solution for wall covering systems requiring desirable mechanical and acoustic properties. Typically, wall panels and wall covering systems include drywall panels made of gypsum. Gypsum panels provide adequate impact strength and other mechanical properties needed to withstand normal use. One problem with typical drywall panels is poor acoustics. Typical acoustic panels, such as ceiling panels and wall panel located above 7ft over ground level, include mineral wool blended with inorganic materials. While those panels provide excellent acoustic properties, they typically do not provide mechanical properties needed for walls located up to about 7ft above ground level, such as impact resistance. Accordingly, thepresent disclosure provides a solution to the problem by providing wall panels and wall panel systems that are both impact resistant and have desirable acoustic properties.

[0007] Typically, wall covering panels and systems are painted with a coating composition for aesthetics. One downfall to the coating is the impact on acoustics. Many coatings block airflow to the panels, thus interfering with acoustic performance. The present application presents a solution to this problem by microperforating the coating to allow for airflow. Specifically, it has been found that perforating the coating with a plurality of microperforations allows for improved acoustics by breaking up the barrier created by the coating.

[0008] The present disclosure is directed to methods for manufacturing acoustic wall panels and wall covering systems and acoustic ceiling panels and ceiling covering systems.

[0009] In one example, the method includes positioning a first substrate adjacent a second substrate such that a seam is defined between the first acoustic wall panel and the second acoustic wall panel, applying a seam-filling material to the seam, applying a coating composition over the first substrate, the second substrate, and the seam-filling material, and perforating at least a portion of the coating.

[0010] In one example, the perforating includes positioning a perforation roller tool having a plurality of pins against the coating of the first major surface, applying pressure to the perforation roller tool, and passing the perforation roller tool over at least a portion of the first major surface. In one example, the perforating includes passing the perforation roller tool over the first major surface at least two times, wherein each pass is performed at an offset position on the first major surface such that none of the perforations overlap. In one example, the perforating includes defining a plurality of perforations in the coating and at least a portion of one of the first substrate and the second substrate. In one example, the perforating includes performing a series of offset passes over the first major surface to yield an irregular pattern of perforations across the first major surface.

[0011] In one example, the perforating yields a plurality of perforations that are present in a perforation density' ranging from about 10 perforation / in2 to about 600 perforation / in2. In one example, the perforating yields a plurality of perforations having an average diameter ranging from about 0. 1 mm to about 1mm. In one example, the seam-filling material comprises gypsum plaster.

[0012] A method for manufacturing an acoustic wall panel includes providing a substrate having a first major surface opposite a second major surface and a coating over the first major surface, positioning a perforation roller tool having a plurality of pins against the coating of the first major surface, applying pressure to the perforation roller tool, and passing the perforation roller tool over at least a portion of the first major surface to perforate the coating.

[0013] In one example, the passing includes performing a first pass over a first portion of the first major surface and performing a second pass over a second portion of the first major surface that is offset from the first portion of the first major surface.

[0014] In one example, the passing yields a plurality7of perforations that are present in a perforation density ranging from about 10 perforation / in2to about 600 perforation / in2. In one example, the passing yields a plurality of perforations having an average diameter ranging from about 0. 1mm to about 1mm. In one example, the passing yields a plurality of perforations having an average depth ranging from about 0. 1 mm to about 4mm. In one example, the passing includes performing a series of passes over first major surface such that an irregular pattern of perforations is defined across the first major surface.

[0015] A method for manufacturing an acoustic wall panel includes forming a blend by combining together a binder composition, an inorganic material, a recycled organic material, and water, flowing the blend into a mold having a geometry', hardening the blend in the mold such that the binder composition and recycled material conform to the geometry' of the mold to yield a substrate having a first major surface opposite a second major surface, applying a coating over the first major surface, and perforating the coating to yield the acoustic wall panel. In another example, the method includes forming the substrate via in a wet laid process on a continuously moving wire.

[0016] In one example, the perforating includes positioning a perforation roller tool having a plurality of pins against the coating of the first major surface, applying pressure to the perforation roller tool, and passing the perforation roller tool over at least a portion of the first major surface.

[0017] In one example, the perforating includes passing the perforation roller tool over the first major surface at least two times, wherein each pass is performed at an offset position on the first major surface such that none of the perforations overlap.

[0018] In one example, the perforating includes passing the perforation roller tool over the first major surface at least two times, wherein at least two passes are performed at an overlapping position on the first major surface. In one example, the perforating includes defining a plurality of perforations in the coating and at least a portion of the substrate. In one example, the perforating includes performing a series of offset passes over the first major surface to yield an irregular pattern of perforations across the first major surface.

[0019] In one example, the perforating yields a plurality of perforations that are present in a perforation density ranging from about 10 perforation / in2to about 600 perforation / in2. In one example, the perforating yields a plurality of perforations that are present in a perforation densityranging from about 10 perforation / in2to about 600 perforation / in2. In one example, perforatingyields a plurality of perforations having an average diameter ranging from about 0. 1mm to about 1mm.

[0020] In one example, the acoustic wall panel has a length and a width, the length ranging from about 1 ft. to about 8ft and the width ranging from about 1 ft. to about 4 ft.

[0021] In one example, the method includes coupling a scrim to the first major surface of the substrate prior to applying the coating to the first major surface. In one example, the scrim is comprised of a fibrous material selected from one or more of fiberglass, mineral wool, and combinations thereof. In one example, the scrim has an airflow resistance from about 30 mks ralys to about 200000 mks ralys, preferably from about 30 mks ralys to about 5000 mks ralys. In one example, the perforating comprising defining a plurality of perforations in the coating and at least a portion of the scrim.

[0022] In one example, the substrate includes inorganic material present in an amount ranging from about 20 wt. % to about 80 wt. % based on the total dry-weight of the substrate, organic recycled material present in an amount ranging from about 5 wt. % to about 80 wt. % based on the total dry -weight of the substrate, and a binder present in an amount ranging from about 5 wt. % to about 15 wt. % based on the total dry-weight of the substrate, wherein the organic recycled material comprises a blend of two or more cellulosic materials.

[0023] In one example, the inorganic fiber comprises mineral wool. In one example, the inorganic material comprises clay present in an amount ranging from about 25 wt. % to about 55 wt. % based on the total dry-w eight of the substrate. In one example, the organic recycled material comprises starch material, cellulosic material, or combinations thereof. In one example, the organic recycled material comprises newsprint, refined paper, w ood fiber, or combinations thereof. In one example, the organic recycled material comprises dry broke present in an amount ranging from about 15 wt. % to about 40 wt. % based on the total dry -weight of the substrate. In one example, the substrate exhibits an airflow resistance from about 30 mks ralys to about 200000 mks ralys.

[0024] Also disclosed is a perforation roller tool.

[0025] In one example, a perforating roller tool comprises a handle, a roller support, and a roller rotatably supported by the roller support, wherein the roller comprises a cylinder comprising an outer surface, and pins extending from the cylinder.BRIEF DESCRIPTION OF THE DRAWINGS

[0026] Figure 1 is a perspective view of an acoustic wall panel;

[0027] Figure 2 is side cross-sectional view of the acoustic wall panel of Figure 1;

[0028] Figure 3 is a perspective view of a wall covering system;

[0029] Figure 4 is a side cross-sectional view of the wall covering system of Figure 3;

[0030] Figure 5 is a top plan view of an acoustic wall panel;

[0031] Figure 6 is a perspective view of a wall covering system;

[0032] Figure 7 is a side cross-sectional view of the wall covering system of Figure 6;

[0033] Figure 8 is a building system comprising one or more of the acoustic wall panels and wall covering systems of Figures 1 to 7;

[0034] Figure 9 is a perspective view of two perforation roller tools;

[0035] Figure 10 comprises detail views of a roller of a perforation roller tool of Figure 9;

[0036] Figure 10A is an end view of the roller of Figure 10;

[0037] Figure 11 comprises detail views of a roller of a perforation roller tool of Figure 9;

[0038] Figure 12 is a partial perspective view of a roller assembly of a perforation roller tool;

[0039] Figure 13 is a perspective view of a perforation roller tool shown in Figure 12;

[0040] Figure 14 is a perspective view of a perforation roller tool shown in Figure 12;

[0041] Figure 15 is a perspective view' of a perforation roller tool shown in Figure 12;

[0042] Figure 16 is a perspective view of a perforation roller tool shown in Figure 12;

[0043] Figure 17 is a perspective view of a perforation roller tool shown in Figure 12;

[0044] Figure 18 is a plan view of a perforation pattern created by a single pass of a perforation roller tool on an acoustic w all panel;

[0045] Figure 19 is a plan view of a perforation pattern created by five passes of the perforation roller tool of Figure 18 on an acoustic wall panel;

[0046] Figure 20 is a plan view of a perforation pattern created by five passes of the perforation roller tool of Figure 18 on an acoustic w all panel;

[0047] Figure 21 is a plan view of a perforation pattern created by five passes of the perforation roller tool of Figure 18 on an acoustic wall panel;

[0048] Figure 22 is a plan view of a perforation pattern created by five passes of the perforation roller tool of Figure 18 on an acoustic w all panel;

[0049] Figure 23 is a plan view' of a perforation pattern created by five passes of the perforation roller tool of Figure 18 on an acoustic wall panel;

[0050] Figure 24 is a plan view of a perforation pattern created by five passes of the perforation roller tool of Figure 18 on an acoustic wall panel and also transverse passes of the perforation roller tool of Figure 18 extending transversely to the five passes;

[0051] Figure 25 is a plan view of a perforation pattern created by five passes of a perforation roller tool having a regular, non-randomized array of pins extending from a roller that do not vary in pin population density across the face of the roller;

[0052] Figure 26 is a plan view of a perforation patern created by five passes of a perforation roller tool having an irregular, random array of pins extending from a roller that do not vary in pin population density across the face of the roller;

[0053] Figure 27 is a plan view of a perforation patern created by five passes of a perforation roller tool having an irregular, random array of pins extending from a roller that vary in pin population density across the face of the roller;

[0054] Figure 28 is a schematic of a portion of a surface covering system;

[0055] Figure 29 is a schematic of a roller assembly;

[0056] Figure 30 is a schematic of a roller assembly; and

[0057] Figure 31 is a schematic of a roller assembly.

[0058] The detailed description of the disclosure will be beter understood when read in conjunction with the appended drawings. It should be understood, however, that the disclosure is not limited to the precise arrangements and instrumentalities of the examples shown in the drawings.DETAILED DESCRIPTION

[0059] For illustrative purposes, the principles of the present disclosure are described by referencing various examples thereof. Although certain examples of the disclosure are specifically described herein, one of ordinary skill in the art will readily recognize that the same principles are equally applicable to, and can be employed in other applications and methods. It is to be understood that the disclosure is not limited in its application to the details of any particular example shown. The terminology used herein is for the purpose of description and not to limit the disclosure, its application, or uses.

[0060] As used herein and in the appended claims, the singular forms “a”, ‘'an”, and “the” include plural references unless the context dictates otherwise. The singular form of any class of the ingredients refers not only to one chemical species within that class, but also to a mixture of those chemical species. The terms “a” (or “an”), “one or more” and “at least one” may be used interchangeably herein. The terms “comprising”, “including”, “containing”, and “having” may be used interchangeably. The term “include” should be interpreted as “include, but are not limited to”. The term “including” should be interpreted as “including, but are not limited to”.

[0061] As used throughout, ranges are used as shorthand for describing each and every value that is within the range. Any value within the range can be selected as the terminus of the range. Thus, any range of values disclosed herein is merely exemplary and includes all values and sub-ranges there-between

[0062] Unless otherwise specified, all percentages and amounts expressed herein and elsewhere in the specification should be understood to refer to percentages by weight of the total composition. Unless otherwise specified, reference to a molecule, or to molecules, being present at a “wt. %” refers to the amount of that molecule, or molecules, present in the composition based on the total dry-weight of the composition. Unless otherwise specified, reference to a molecule, or to molecules, being present “based on the dry weight of the composition’" refers to that molecule, or molecules, being present in the composition based on the total dry -weight of the composition in a dry state. The “dry state” refers to solvent being present in the composition at an amount less than 5.0 wt %, less than about 3.0 wt. %, less than about 1.0 wt. %; preferably less than about 0.5 wt %, and more preferably less than about 0.25 wt. % of the composition. For example, a composition in the dry state may refer to a composition having about 95% solids, about 98% solids, preferably about 99% solids, or more preferably about 100% solids. By contrast, unless otherwise specified, reference to a molecule, or to molecules, being present “based on the wet weight of the composition” refers to that molecule, or molecules, being present in the composition based on the total dry -weight of the composition which includes at least 5 wt. % of solvent.

[0063] According to the present application, use of the term “about” in conjunction with a numeral value refers to a value that may be + / - 5% of that numeral. As used herein, the term “substantially free” is intended to mean an amount less than about 5.0 wt. %, less than 3.0 wt. %, less than 1.0 wt. %; preferably less than about 0.5 wt. %, and more preferably less than about 0.25 wt. % of the composition.

[0064] Unless defined otherwise, all technical and scientific terms used herein have the same meanings as commonly understood by one of ordinary skill in the art to which this disclosure belongs. All patents, patent applications, publications, and other references cited or referred to herein are incorporated by reference in their entireties for all purposes. In the event of a conflict in a definition in the present disclosure and that of a cited reference, the present disclosure Comparatives.

[0065] In the description of examples disclosed herein, any reference to direction or orientation is merely intended for convenience of description and is not intended in any way to limit the scope of the present disclosure. Relative terms such as "lower," "upper," “horizontal,” “vertical,”, “above,” “below,” “up,” “down,” “top” and “bottom” as well as derivatives thereof (e.g., “horizontally,” “downwardly,” “upwardly,” etc.) should be construed to refer to the orientation as then described or as shown in the drawing (if applicable) under discussion. These relative terms are for convenience of description only and, unless specified otherwise, do not require that the apparatus be constructed or operated in a particular orientation.

[0066] As used herein, terms such as “attached,’' “affixed,"’ “connected,’" “coupled,” “interconnected,” and the like refer to a relationship wherein structures are secured or attached to one another either directly or indirectly through intervening structures, as well as both movable or rigid attachments or relationships, unless expressly described otherwise. Accordingly, the disclosure is not limited to such examples illustrating certain combinations of features that may exist alone or in combination with other features.

[0067] In one aspect, the disclosure provides a single-layer acoustic wall panel and system that yields desired acoustic properties, including a higher Noise Reduction Coefficient (NRC), while achieving desired mechanical properties, including impact resistance. It has been discovered that simultaneously achieving desired acoustic and mechanical properties is possible via the combination of materials disclosed herein exhibiting high skeletal density to provide desirable porosity, impact resistance, and acoustics.

[0068] The present disclosure provides a solution for wall covering systems having ideal mechanical and acoustic properties. Typically, wall panels and wall covering systems include drywall panels made of gypsum. Gypsum panels provide adequate impact strength and other mechanical properties needed to withstand normal use. One problem with typical drywall panels is that they do not provide good acoustics. Typical acoustic panels, such as ceiling panels and wall panel located above 7ft over ground level, include mineral wool blended with inorganic materials. While those acoustic panels provide excellent acoustic properties, they typically do not provide mechanical properties needed for walls located up to about 7ft above ground level, such as impact resistance. Accordingly, the present disclosure provides a solution to the problem by providing wall panels and wall panel systems that are both impact resistant and have desirable acoustic properties.

[0069] Typically, wall covering panels and systems are painted with a coating composition for aesthetics. One downfall to the coating is the impact on acoustics. Many coatings block airflow to the panels, thus interfering with acoustic performance. The present application presents a solution to this problem by microperforating the coating to allow7for airflow. Specifically, it has been found that perforating the coating with a plurality of microperforations allows for improved acoustics by breaking up the barrier created by the coating.

[0070] Disclosed is a method for manufacturing an acoustic wall panel 100, see Figure 1 and Figure 2. The acoustic wall panel 100 includes a substrate 110 that may have a substrate thickness ti as measured from the first major surface 112 to the second major surface 114. The substrate 110 thickness ti may range from about 12 mm to about 40 mm - including all values and sub-ranges there-between. The acoustic wall panel 100 may have a length Lp ranging from about 30 cm toabout 310 cm - including all values and sub-ranges there-between. The acoustic wall panel 100 may have a width Wp ranging from about 10 cm to about 125 cm - including all values and subranges there-between.

[0071] The acoustic wall panel 100 includes a substrate 110 having a first major surface 112 opposite a second major surface 114 and a side surface 113 extending therebetween. The substrate 110 includes a combination of inorganic and organic materials, some recycled, with a binder to yield desirable acoustic and mechanical properties.

[0072] The method includes forming a blend by combining together a binder composition, an inorganic material, a recycled organic material, and water to yield a slurry. The method further includes flowing the blend or slurry into a mold having a geometry, such as a rectangular wall panel shape that may have tapered or beveled edges as further described below.

[0073] The method further includes hardening the blend in the mold such that the binder composition and recycled material conform to the geometry of the mold to yield a substrate 110 having a first major surface 112 opposite a second major surface 114. In one example, the hardening includes drying the blend at a predetermined temperature for a predetermined period of time.

[0074] Alternatively, the method may include forming the substrate 110 via in a wet laid process on a continuously moving wire.

[0075] In one or more examples, the method further includes applying a coating composition over the first major surface 112 to yield a coating 140. The coating composition may be applied directly to the first major surface 112 or to a scrim 120 over the first major surface 112. The coating composition may be applied such that it forms a coating 140 present at a thickness ts. In one example, the coating 140 thickness ts is present in an amount ranging from about 30 g / ft2to about 120 g / ft2. In another example, the acoustic wall panel 100 includes more than one coating 140.

[0076] The acoustic wall panel 100 may be characterized by its total thickness to as measured from the first major exposed surface 116 to the second major exposed surface 118, including the thickness of the substrate 110 ti, the thickness of the scrim 120 t2, and the thickness of the coating 140 ts. The first major exposed surface 116 may be the same surface as the first major surface 112 or may be defined by a scrim 120 or coating 140 as described herein.

[0077] In one example, the coating composition and coating 140 includes a pigment blend and a binder. In one example, the binder comprises vinyl acrylic polymer. The pigment blend and binder may be present a ratio of pigment-to-binder from about 5 to about 20- including all values and sub-ranges there-between.

[0078] In one or more examples, the pigment blend comprises two or more of calcium carbonate, titanium dioxide, barium sulfate, calcined diatomaceous earth, and aluminum hydroxide. In one example, pigment blend includes calcined diatomaceous earth present in an amount from about 3 wt. % to about 20 wt. %, from about 5 wt. % to about 17.5 wt. %, or from about 7.5 wt. % to about 15 wt. %, based on the dry weight of the coating composition.

[0079] In one or more examples, the pigment blend comprises titanium dioxide present at a concentration of about 0. 1 wt. % to about 15 wt. %, from about 0.5 wt. % to about 10 wt. %, or from about 1 wt. % to about 8 wt. %, based upon the dry weight of the coating composition.

[0080] In one or more examples, the pigment blend comprises barium sulfate present at a concentration of about 0.1 wt. % to about 15 wt. %, from about 0.5 wt. % to about 10 wt. %, or from about 1 wt. % to about 8 wt. %, based upon the dry weight of the coating composition.

[0081] In one or more examples, the pigment blend includes aluminum hydroxide present in an amount from about 3 wt. % to about 20 wt. %, from about 5 wt. % to about 18 wt. %, or from about 10 wt. % to about 15 wt. %, based on the dry weight of the coating composition.

[0082] In one or more examples, the pigment blend includes calcium carbonate present in an amount from about 20 wt. % to about 60 wt. %, from about 25 wt. % to about 35 wt. %, or from about 27.0 wt. % to about 32.5 wt. %, based on the dry weight of the coating composition.

[0083] In one or more examples, the coating 140 includes one or more additives, including one or more of a defoamer, humectant, clay, wetting and dispersing additive, calcined extender, hydrophobic polymer emulsion, biocide, or precipitated synthetic silicate.

[0084] The coating 140 may be applied in any amount needed to sufficiently achieve desired aesthetic and acoustic properties. In one example, the coating 140 is applied in an amount ranging from about 40 g / ft2to about 60 g / ft2— including all values and sub-ranges there-between.

[0085] In one or more examples, the method includes perforating the first major exposed surface 116, which may be the coating 140, to yield the acoustic wall panel 100 having a plurality of perforations 130. Perforating advantageously allows for airflow through the coating composition, thus providing desirable acoustic properties. The perforating may include positioning a perforation roller tool having a plurality of pins, as further described in detail below, against the first major exposed surface 116 or coating 140, applying pressure to the perforation roller tool, and passing the perforation roller tool over at least a portion of the first major exposed surface 116 such that it penetrates the coating 140, yielding a plurality of perforations 130 in the first major exposed surface 116, or the coating 140.

[0086] In one or more examples, the perforating includes passing the perforation roller tool over the first major exposed surface 116 at least two times. Each pass may be performed at an offset position on the first major exposed surface 116 such that none of the perforations overlap.

[0087] In one or more examples, the perforating includes passing the perforation roller tool over the first maj or exposed surface 1116 defining a plurality of perforations 130 in the coating 140 and at least a portion of the substrate 110. In another example, the perforating includes performing a series of offset passes over the first major exposed surface 116 to yield an irregular pattern of perforations across the first major exposed surface 11 .

[0088] In one or more examples, the perforating yields a plurality of perforations 130 that are present in a perforation density ranging from about 10 perforation / in2to about 600 perforation / in2. In another example, the perforating yields a plurality of perforations 130 having an average diameter ranging from about 0. 1mm to about 1mm.

[0089] The number of perforations of the plurality of perforations 130 is selectively designed to yield desired material properties. To convert air flow to air flow resistivity, the formulation r=A / Pd is utilized, where a is the area, p is the permeability, and d is the thickness of the substrate. In one example, the acoustic properties of a perforated substrate are characterized by the Transparency Index, as defined by Schultz’s guideline. As outlined, the transparency index, TI, is defined by the following: TI=nd2 / ta2, where n is the number of holes per square inch, d is the perforation diameter (in inches), t is the sheet thickness (in inches), a is the distance between the holes, where a is represented as a=b-d, where b is the on-center hole spacing (in inches).

[0090] In one or more examples, the method further includes coupling a scrim 120 to the first major surface 112 of the substrate 110 prior to applying the coating 140 to the first major surface 112. The scrim 120 is comprised of a fibrous material selected from one or more of fiberglass, mineral wool, and combinations thereof. The scrim 120 has an airflow resistance from about 30 mks ralys to about 200000 mks ralys, preferably from about 30 mks ralys to about 5000 mks ralys.

[0091] In one or more examples, the perforating includes defining a plurality of perforations 130 on the first major exposed surface 116 such that the perforations penetrate the coating 140 and at least a portion of the scrim 120. In another example, the perforating includes defining a plurality of perforations 130 on the first major exposed surface 116 such that the perforations penetrate the coating 140, the scrim 120, and a least a portion of the substrate 110.

[0092] In another example, a method for manufacturing an acoustic wall panel 100 includes providing a substrate 110 having a first major surface 112 opposite a second major surface 114 and a coating 140 over the first major surface 112, the coating 140 defining a first major exposed surface 116.

[0093] The method further includes positioning a perforation roller tool having a plurality of pins against the coating 140 of the first major surface 112, applying pressure to the perforation roller tool, and passing the perforation roller tool over at least a portion of the first major exposed surface 116 defined by the coating 140 to perforate the coating 140. Perforating advantageously allows for airflow through the coating composition, thus providing desirable acoustic properties. Upon completion of perforation, the acoustic wall panel 100 exhibits an NRC ranging from about 5 to about 80.

[0094] In one or more examples, the passing includes performing a first pass over a first portion of the first major exposed surface 116 and performing a second pass over a second portion of the first maj or exposed surface 116 that is offset from the first portion of the first maj or exposed surface 116.

[0095] In one example, the passing yields a plurality of perforations 130 that are present in a perforation density ranging from about 10 perforation / in2to about 600 perforation / in2. In another example, the passing yields a plurality7of perforations 130 having an average diameter ranging from about 0.1mm to about 1mm. in yet another example, the passing yields a plurality of perforations 130 having an average depth ranging from about 0. 1mm to about 4mm.

[0096] In one or more examples, the passing includes performing a series of passes over first major exposed surface 116 such that an irregular pattern of perforations is defined across the first major exposed surface 116. The visually random or irregular pattern results in a pin population that varies across the first major exposed surface 116.

[0097] Also disclosed is a method for forming an acoustic wall covering system 200 as shown in Figure 3 and Figure 4. The wall covering system 200 includes a plurality of acoustic wall panels 202 positioned adjacent each other, joined along a plurality7of seams 215, to define a first major exposed surface 216. see Figure 4.

[0098] In one or more examples, each acoustic wall panel 202' of the plurality of acoustic wall panels 202 may have a panel thickness t4 as measured from the first major exposed surface 216 to the second major exposed surface 218. The panel thickness ty may range from about 0.25 inch to about 1.0 inch - including all values and sub-ranges there-between. The first major exposed surface 216 may be the same surface as the first major surface 212 or may be defined by a scrim 220 or coating 230 as described below.

[0099] Each substrate 210 of the plurality7of acoustic wall panels 200 may have a body thickness ts that extends from the first major surface 212 to the second major surface 214. The body thickness ts may range from about 0.25 inch to about 1 inch - including all values and sub-ranges therebetween.

[0100] In one or more examples, the method includes positioning a substrate 210 adjacent another substrate 210 such that a seam 215' is defined between the acoustic wall panels 202 or substrates 210. The positioning may include fastening each substrate 210 to a wall stud 9, see Figure 8.

[0101] In one or more examples, the method further includes applying a seam-filling material to the seam 215' . The seam-filling material, or joint compound, is configured to be applied to each seam 215' of the plurality of seams 215 of the wall covering system 200. The seam-filling material is configured to couple or join two acoustic wall panels 202' to each other. In one example, the seam-filling material includes gypsum plaster. In another example, the seam-filling material is free from perforations.

[0102] In one or more examples, the method further includes applying a coating composition over the substrates 210 and the seam-filling material to yield a coating 240. The coating 240 may be applied in any amount needed to sufficiently achieve desired aesthetic and acoustic properties. In one example, the coating 240 is applied in an amount ranging from about 40 g / ft2to about 60 g / ft2- including all values and sub-ranges there-between.

[0103] In one or more examples, the method includes perforating at least a portion of the first major exposed surface 216. Perforating advantageously allows for airflow through the coating composition, thus providing desirable acoustic properties. The perforating may include positioning a perforation roller tool having a plurality of pins against the coating 240 defining the first major exposed surface 216, applying pressure to the perforation roller tool, and passing the perforation roller tool over at least a portion of the first major exposed surface 216.

[0104] In one or more examples, the perforating includes passing the perforation roller tool over the first major exposed surface 216 at least two times, wherein each pass is performed at an offset position on the first major exposed surface 216 such that none of the perforations overlap. In another example, the perforating includes defining a plurality of perforations 230 in the coating 240 and at least a portion of one of the first substrate and the second substrate of the plurality' of acoustic wall panels 202. In another example, the perforating includes performing a series of offset passes over the first major exposed surface 216 to yield an irregular pattern of perforations across the first major exposed surface 216.

[0105] Referring to Figures 5 to 7. the method may be used to manufacture an acoustic wall panel 1 1100 having a tapered or beveled edge and related acoustic wall covering system 11200. The acoustic wall panel 11100 includes a substrate 11110 having a first major surface 11112 opposite a second major surface 11114. The acoustic wall panel 11100 has a length and a width, the length ranging from about 1 ft. to about 8ft and the width ranging from about 1 ft. to about 4 ft, as further described below.

[0106] Still referring to FIG. 5, the acoustic wall panel 11100 defines a central portion 11102, a beveled portion 11104, and an edge portion 11106. The central portion 11102 is substantially centered within the acoustic wall panel 11100 with the beveled portion 11104 defining a penmeter about the central portion 11102, and the edge portion 11106 defines a perimeter about the beveled portion 11104, also defining a width and length of the acoustic w all panel 11100 as described below.

[0107] The central portion 11102 has a length Lcas measured by the distance between a first central edge 11102a and a second central edge 1 1102b. In one example, the length Lcis about 0. 10 inches to about 12 inches. The central portion 11102 has a width Wcas measured by the distance between a third central edge 11102c and a fourth central edge 11102d. In one example, the width Wcis about 0.1 inches to about 12 inches. In one non-limiting example, the length Lcis approximately twice the width Wc.

[0108] The beveled portion 11104 defines a perimeter about the central portion 11102. In one example, the bevel of the beveled portion 11104 is about 1 / 16’'. The beveled portion 11104 has a length Lb as measured by the distance between a first beveled edge 1104a and a second beveled edge 11104b. In one example, the length Lb is about 12 inches to about 96 inches. The beveled portion 1 1104 has a width Wb as measured by the distance between a third beveled edge 11104c and a fourth beveled edge 11104d. In one example, the width Wb is about 12 inches to about 48 inches. In one non-limiting example, the length Lb is approximately twice the width Wb.

[0109] The edge portion 11106 defines a perimeter about the beveled portion 11104. The edge portion 11106 has a length Leas measured by the distance between a first side 11106a and a second side 11106b. In one example, the length Le is about 12 inches to about 96 inches. The edge portion 11106 has a width Weas measured by the distance betw een a third side 11106c and a fourth side 11106d. In one example, the width Weis about 0.1 inches to about 3 inches. In one non-limiting example, the length Leis approximately twice the width We.

[0110] Referring to Figures 6 and 7, the method may be used to form an acoustic wall covering system 11200. The acoustic wall covering system 11200 includes a plurality7of acoustic w all panels 11202 as disclosed herein. The plurality of acoustic wall panels 11202 are configured to be positioned adjacent each other so as to define a plurality of seams 11215 between each acoustic panel 11202' of the plurality of acoustic w all panels 11202.[OHl] In one example, each acoustic panel 11202' of the plurality of acoustic w all panels 11202 includes a substrate 11210 having a first major surface 11212 opposite a second major surface 11214. The substrate 11210 is defined by its airflow resistance. The unit of measure MKS rayls (Pa s / m) is measured according to the methodology set forth in ASTM C522 ‘'Standard TestMethod for Airflow Resistance of Acoustical Materials. In one example, the substrate is comprised of a material that is non-acoustic, meaning its airflow resistance is beyond the airflow resistance required to be an acoustic material. Examples of materials that are non-acoustic include metals, ceramics, composites, granite, wood, and other materials have non-acoustic properties. In one example, the substrate 11210 is comprised of a material having an airflow resistance of less than about 300 mks rayls.

[0112] Still referring to Figures 6 and 7, each acoustic panel 11202' of the plurality of acoustic wall panels 11202 may have a panel thickness t4 as measured from the first major exposed surface 11216 to the second major exposed surface 11218. The panel thickness t4 may range from about 0.25 inch to about 1.0 inch - including all values and sub-ranges there-between. The first major exposed surface 11216 may be the same surface as the first major surface 11212 or may be defined by a scrim 11220 or coating 11240 as described below.

[0113] The substrate 11210 may have a body thickness t5 that extends from the first major surface 11112 to the second major surface 11214. The body thickness t5 may range from about 0.25 inch to about 1 inch - including all values and sub-ranges there-between.

[0114] In one or more examples, the substrate 11210 includes a plurality of perforations 11230. The plurality of perforations 1 1230 extend from the first major surface 11212 to the second major surface 11214 such that they extend through an entirety of the thickness of the substrate 11210. The number of perforations of the plurality of perforations 11230 is selectively designed to yield desired material properties. For example, the plurality of perforations 11230 is determined by the overall surface area and dimensions of the substrate 1 1210, including length, width, and thickness of the substrate 11210. In another aspect, the plurality7of perforations 11230 is determined by the material properties of the substrate 11210. For example, a substrate 11210 material having lower porosity and less airflow resistance will require less perforations than a material having higher porosity and more airflow.

[0115] In one example, the plurality of perforations 11230 are present in a perforation density ranging from about 10 perforation / in2to about 600 perforation / in2- including all values and subranges there-between.

[0116] The plurality of perforations 11230 have predetermined dimensions, such as diameter and shape, needed for the desired material properties. In one example, each perforation 11132 of the plurality of perforations 11230 has the same dimensions. In another example, the plurality of perforations 11230 includes perforations of various dimensions. In one example, the plurality7of perforations 11230 have an average diameter ranging from about 50 mils to about 500 mils- including all values and sub-ranges there-between.

[0117] Each acoustic panel 11202’ of the system 11200 and each substrate 11210 is further characterized by their acoustic properties. In one example, the substrate 11210 exhibits an NRC value ranging from about 5 to about 80, selectively controlled by the number and size of the perforations. In another example, the substrate 11210 exhibits a CAC value above 20.

[0118] Referring to Figure 2, each acoustic panel 11202' of the system 11200 includes a scrim 11220 having a first major scrim surface 11222 opposite a second major scrim surface 11224. In one example, the scrim 11220 is coupled to the substrate 1210 such that the second major scrim surface 11224 is adhered to the first major surface 1 1212 of the substrate 11210. The scrim 11220 is adhered to the substrate 11210 with an adhesive. In one example, the adhesive includes polyvinyl acetate emulsion.

[0119] The scrim 11220 of each acoustic panel 11202' of the system 11200 is comprised of a fibrous material selected from one or more of fiberglass, mineral wool, and combinations thereof. In one example, the scrim 11220 has an airflow resistance from about 300 mks rayls to about 2000 mks rayls - including all values and sub-ranges there-between. Each acoustic panel 11202' of the system 11200 may include an unfilled scrim or a filled scrim based upon the desired application. In one example, the scrim 1 1220 is a filled scrim having a filler material selected from calcium carbonate, aluminum trihydrate, and combinations thereof. In another example, the scrim 11220 is an unfilled scrim.

[0120] Still referring to Figure 6 and Figure 7, the acoustic wall covering system 11200 includes a seam-filling material. The seam-filling material, or joint compound, is configured to be applied to each seam 11215' of the plurality of seams 11215. The seam-filling material is configured to couple or join two acoustic wall panels 205' to each other. In one example, the seam-filling material includes gypsum plaster.

[0121] Referring to Figure 7, in one or more examples, the acoustic wall covering system 11200 includes a coating 11240 configured to be applied to the plurality of acoustic wall panels 1 1202 and the seam-filling material over the plurality of seams 11215. In one example, each acoustic panel 11202' of the system 11200 includes coating 11240. In one example, the coating 11240 is applied at a thickness t6 in an amount ranging from about 40 g / ft2to about 60 g / ft2- including all values and sub-ranges there-between. The coating 11240 may be a white coating, a deep base coating having a light reflectance from about 40 to about 70, or an ultra-deep base coating having a light reflectance of about 40. The coating 11240 may be characterized by its hiding power, wherein a perfect hiding power value is 1. In one example, the coating 11240 configured to be applied demonstrates a hiding power of about 0.99.

[0122] In one or more examples, at least two coatings 11240 are configured to be applied to the plurality of acoustic wall panels 11202 and the seam-filling material of plurality of seams 11215 of the acoustic wall covering system 1 1200. In another example, at least three coatings 11240 are configured to be applied to the plurality of acoustic wall panels 11202 and the seam-filling material of the acoustic wall covering system 11200. In yet another example, at least four coatings 11240 are configured to be applied to the plurality of acoustic wall panels 11202 and the seam-filling material if the acoustic wall covering system 11200.

[0123] The coating 11240 may be a paint having a pigment blend and a binder. In one example, the coating has a pigment-to-binder is from about 5 to about 20. In one example, the binder includes vinyl acrylic polymer. In another example, the pigment blend includes two or more of calcium carbonate, titanium dioxide, calcined diatomaceous earth, and aluminum hydroxide.

[0124] In one or more examples, the coating 11240 includes titanium dioxide present at a concentration of about 0.1 wt. % to about 15 wt. %, from about 0.5 wt. % to about 10 wt. %, or from about 1 wt. % to about 8 wt. %, based upon the dry weight of the composition.

[0125] In one or more examples, the coating 11240 includes calcined diatomaceous earth present in an amount from about 3 wt. % to about 20 wt. %, from about 5 wt. % to about 17.5 wt. %, or from about 7.5 wt. % to about 15 wt. %, based on the dry w eight of the composition.

[0126] In one or more examples, the coating 11240 includes aluminum hydroxide present in an amount from about 3 wt. % to about 20 wt. %, from about 5 wt. % to about 18 wt. %, or from about 10 wt. % to about 15 wt. %, based on the dry weight of the composition.

[0127] In one or more examples, the coating 11240 includes calcium carbonate present in an amount from about 20 wt. % to about 60 wt. %, from about 25 wt. % to about 35 wt. %, or from about 27.0 wt. % to about 32.5 wt. %, based on the dry weight of the composition.

[0128] In one or more examples, the coating 11240 includes one or more of a defoamer, humectant, clay, wetting and dispersing additive, calcined extender, hydrophobic polymer emulsion, biocide, or precipitated synthetic silicate.

[0129] Each acoustic panel 11202' of the plurality of acoustic w all panels 11202 defines a central portion 11204, a beveled portion 11206. and an edge portion 11208. The central portion 11204 is substantially centered within the acoustic panel 1202' with the beveled portion 11206 defining a perimeter about the central portion 11204, and the edge portion 11208 defines a perimeter about the beveled portion 11206 , also defining a width and length of the acoustic panel 11100 as described below.

[0130] The central portion 11204 has a length Lcas measured by the distance between a first central edge 11204a and a second central edge 11204b. In one example, the length Lc is about 0. 10inches to about 1 inches. The central portion 11204 has a width Wcas measured by the distance between a third central edge 11204c and a fourth central edge 11204d. In one example, the width Wcis about 12 inches to about 48 inches. In one non-limiting example, the length Lcis approximately twice the width Wc.

[0131] The beveled portion 11206 defines a perimeter about the central portion 11204. In one example, the bevel of the beveled portion 11206 is about 1 / 16’'. The beveled portion 11206 has a length Lb as measured by the distance between a first beveled edge 11104a and a second beveled edge 11104b. In one example, the length Lb is about 122 inches to about 48 inches. The beveled portion 11206 has a width Wb as measured by the distance between a third beveled edge 11104c and a fourth beveled edge 1104d. In one example, the width Wb is about 12 inches to about 48 inches. In one non-limiting example, the length Lb is approximately twice the width Wb.

[0132] The edge portion 11208 defines a perimeter about the beveled portion 11206. The edge portion 11208 has a length Le as measured by the distance between a first side 11208a and a second side 11208b. In one example, the length Le is about 12 inches to about 48 inches. The edge portion 11208 has a width We as measured by the distance between a third side 11208c and a fourth side 11208d. In one example, the width We is about 0.1 inches to about 3 inches. In one non-limiting example, the length Leis approximately twice to the width We.

[0133] The acoustic wall panel 100, 11100 and substrate 110, 11110 manufactured by the method are further characterized by their acoustic properties. NRC is a measure of sound energy absorption of a material. An NRC rating of 0 is a perfect sound reflection material. An NRC rating of 1 is a perfect sound absorption material. CAC is a measure for rating the performance of a ceiling material as a barrier to block airborne sound transmission through the material to / from the plenum above the ceiling. In one example, the acoustic wall panel 100, 11100 exhibits an NRC value ranging from about 5 to about 80.

[0134] The acoustic wall panel 100, 11100 may be further characterized by its Sound Transmission Coefficient (STC). In one example, the acoustic wall panel 100, 11100 exhibits an STC value ranging from about 25 to about 75.

[0135] The substrate 110, 210, 11110, 11210 may be characterized by its physical properties, including airflow resistance, porosity, and skeletal density. The unit of measure MKS rayls (Pa s / m) is measured according to the methodology set forth in ASTM C522 ‘‘Standard Test Method for Airflow Resistance of Acoustical Materials. In one example, the substrate exhibits an airflow resistance from about 30 mks ralys to about 200000 mks ralys inch - including all values and sub-ranges there-between.

[0136] In one or more examples, the substrate 110, 210, 11110, 11210 has a porosity ranging from about 70.0 % to about 82.0 %- including all values and sub-ranges there-between. In another example, the substrate 110, 210, 1 1110, 11210 has a porosity ranging from about 72.0 % to about 80.0 %- including all values and sub-ranges there-between. In another example, the substrate 110, 210, 11110, 11210 has a porosity ranging from about 72.0 % to about 78.0 %- including all values and sub-ranges there-between. In yet another example, the substrate 210 has a porosity ranging from about 74.0 % to about 78.0 %- including all values and sub-ranges there-between. In a further example, the substrate 210 has a porosity ranging from about 75.0 % to about 77.0 %- including all values and sub-ranges there-between.

[0137] In one or more examples, the substrate 110, 210, 11110, 11210 has a skeletal density ranging from about 1 g / cc to about 2.5 g / cc inch - including all values and sub-ranges therebetween. In another example, the substrate 110, 210, 11110, 11210 has a skeletal density ranging from about 1.2 g / cc to about 2.4 g / cc inch - including all values and sub-ranges there-between. In another example, the substrate 110, 210, 11110, 11210 has a skeletal density' ranging from about 1.6 g / cc to about 2.2 g / cc inch - including all values and sub-ranges there-between.

[0138] The skeletal density and porosity, along with the disclosed composition, advantageously yield an acoustic wall panel 100 having high impact resistance. In one example, the acoustic wall panel 100 exhibits an impact resistance of about 0.040” to about 0.1” - including all values and sub-ranges there-between - when tested via ball impact testing to determine durability per ASTM D1037-99 Standard Test Methods for Evaluating Properties of Wood-Base Fiber and Particle Panel Materials and ASTM C 367-99 Standard Test Methods for Strength Properties of Prefabricated Architectural Acoustical Tile or Lay-In Ceiling Panels.

[0139] Referring to Figure 8, in one or more examples, the present disclosure may be implemented in a acoustic wall system 1. In one example, the present disclosure includes a acoustic wall system 1 comprising one or more of the acoustic wall panels 100 or plurality- of acoustic wall panels 202 installed in an interior space 8. Figure 8 shows the acoustic wall panel 100 and system 200 installed, however, the following discussion applies to any configuration disclosed herein.

[0140] The interior space 8 may comprise a floor surface 4, equivalent to ground level as disclosed herein, that is opposite a ceiling surface 5. The interior space 8 may further comprise a cavity space 3 and an active room environment 2. The cavity space 3 may provide afree volume for joists and / or wall stud 9 to be located within the acoustic wall system 1. The active room environment 2 provides room for the acoustic wall occupants during normal intended use of the acoustic wall (e.g., in an office acoustic wall, the active space would be occupied by offices containing computers, lamps, etc.). The floor surface 4 provides for acoustic wall occupants to walk on within the roomenvironment 2. The floor surface 4 may extend into the cavity space 3. The floor surface 4 may be formed a acoustic wall material (e.g., wood flooring, concrete flooring, metal grate, etc.).

[0141] In the installed state, the acoustic wall panels 100, plurality of acoustic wall panels 202, and / or surface covering system 200 may be supported in the interior space 8 by one or more of the wall studs 9 (for acoustic wall panels 100 that function as wall panels) and / or one or more of the ceiling joists (for acoustic wall panels 100 that function as ceiling panels - not pictured). In the installed state, the plurality of acoustic wall panels 100 supported by the wall studs 9 may form a wall surface 50. In the installed state, the plurality of acoustic wall panels 100 supported by the ceiling joists may form a ceiling surface 5.

[0142] The plurality of wall studs 9 may be arranged substantially parallel to each other. The plurality of wall studs 9 may be offset from each other by a distance Dws of about 16 inches - as measured on center from each adjacent wall stud 9. The distance Dws between wall studs 9 may provide for an open cavity volume 11. The open cavity' volume 11 may be an unoccupied space within the acoustic wall system 1. In other embodiments, insulation may be installed into the open cavity volume 11 - non-limiting examples of insulation include sound insulation, thermal insulation, and combinations thereto.

[0143] The wall studs 9 may be an elongated body having a substantially vertical orientation - extending in a direction that spans between the floor surface 4 and the ceiling surface 5. Depending on the room layout design, the wall studs 9 may be oriented orthogonal to the floor surface 4 - i.e., resulting in a wall surface 50 that is completely vertical (also referred to as a “vertical wall surface" 50). In other embodiments, the wall studs 9 may be oriented at an angle between about 46° to about 89° relative to the floor surface 4 - i.e., resulting in a wall surface 50 that is slanted (also referred to as a “slanted wall surface” 50).

[0144] Depending on the room layout design, the ceiling surface 5 may be substantially parallel to the floor surface 4 - i.e., resulting in a ceiling surface 5 that is completely horizontal (also referred to as a “horizontal ceiling surface” 5). In other embodiments, the ceiling surface 5 may be oriented at an angle between about 1° to about 44° relative to the floor surface 4 - i.e., resulting in a ceiling surface 5 that is slanted (also referred to as a “slanted ceiling surface” 5).

[0145] The cavity space 3 may exist behind each one of the plurality of acoustic wall panels 202. The active room environment 2 may exists in front of each one of the plurality of acoustic wall panels 202. The first major exposed surface 116 of each acoustic wall panel 100 may face the active room environment 2. The second major exposed surface 118 of each acoustic wall panel 100 may face the cavity space 3. As discussed further herein, the acoustic wall panels 100 of the presentinvention have airflow properties required for the acoustic wall panels 100 to functional as acoustical acoustic wall panels - as discussed further herein.

[0146] In a non-limiting embodiment, the acoustic wall panels 100 may be supported by the one or more of the wall studs 9 using a mechanical fastener (e.g., screw), adhesive, or combinations thereto. In a non-limiting embodiment, the acoustic wall panels 100 may be support by the one or more ceiling joists using a mechanical fastener (e.g., screw), adhesive, or combinations thereof.

[0147] Each of the acoustic wall panels 100 may be positioned within acoustic wall system 1 such that at least one of the side exposed surfaces 113 is located adjacent to the floor surface 4. Specifically, the first side surface 113a (or second side surface 113b) may be located adjacent to the floor surface 4 - whereby in such arrangement, the wall acoustic wall panel 100 is vertically oriented in a sideways manner (not pictured). The wall acoustic wall panel 100 vertically oriented in the sideways manner may comprise the third side surface 113c and the fourth side surface 113d being substantially parallel to the elongated body of the wall studs 9 - whereby each one of the third side surface 113c and / or fourth side surface 113d may overlap with a single wall stud 9. The wall acoustic wall panel 100 vertically oriented in the sideways manner may comprise the first side surface 113a and the second side surface 113b being substantially orthogonal to the elongated body of the wall studs 9 - whereby each one of the first side surface 113a and / or second side surface 113b may overlap with a plurality of wall studs 9.

[0148] In other embodiments, each of the acoustic wall panels 100 may be positioned within acoustic wall system 1 such that at least one of the side surfaces 113 is located adjacent to the floor surface 4 such that the third side surface 113c (or fourth side surface 113d) may be located adjacent to the floor surface 4 - whereby in such arrangement, the w all acoustic wall panel 100 is vertically oriented in an upstanding manner. The wall acoustic wall panel 100 vertically oriented in the upstanding manner may comprise the first side surface 113a and the second side surface 113b being substantially parallel to the elongated body of the wall studs 9 - whereby each one of the first side surface 113a and / or second side surface 113b may overlap with a single wall stud 9. The wall panel 100 vertically oriented in the upstanding manner may comprise the third side surface 113c and the fourth side surface 113d being substantially orthogonal to the elongated body of the wall studs 9 - whereby each one of the third side surface 113c and / or fourth side surface 113d may overlap with a plurality of w all studs 9.

[0149] In the installed state, the acoustic wall panel 100 may be secured to one or more of the wall studs 9 such that the acoustic wall panel 100 is located from the floor surface 4 by a panel -floor distance DPF. The panel-floor distance DPF may be determined by the vertical distance spanning between the floor surface 4 and the most-proximate point on the acoustic wall panel 100 from thefloor surface 4. The panel-floor distance DPF may range from zero to about 7 feet - including all distances and sub-ranges there-between. The panel-floor distance DPF may range from zero to about 6 feet - including all distances and sub-ranges there-between. When the panel-floor distance DPF is zero, the acoustic wall panel 100 may be in direct contact with the floor surface 4. In some embodiments, the panel-floor distance DPF is less than about 6 feet.

[0150] In another aspect, Figure 8 demonstrates that a first acoustic wall panel 100a and a second acoustic wall panel 100b may be positioned adjacent to each other, whereby a panel seam 215' is located where the first side surface 113a of the first acoustic wall panel 100a is located adjacent to the second side surface 113b of the second acoustic w all panel 100b.

[0151] Figure 28 is another example of the panel configuration of the building system of Figure 8. As shown in Figure 28, the panels may be positioned such that they are offset from each other. This offset arrangement advantageously reduces the risk of visual effects from seams lining up between panels.

[0152] In other embodiments, the acoustic w all panel 100 may also be installed such that it forms a ceiling surface (not pictured) and / or be position above the panel-floor distance DPF.

[0153] Furthermore, the disclosed plurality of acoustic wall panels 202 of the surface covering system 200 includes a first acoustic wall panel positioned betw een ground level and up to 7ft above ground level. The plurality of acoustic wall panels 202 further includes a second acoustic wall panel positioned adjacent the first acoustic wall panel and more than 7ft above ground level (not shown). The panels are defined such that the first acoustic wall panel has a first skeletal density and the second acoustic wall panel has a second skeletal density, and the first skeletal density is higher than the second skeletal density. Furthermore, the first acoustic wall panel has a higher impact resistance than the second acoustic w all panel.

[0154] A perforation roller tool 1000 is illustrated in Figure 9. The perforation roller tool 1000 comprises a handle 1100, a roller assembly 1200, and a mount 1300 connecting the roller assembly 1200 to the handle 1100. The handle 1100 comprises an elongate wood pole, but can be comprised of any suitable material, such as aluminium and / or plastic, for example, and can comprise any suitable configuration. The pole is 5 feet long, for example, but can have any suitable length, such as 1 foot. 2 feet, 3 feet, 4 feet, 6 feet, 7 feet, or between 1 foot and 7 feet, for example, and can be grasped by a user using one hand or two hands depending on the circumstances. The roller assembly 1200 comprises a frame including base 1210 and lateral plates 1220 extending from the base 1210. Each lateral plate 1220 is fastened to the base 1210 by one or more fasteners, but can be attached to the base 1210 in any suitable manner, such as by welding, for example. In other embodiments, one or both of the lateral plates 1220 are formed integrally with the base 1210. Themount 1300 comprises a flange fastened to the base 1210 by one or more fasteners, but could be attached to the base 1210 in any suitable manner, such as by welding, for example. The mount 1300 comprises a compression collar 1310 in which a distal end of the handle 1100 is received. The compression collar 1310 is clamped tightly onto the handle 1100 by screws 1320 which can be loosened to release and replace the handle 1100. In another example, the compression collar 1310 is pivotably locked to the handle 1100. In yet another example, the compression collar 1310 is threadedly engageable with the handle 1100.

[0155] Referring again to Figure 10, the roller assembly 1200 further comprises a roller 1250. The roller 1250 has a lateral width of 12 inches, for example, but can have any suitable lateral width such as 2 inches, 6 inches, 18 inches, 24 inches, 30 inches, or between 2 inches and 30 inches, for example. The roller 1250 comprises a cylindrical frame 1252 closely received between the lateral plates 1220. The cylindrical frame 1252 is comprised of metal, such as stainless steel, aluminum, and / or brass, for example, but can be comprised of any suitable material. The roller 1250 further comprises pins 1254 extending from the cylindrical frame 1252. The pins 1254 are mounted to the cylindrical frame 1252 and are comprised of metal, such as stainless steel, aluminum, and / or brass, for example, but can be comprised of any suitable material. The pins 1254 are w elded and / or soldered to the cylindrical frame 1252, but can be affixed to the cylindrical frame 1252 in any suitable manner. In various embodiments, the cylindrical frame 1252 comprises an array of apertures defined, or drilled, therein which are each configured to receive a pin 1254 therein and align the pin 1254 relative to cylindrical frame 1252 such that the pin 1254 extends orthogonally, or at least substantially orthogonally, relative to the outer surface of the cylindrical frame 1252 surrounding the pin 1254. In various embodiments, the pins 1254 extend at acute angles relative to the outer surface, or face, of the roller 1250.

[0156] Referring again to Figure 10, the cylindrical frame 1252 defines an aperture 1253 therein. Referring to Figure 10A, the roller 1250 further comprises end plates 1260 affixed to the cylindrical frame 1252 that enclose, or at least substantially enclose, the aperture 1253. The end plates 1260 are welded to the cylindrical frame 1252, but can be attached to the cylindrical frame 1252 in any suitable manner, such as with fasteners, for example. Each end plate 1260 comprises a central aperture defined therein and a bearing 1270 supported in the central aperture. Each bearing 1270 comprises a bearing mount affixed to an end plate 1260 and a rotatable inner portion rotatably supported by the bearing mount. The bearings 1270 comprise needle bearings, for example, that are capable of resisting both radial compression forces and axial thrust forces. In various embodiments, the bearings comprise ball bearings, for example, and / or any other suitable bearing. The rotatable inner portions of the bearings 1270 are configured to receive rods extending fromthe lateral plates 1220 such that, when the roller assembly 1200 is rolled against an acoustic wall panel, the roller 1250 can rotate relative to the rods about an axis of rotation 1251 (Figure 10).

[0157] In various embodiments, the roller assembly 1200 comprises a spindle mounted to the lateral plates 1220 that rotatably supports a roller 1250. In various embodiments, the spindle is attached to the lateral plates 1220 such that the spindle does not rotate relative to the lateral plates 1220. Rather, referring to Figure 10, the spindle is closely received within the aperture 1253 such that the roller 1250 can rotate relative to the spindle about an axis of rotation 1251. In other embodiments, the spindle is rotatable relative to the lateral plates 1220. In at least one such embodiment, the spindle is tightly received within the aperture 1253 such that the spindle and the roller 1250 rotate together.

[0158] Referring again to Figure 10, the pins 1254 are arranged in an array of rows about the periphery' of the cylindrical frame 1252. For instance, the pins 1254 are arranged in cylindrical rows 1258 and lateral rows 1259. Within each cylindrical row 1258, the pins 1254 are evenly spaced, or at least substantially evenly spaced, about the perimeter of the cylindrical frame 1252. The pins 1254 within a cylindrical row 1258 extend radially outwardly and point in different radial directions. In at least one embodiment, the pins 1254 extend in different radial directions along radial axes separated by 1.8 degrees, for example, although other embodiments are envisioned in which the pins 1254 extend along radial axes separated by 1.5 degrees or 2.0 degrees, for example, or between 1 degree and 3 degrees, for example. That said, any suitable radial separation could be used. The pins 1254 within a lateral row 1259 are evenly spaced, or at least substantially evenly spaced, along 0.25 inch centerlines within the lateral row 1259, for example, although other embodiments are envisioned in which the pins 1254 are spaced along 0.125 inch centerlines or 0.50 inch centerlines, for example, or between 0. 125 inch centerlines and 0.50 inch centerlines, for example. That said, any suitable spacing could be used.

[0159] Referring again to Figure 10, each pin 1254 comprises a base attached to the cylindrical frame 1252, an elongate shaft, and a tip 1255. The elongate shaft comprises a cylindrical configuration having a constant diameter, or an least substantially constant diameter, along the length thereof, for example. In at least one embodiment, the pins 1254 have a 0.6 mm diameter, for example. In other embodiments, the pins 1254 have a 0.1 mm diameter, a 1.0 mm diameter, and / or a diameter between 0.1 mm and 1.0 mm, for example. In various embodiments, the pins 1254 have a square cross-section, and / or any other suitable cross-section. The tips 1255 of the pins 1254 are configured to penetrate and perforate an acoustic wall panel, for example. In one example, ach tip 1255 comprises a tapered configuration extending radially along a length that terminates in a sharp point. As a result, the tips 1255 can easily penetrate an acoustic wall panel,for example. The radial length of each tip 1255 is equal to or greater than the diameter of the pin shaft, for example. In at least one embodiment, the radial length of each tip 1255 is equal to twice the diameter of the pin shaft, for example. In other embodiments, the radial ends of the tips 1255 are rounded, or radiused. In such embodiments, the pins 1254 may be less likely to tear the wall substrate, for example. In another example, the pins 1254 may have a blunt tip that has a diameter less than the diameter of the pin shaft, but greater than the diameter of the tips 1255 having a pointed configuration. In a further example, the pins 1254 have no tip. and the diameter of the portion penetrating the panels is equal to the diameter of the shaft.

[0160] Referring again to Figure 10, the roller assembly 1250 further comprises an outer cover, or sheath, 1256 extending around the circumference of the cylindrical frame 1252. The outer cover 1256 comprises an aperture defined therein and the cylindrical frame 1252 is closely received within the aperture. The outer cover 1256 has an outer surface, or face, 1257 and defines an outer diameter of 2.5 inches, for example, but can have any suitable diameter, such as 1.0 inch, 4.0 inches, or between 1.0 and 4.0 inches, for example. The outer cover 1256 further comprises pin holes defined therein through which the pins 1254 extend. The pins 1254 are longer than the thickness of the outer cover 1256 such that the pin tips 1255 protrude from the outer surface 1257 of the outer cover 1256. The pins 1254 extend 1.5 mm from the outer surface 1257, for example, but can extend any suitable distance from the outer surface 1257, such as 0. 1 mm, 4.0 mm, and / or between 0. 1 mm and 4.0 mm, for example. Notably, only the pin tips 1255 of the pins 1254 extend from the outer surface 1257, and not the elongate shafts of the pins 1254. As a result, only the tapered portion of the pins 1254 extend from the outer surface 1257. Such an arrangement reduces the possibility of the roller assembly 1250 becoming stuck in a wall substrate, for example. In other embodiments, however, an untapered portion of the pins 1254 can also extend from the outer surface 1257. Such an arrangement can reduce the possibility of the pins 1254 being bent during use, for example.

[0161] Further to the above, the pins 1254 of the roller assembly 1250 are arranged in an ordered, repeating pattern. Within each cylindrical row 1258, gaps are present between adjacent pins 1254 in the cylindrical row 1258 and the cylindrical rows 1258 are clocked such that the pins 1254 of one cylindrical row 1258 are aligned with, and centered relative to, the gaps in an adjacent cylindrical row 1258, as illustrated in Figure 10. Similarly, within each lateral row 1259, gaps are present between adjacent pins 1254 in the lateral row 1259 and the lateral rows 1259 are laterally shifted, or offset, such that the pins 1254 of one lateral row 1259 are aligned with, and centered relative to, the gaps in an adjacent lateral row 1259, as also illustrated in Figure 10. Such an arrangement can create a regular, repeating pattern of perforations or holes in a wall substratewhich can be desirable in some circumstances. In other circumstances, it may be desirable for the perforations or holes in a wall substrate to be less regular, irregular, or visually random. To create such an effect, in at least one embodiment, the cylindrical rows 1258 are clocked such that the pins 1254 of a cylindrical row 1258 are not centered relative to the gaps in an adjacent cylindrical row 1258. Similarly, in at least one embodiment, the lateral rows 1259 can be laterally shifted, or offset, such that the pins 1254 of a lateral row 1259 are not centered relative to the gaps in an adjacent lateral row 1259. Various embodiments are envisioned in which the pins 1254 are arranged in a random manner which can create the random appearance of perforations or holes in an acoustic wall panel, for example.

[0162] Further to the above, referring again to Figure 10, the roller assembly 1250 has 198 lateral rows 1259 with 16 pins in each lateral row 1259 for a total of 3168 pins. That said, other embodiments are envisioned with more pins or less pins. As discussed above, the pins 1254 extend from the outer surface, or face, 1257 of the roller assembly 1250. The pins 1254 are distributed across the outer surface 1257 in a uniform, or an least substantially uniform, manner and, on average, there are 80 pins per square inch (ppsi) measured relative to the outer surface 1257, for example. In various other embodiments, further to the above, the pins 1254 are arranged randomly and there are 80 pins per square inch, on average. In various embodiments, the population of the pins 1254 on the outer surface 1257 is, on average, 1 pin per square inch, 20 pins per square inch, 300 pins per square inch, or between 1 pin per square inch and 300 pins per square inch, for example.

[0163] Further to the above, various embodiments are envisioned in which the pins 1254 are not uniformly distributed across the outer surface 1257. In at least one embodiment, the pin population density varies across the lateral width of the roller 1250. For example, the pin population density continuously varies across the later width of the roller 1250. In at least one such embodiment, the pin population is more dense in the center of the roller 1250 and less dense traversing away from the center of the roller 1250. In such an embodiment, the pin population is most dense at the center of the roller 1250 and least dense at the ends of the roller 1250. In various embodiments, the pin population density at the ends of the roller 1250 is half of the pin population density at the center of the roller 1250, for example. In various other embodiments, the pin population density at the ends of the roller 1250 is one third, one quarter, one eighth, or between one eighth and one half of the pin population density at the center of the roller 1250, for example. In use, the perforation roller tool 1000 may be used to make perforations or holes in an acoustic wall panel during several passes which, in various instances, can overlap one another and. owing to the lower pin population on the ends of the roller 1250, the possibility of creating overly dense populations of perforationsor holes in certain regions of the acoustic wall panel can be reduced.

[0164] In use, the user of the perforation roller tool 1000 can push the pins 1254 into an acoustic wall panel by positioning the roller 1250 against the acoustic wall panel and pushing distally on the handle 1100 to sink the pins 1254 into the acoustic wall panel. The user can push the perforation roller tool 1000 distally until the outer surface 1257 of the roller 1250 comes into contact with the acoustic wall panel. At such point, the user can move the roller 1250 across the face of the acoustic wall panel to create additional perforations or holes in the acoustic wall panel.

[0165] Referring to Figure 9, the perforation roller tool 2000 is similar to the perforation roller tool 1000 in many respects. For instance, the perforation roller tool 2000 comprises a handle 1100 and a mount 1300. The perforation roller tool 2000 further comprises a roller assembly 2200 that is similar to the roller assembly 1200 in many respects. For instance, the roller assembly 2200 comprises a base 1210 and lateral plates 1220 extending from the base 1210. The roller assembly 2200 further comprises a roller 2250 that is similar to the roller 1250 in many respects. Referring to Figure 11, the roller 2250 comprises a cylindrical frame 2252 that is closely received between the lateral plates 1220. The cylindrical frame 2252 is comprised of metal, such as stainless steel, aluminum, and / or brass, for example, but can be comprised of any suitable material. The roller 2250 further comprises pins 2254 extending from the cylindrical frame 2252. The pins 2254 are mounted to the cylindrical frame 2252 and are comprised of metal, such as stainless steel, aluminum, and / or brass, for example, but can be comprised of any suitable material. The pins 2254 are welded and / or soldered to the cylindrical frame 2252, but can be affixed to the cylindrical frame 2252 in any suitable manner. In various embodiments, the cylindrical frame 2252 comprises an array of apertures defined, or drilled, therein which are each configured to receive a pin 2254 therein and align the pin 2254 relative to cylindrical frame 2252 such that the pin 2254 extends orthogonally, or at least substantially orthogonally, relative to the outer surface of the cylindrical frame 2252 surrounding the pin 2254.

[0166] Referring to Figure 11 , the pins 2254 are arranged in an array of rows about the periphery of the cylindrical frame 2252. For instance, the pins 2254 are arranged in cylindrical row s 2258 and lateral rows 2259. Within each cylindrical row72258, the pins 2254 are evenly spaced, or at least substantially evenly spaced, about the perimeter of the cylindrical frame 2252. The pins 2254 within a cylindrical row 2258 extend radially outwardly and point in different radial directions. In at least one embodiment, the pins 2254 extend in different radial directions along radial axes separated by 4.9 degrees, for example, although other embodiments are envisioned in which the pins 2254 extend along radial axes separated by 4 degrees or 6 degrees, for example, or between 3 degrees and 7 degrees, for example. That said, any suitable radial separation could be used. Thepins 2254 within a lateral row 2259 are evenly spaced, or at least substantially evenly spaced, along 0.25 inch centerlines within the lateral row 2259, for example, although other embodiments are envisioned in which the pins 2254 are spaced along 0. 125 inch centerlines or 0.50 inch centerlines, for example, or between 0.125 inch centerlines and 0.50 inch centerlines, for example. That said, any suitable spacing could be used.

[0167] Referring again to Figure 11, each pin 2254 comprises a base attached to the cylindrical frame 2252, an elongate shaft, and a tip 2255. The elongate shaft comprises a cylindrical configuration having a constant diameter, or an least substantially constant diameter, along the length thereof, for example. In at least one embodiment, the pins 2254 have a 0.6 mm diameter, for example. In other embodiments, the pins 2254 have a 0.1 mm diameter, a 1.0 mm diameter, and / or a diameter between 0.1 mm and 1.0 mm, for example. In various embodiments, the pins 2254 have a square cross-section, and / or any other suitable cross-section. The tips 2255 of the pins 2254 are configured to penetrate and perforate an acoustic wall panel, for example. Each tip 2255 comprises a tapered configuration extending radially along a length that terminates in a sharp point. As a result, the tips 2255 can easily penetrate an acoustic wall panel, for example. The radial length of each tip 2255 is equal to or greater than the diameter of the pin shaft, for example. In at least one embodiment, the radial length of each tip 2255 is equal to twice the diameter of the pin shaft, for example. In other embodiments, the radial ends of the tips 2255 are rounded, or radiused. In such embodiments, the pins 2254 may be less likely to tear the acoustic wall panel, for example.

[0168] Referring again to Figure 11. the roller assembly 2250 further comprises an outer cover, or sheath, 2256 extending around the circumference of the cylindrical frame 2252. The outer cover 2256 comprises an aperture defined therein and the cylindrical frame 2252 is closely received within the aperture. The outer cover 2256 has an outer surface, or face, 2257 and defines an outer diameter of 3.0 inches, for example, but can have any suitable diameter, such as 1.0 inch, 5.0 inches, or between 1.0 and 5.0 inches, for example. The outer cover 2256 further comprises pin holes defined therein through which the pins 2254 extend. The pins 2254 are longer than the thickness of the outer cover 2256 such that the pin tips 2255 protrude from the outer surface 2257 of the outer cover 2256. The pins 2254 extend 2.0 mm from the outer surface 2257, for example, but can extend any suitable distance from the outer surface 2257, such as 0. 1 mm, 4.0 mm. and / or between 0.1 mm and 4.0 mm, for example. Notably, only the tapered pin tips 2255 of the pins 2254 extend from the outer surface 2257, and not the elongate shafts of the pins 2254. As a result, only the tapered portion of the pins 2254 extend from the outer surface 2257. Such an arrangement reduces the possibility of the roller assembly 2250 becoming stuck in an acoustic wall panel, for example. In other embodiments, however, an untapered portion of the pins 2254 can also extendfrom the outer surface 2257. Such an arrangement can reduce the possibility of the pins 2254 being bent during use, for example.

[0169] Further to the above, the pins 2254 of the roller assembly 2250 are arranged in an ordered, repeating pattern. Within each cylindrical row 2258, gaps are present between adjacent pins 2254 in the cylindrical row 2258 and the cylindrical rows 2258 are clocked such that the pins 2254 of one cylindrical row 2258 are aligned with, and centered relative to, the gaps in an adjacent cylindrical row 2258, as illustrated in Figure 11. Similarly, within each lateral row 2259. gaps are present between adjacent pins 2254 in the lateral row 2259 and the lateral rows 2259 are laterally shifted, or offset, such that the pins 2254 of one lateral row 2259 are aligned with, and centered relative to, the gaps in an adjacent lateral row 2259, as also illustrated in Figure 11. Such an arrangement can create a regular, repeating pattern of perforations or holes in an acoustic wall panel which can be desirable in some circumstances. In other circumstances, it may be desirable for the perforations or holes in an acoustic wall panel to be less regular, irregular, or visually random. To create such an effect, in at least one embodiment, the cylindrical rows 2258 are clocked such that the pins 2254 of a cylindrical row 2258 are not centered relative to the gaps in an adjacent cylindrical row 2258. Similarly, in at least one embodiment, the lateral rows 2259 can be laterally shifted, or offset, such that the pins 2254 of a lateral row 2259 are not centered relative to the gaps in an adjacent lateral row 2259. Various embodiments are envisioned in which the pins 2254 are arranged in a random manner which can create the random appearance of perforations or holes in an acoustic wall panel, for example.

[0170] Further to the above, referring again to Figure 11, the roller assembly 2250 has 74 lateral rows 2259 with 16 pins in each lateral row 2259 for a total of 1184 pins, for example. That said, other embodiments are envisioned with more pins or less pins. As discussed above, the pins 2254 extend from the outer surface, or face, 2257 of the roller assembly 2250. The pins 2254 are distributed across the outer surface 2257 in a uniform, or an least substantially uniform, manner and, on average, there are 30 pins per square inch (ppsi) measured relative to the outer surface 2257, for example. In various other embodiments, further to the above, the pins 2254 are arranged randomly and there are 30 pins per square inch, on average. In various embodiments, the population density of the pins 2254 on the outer surface 2257 is. on average, 1 pin per square inch, 20 pins per square inch, 300 pins per square inch, or between 1 pin per square inch and 300 pins per square inch, for example.

[0171] Further to the above, various embodiments are envisioned in which the pins 2254 are not uniformly distributed across the outer surface 2257. In at least one embodiment, the pin population density varies across the lateral width of the roller 2250. In at least one such embodiment, the pinpopulation is more dense in the center of the roller 2250 and less dense traversing away from the center of the roller 2250. In such an embodiment, the pin population is most dense at the center of the roller 2250 and least dense at the ends of the roller 2250. In various embodiments, the pin population density at the ends of the roller 2250 is half of the pin population density at the center of the roller 2250, for example. In various other embodiments, the pin population density at the ends of the roller 2250 is one third, one quarter, one eighth, or between one eighth and one half of the pin population density at the center of the roller 2250. for example. In use, the perforation roller tool 2000 may be used to make perforations or holes in an acoustic wall panel during several passes which, in various instances, can overlap one another and, owing to the lower pin population on the ends of the roller 2250, the possibility of creating overly dense populations of perforations or holes in certain regions of the acoustic wall panel can be reduced.

[0172] A perforation roller tool 3000 is illustrated in Figure 12. The perforation roller 3000 comprises a handle and a roller assembly 3200. The roller assembly 3200 comprises a frame including lateral supports 3220 and a threaded rod 3230 extending between and supported by the lateral supports 3220. The threaded rod 3230 comprises a spindle that is locked in position and prevented from rotating relative to the lateral supports 3220 by nuts 3225 and 3235. The roller assembly 3200 further comprises roller elements 3250a, 3250b, 3250c, 3250d, etc., rotatably supported on the threaded rod 3230 extending through apertures defined in the roller elements. The roller elements are not threadably engaged with the threaded rod 3230 and can rotate relative to the threaded rod 3230. The roller elements are arranged in an end-to-end manner, or stack, and the ends 3259 of the roller elements are held in close proximity to one another by end nuts 3240 threadably engaged with the threaded rod 3230. In various instances, the ends 3259 of the roller elements comprise connectors that key the roller elements together such that the roller elements rotate together in use.

[0173] Each roller element comprises a cylindrical frame 3252 and pins 3254 extending therefrom. The cylindrical frame 3252 is comprised of wood or plastic, for example, but can be comprised of any suitable material, and the pins 3254 are embedded in the wood. All of the pins 3254 of the roller element 3250a, for example, have the same diameter and the same length. In at least one embodiment, the pins 3254 have the same diameter when the diameters of the pins 3254 are within a range comprising a nominal diameter that is bounded by +10% of the nominal diameter and -10% of the nominal diameter, for example. In at least one embodiment, the pins 3254 have the same length when the length of the pins 3254 are within a range comprising a nominal length - measured from the surface of the cylindrical frame 3252 - that is bounded by + 10% of the nominal length and -10% of the nominal length, for example.

[0174] Referring again to Figure 12, the pins 3254 of the roller element 3250b, however, are different than the pins 3254 of the roller element 3250a. For instance, the pins 3254 of the roller element 3250b have a different diameter than the pins 3254 of the roller element 3250a and / or a different length than the pins 3254 of the roller element 3250a. In at least one embodiment, the pins 3254 of the roller element 3250b have a different pin diameter when the pin diameter is outside of a range comprising a nominal diameter that is bounded by +10% of the nominal diameter and - 10% of the nominal diameter of the pins 3254 of the roller element 3250a, for example. In at least one embodiment, the pins 3254 of the roller element 3250b have a different pin length when the pin length is outside of a range comprising a nominal length - measured from the surface of the cylindrical frame 3252 of the roller element 3250a - that is bounded by +10% of the nominal length and -10% of the nominal length of the pins 3254 of the roller element 3250a, for example.

[0175] The pins 3254 of the roller elements 3250c and 3250d are the same as the pins 3254 of the roller element 3250b, although, in other embodiments, the pins of the roller element 3250c and / or the roller element 3250d are different than the pins of the roller element 3250b. Moreover, the roller assembly 3200 comprises two roller elements 3250a - one at each end of the roller element stack. However, other embodiments are envisioned in which roller element stack has a roller element 3250a at one end of the roller stack and a roller element 3250b, for example, at the other end of the roller stack.

[0176] In at least one embodiment, further to the above, the pins 3254 of the end roller elements 3250a are narrower than the pins 3254 of the middle roller elements 3250b, 3250c. 3250d, etc. In such an embodiment, the holes made in an acoustic wall panel by the pins 3254 of the end roller elements 3250a can be smaller than the holes made by the pins 3254 of the middle roller elements 3250b, 3250c, 3250d, etc. Moreover, in such an embodiment, less force may be needed to make the holes in an acoustic wall panel at the ends of the roller assembly 3250 than at the middle of the roller assembly 3250 which can make the perforation roller tool 3200 easier to turn when pressed against the acoustic wall panel. Moreover, in at least one embodiment, the pins 3254 of the end roller elements 3250a are shorter than the pins 3254 of the middle roller elements 3250b, 3250c, 3250d, etc. In such an embodiment, the holes made in a wall substrate by the pins 3254 of the end roller elements 3250a can be shallower than the holes made by the pins 3254 of the middle roller elements 3250b, 3250c, 3250d, etc., which can permit the roller assembly 3250 to rock relative to the acoustic wall panel making the perforation roller tool 3200 easier to turn when pressed against the acoustic wall panel. In at least one embodiment, the end roller elements 3250a have less pins 3254 than the middle roller elements 3250b. 3250c, 3250d, etc. In such an embodiment, the roller assembly 3200 will make less holes at the ends thereof than in the middle for a given pass of theperforation roller tool 3000 over an acoustic wall panel. Such an arrangement can be useful where it is possible that two adjacent passes of the perforation roller tool 3200 over the acoustic wall panel may overlap with one another.

[0177] In various embodiments, the advantages discussed above in connection with the roller assembly 3200 can be achieved with the roller assemblies 1200 and 2200 discussed above and / or any of the roller assemblies discussed herein. In at least one embodiment, the roller assembly 1200, for example, has shorter pins 1254 at the ends of the roller 1250 than in the middle of the roller 1250. In at least one embodiment, the roller assembly 1200, for example, has narrower pins 1254 at the ends of the roller 1250 than in the middle of the roller 1250. In at least one embodiment, the roller assembly 1200, for example, has a lower pin population per unit area at the ends of the roller 1250 than in the middle of the roller 1250.

[0178] A perforation roller instrument 4000 is illustrated in Figure 13. The perforation roller instrument 4000 comprises a handle 4100 and a roller assembly 4200. The handle 4100 comprises a shaft 4110 and a grip 4120 mounted to the shaft 4110. The grip 4120 is comprised of plastic, for example, and is sized and configured to be gripped with one hand, if desired. The roller assembly 4200 comprises a frame 4210 and a roller 4250 rotatably supported by the frame 4210. The frame 4210 is welded to the shaft 4110 at mount 4300, but can be connected to the shaft 4110 in any suitable manner, such as by fasteners, for example. The roller 4250 comprises a rotatable spindle 4230 and perforation wheels 4260 mounted to the spindle 4230. The perforation wheels 4260 are welded to the spindle 4230, but could be mounted to the spindle 4230 in any suitable manner. Each perforation wheel 4260 comprises an array of teeth and / or pins extending around the circumference thereof which are sharp enough to penetrate an acoustic wall panel, for example, as described herein. The perforation wheels 4260 are separated by a gap therebetween and are connected to one another by the spindle 4230. In various alternative embodiments, the spindle 4230 is not rotatable and the perforation wheels 4260 can rotate relative to the spindle 4230. In either event, the shaft 4110 of the handle 4100 defines a longitudinal axis and the spindle 4230 defines an axis of rotation that is transverse to the longitudinal axis of the handle 4100. Notably, though, the axis of rotation of the spindle 4230 does not transect the longitudinal axis of the handle 4100; rather, the axis of rotation of the spindle 4230 is offset from, or below, the longitudinal axis of the handle 4100.

[0179] A perforation roller tool 5000 is illustrated in Figure 14. The perforation roller tool 5000 comprises a handle 5100 and a roller assembly 5200. The handle 5100 comprises a shaft 5110, a grip 5120 attached to the shaft 5110, and an offset mount 5130. The shaft 5110 defines a longitudinal handle axis and the offset mount 5130 extends laterally relative to the longitudinal handle axis. The roller assembly 5200 comprises a spindle 5230 and a roller 5250 rotatablysupported by the spindle 5230. The spindle 5230 is integrally formed with the offset mount 5130 and defines an axis of rotation for the roller 5250 that extends transversely to, and intersects with, the longitudinal axis of the handle 5100. The shaft 5110, the offset mount 5130, and the spindle 5230 are comprised of a bent bar, although any suitable arrangement can be used.

[0180] A perforation roller tool 6000 is illustrated in Figure 15. The perforation roller tool 6000 comprises a handle 6100 and a roller assembly 6200. Similar to the perforation roller tool 5000, the handle 6100 of the perforation roller tool 6000 comprises an offset mount 6130 and the roller assembly 6200 comprises a spindle 6230 integral with the offset mount 6130. Also similar to the perforation roller tool, the spindle 6230 and the offset mount 6130 are formed from a bent bar having a round cross-section, for example. The roller assembly 6200 further comprises a roller 6250 rotatably supported by the spindle 6230. The roller 6250 comprises a central core 6252 comprised of plastic, for example, and plastic pins 6254 attached to and extending radially from the plastic central core 6252. The pins 6254 are arranged in annular arrays 6260 extending around the perimeter of the central core 6252. The plastic pins 6254 can be more flexible than steel pins, for example, and can flex to permit the roller 6250 to roll across an acoustic wall panel.

[0181] A perforation roller tool 7000 is illustrated in Figure 16. The perforation roller tool 7000 comprises a handle 7100 and a roller assembly 7200. The handle 7100 comprises a shaft frame 7110 and agrip 7120. The shaft frame 7110 defines a lateral shaft width and the grip 7120 defines a lateral grip width that is wider than the shaft width. The roller assembly 7200 comprises ahead 7220 and a roller 7250 rotatably supported by the head 7220. The roller 7250 comprises lateral rows of pins 7254 that are comprised of brass, for example, but could be comprised of any suitable material. The head 7220 is integrally formed with the shaft frame 7110 and defines a lateral head width that is wider than the lateral shaft width. However, the lateral head width of the head 7220 is equal to or narrower than the lateral grip width of the grip 7120. As a result of the above, the perforation roller tool 7000 can be suitable for perforating wall substrates in the comer of a room, for example. Moreover, the grip 7120 defines a longitudinal axis and the shaft frame 7110 extends upwardly away from the longitudinal axis. The head 7220 comprises lateral plates that extend back downwardly and rotatably support the roller 7250 on a lateral axis that extends transversely to the longitudinal axis. The lateral axis intersects the longitudinal axis, but does not intersect the longitudinal axis in other embodiments. A pocket is defined between the grip 7120 and the head 7220 that is configured to receive part of a user’s hand which allows the user to closely control the perforation roller tool 7000.

[0182] A perforation roller tool 8000 is illustrated in FIG. 17. The perforation roller tool 8000 comprises a handle 8100, a roller assembly 8200, and a mount 8300 connecting the roller assembly8200 to the handle 8100. The handle 8100 comprises a wood grip 8120, for example, and the mount 8300 comprises a metal shaft, or tang, at least partially embedded in the wood grip 8120. In at least one embodiment, the wood grip 8120 is comprised of pine and / or maple, for example, and is easily countourable to create proximal and distal swells 8125 that assist the user of the perforation roller tool 8000 in apply a pushing force and / or a pulling force along a longitudinal axis of the handle 8100. The mount 8300 is comprised of steel, for example, but can be comprised of any suitable material. The roller assembly 8200 comprises a frame attached to the mount 8300 including lateral plates 8220 that rotatably support a roller 8250. The roller 8250 comprises a cylindrical frame 8252 and circumferential rows of cutting blades 8254 attached to and extending from the cylindrical frame. The cutting blades 8254 comprise an elongate cross-section having a longitudinal circumferential width extending partially circumferentially around the cylindrical frame 8252 and a lateral width extending transversely between the lateral plates 8220 where the longitudinal circumferential width is wider than the lateral width. In various embodiments, the longitudinal circumferential width of a cutting blade 8254 is twice its lateral width, for example. In other embodiments, the longitudinal circumferential width of a cutting blade 8254 is more than twice its lateral width.

[0183] Figure 18 illustrates a perforation pattern 12230 created by a perforation roller tool in accordance with at least one embodiment. The perforation pattern 12230 comprises perforations 12130 created in an acoustic wall panel 12202 having a surface 12116 that are created by pins extending from a roller of the perforation roller tool as the roller is rolled over the surface 12116. The pins are arranged on the roller in an irregular manner that gives an appearance of the perforations 12130 of the perforation pattern 12230 being randomly created. In this embodiment, the roller is 8 inches wide and has a 3 inch diameter cylindrical frame where the pins extend radially outwardly from the cylindrical frame. As a result, one revolution of the roller across the surface 12116 creates the perforation pattern 12230 which has a width of 8” and a length of 9.43”. Additional revolutions of the roller in a pass across the surface 12116 of the acoustic wall panel 12202 will create a repeating pattern in 9.43” length segments. That said, a perforation pattern can have any suitable width and length. Notably, the perforation population density in the perforation pattern 12230 is higher near the centerline 12232 of the perforation pattern 12230 than near the lateral edges 12231 of the perforation pattern 12230 owing to a higher pin population density in the center of the roller as compared to the lateral ends of the roller. On average, the perforation pattern 12230 has about 10 perforations per square inch, for example, but can have any suitable perforation population density.

[0184] Figure 19 is a plan view of an acoustic wall panel 13202 having a surface 13116. The surface 13116 has been perforated by five passes 13230 of the roller discussed above in connection with Figure 19. Notably, each pass 13230 creates perforations along a length according to the perforation pattern 12230; however, the passes 13230 overlap one another. More specifically, although the passes 13230 are parallel to one another, the perforation pattern 12230 created by each pass 13230 overlaps an adjacent pass 13230 by 4 inches, or about 4 inches. Even with such an overlap between the passes 13230, the resulting overall perforation pattern does not create a Moire-like pattern.

[0185] Figure 20 is a plan view of an acoustic wall panel 14202 having a surface 14116. The surface 14116 has been perforated by five passes 14230 of the roller discussed above in connection with Figure 19. Notably, each pass 14230 creates perforations along a length according to the perforation pattern 12230; however, the passes 14230 overlap one another. More specifically, although the passes 14230 are parallel to one another, the perforation pattern 12230 created by each pass 14230 overlaps an adjacent pass 14230 by 4 inches, or about 4 inches. Moreover, the passes 14230 are offset horizontally. Such an overall perforation pattern can be created when the initial starting point of a pass is not aligned with the starting points of the other passes. Even with such an overlap and stagger between the passes 14230, the resulting overall perforation pattern does not create a Moire-like pattern.

[0186] Figure 21 is a plan view of an acoustic wall panel 15202 having a surface 15116. The surface 15116 has been perforated by five passes 15230 of the roller discussed above in connection with Figure 19. Notably, each pass 15230 creates perforations along a length according to the perforation pattern 12230; however, the passes 15230 overlap one another. More specifically, although the passes 15230 are parallel to one another, the perforation pattern 12230 created by each pass 15230 overlaps an adjacent pass 15230 by 3 inches, or about 3 inches. Moreover, the passes 15230 are offset honzontally. Such an overall perforation pattern can be created when the initial starting point of a pass is not aligned with the starting points of the other passes. Even with such an overlap and stagger between the passes 15230, the resulting overall perforation pattern does not create a Moire-like pattern.

[0187] Figure 22 is a plan view of an acoustic wall panel 16202 having a surface 16116. The surface 16116 has been perforated by five passes 16230 of the roller discussed above in connection with Figure 19. Notably, each pass 16230 creates perforations along a length according to the perforation pattern 12230: however, the passes 16230 overlap one another. More specifically, although the passes 16230 are parallel to one another, the perforation pattern 12230 created by each pass 16230 overlaps an adjacent pass 16230 by 5 inches, or about 5 inches. Moreover, thepasses 16230 are offset horizontally. Such an overall perforation pattern can be created when the initial starting point of a pass is not aligned with the starting points of the other passes. Even with such an overlap and stagger between the passes 16230, the resulting overall perforation pattern does not create a Moire-like pattern.

[0188] Figure 24 is a plan view of an acoustic wall panel 17202 having a surface 17116. The surface 17116 has been perforated by five passes 17230 of the roller discussed above in connection with Figure 19. Notably, each pass 17230 creates perforations along a length according to the perforation pattern 12230; however, the passes 17230 overlap one another. More specifically, the passes 17230 are not parallel to one another and the perforation pattern 12230 created by each pass 17230 overlaps an adjacent pass 17230 by various distances and amounts. Moreover, the passes 17230 are offset horizontally. Such an overall perforation pattern can be created when the initial starting point of a pass is not aligned with the starting points of the other passes. Even with such an overlap and stagger between the passes 17230, the resulting overall perforation pattern does not create a Moire-like pattern.

[0189] Figure 25 is a plan view of an acoustic wall panel 18202 having a surface 18116. The surface 18116 has been perforated by five passes 18230 of the roller discussed above in connection with Figure 19 as well as additional transverse passes 18230’ of the roller that cross over the five passes 18230. The five passes 18230 are not parallel to one another and the perforation pattern 12230 created by each of these passes 18230 overlaps an adjacent pass 18230 by various distances and amounts. Moreover, the five passes 18230 are offset horizontally. Even with such an overlap, stagger, and cross-hatching between the passes 18230 and 18230’, the resulting overall perforation pattern does not create a Moire-like pattern.

[0190] Figure 26 is apian view of acoustic wall panel 19202 having a surface 19116. The surface 19116 has been perforated by five passes 19230 of a roller that is different than the one discussed above in connection with Figure 19. In this embodiment, the roller has pins extending therefrom that are arranged in a regular, non-randomized pattern. Moreover, the pins of this roller do not vary7in pin population density across the face of the roller. Owing to this arrangement of the roller pins, as can be seen in Figure 26, the overall perforation pattern created by the five passes of the roller creates large clusters of perforations 19130 in the acoustic wall panel 19202 which may be readily noticeable and unaesthetic to an observer.

[0191] Figure 27 is a plan view of acoustic wall panel 20202 having a surface 20116. The surface 20116 has been perforated by five passes 20230 of a roller that is different than the roller discussed above in connection with Figure 19 and the roller discussed above in connection with Figure 26. In this embodiment, the roller has pins extending therefrom that are arranged in an irregular,randomized pattern. The pins of this roller, however, do not vary in pin population density across the face of the roller. Owing to this arrangement of the roller pins, as can be seen in Figure 27, the overall perforation pattern created by the five passes of the roller creates large clusters of perforations 20130 in the acoustic wall panel 20202 which may be noticeable and unaesthetic to an observer. That said, the overall perforation pattern in the acoustic wall panel 20202 may be less noticeable and / or less unesthetic than the overall perforation pattern in the acoustic wall panel 19202.

[0192] Figure 28 is a plan view of acoustic wall panel 21202 having a surface 21116. The surface 21116 has been perforated by five passes 21230 of a roller that is similar to the roller discussed above in connection with Figure 19. In this embodiment, the roller has pins extending therefrom that are arranged in an irregular, randomized pattern and vary in pin population density across the face of the roller. Owing to this arrangement of the roller pins, as can be seen in Figure 29, the overall perforation pattern created by the five passes of the roller does not create large clusters of perforations in the acoustic wall panel 21202 which may be aesthetic to an observer, or at least more aesthetic than the acoustic wall panels 19202 and 20202.

[0193] Referring to FIG. 29 to FIG. 31, a roller assembly 9000 for any perforation tool disclosed herein may include a first roller assembly portion 9100 and a second roller assembly portion 9200 that are independently rotatable about an axis, see FIG. 29. In one example, the first roller assembly portion 9100 and the second roller assembly portion 9200 include an equal number of pins. In another example, the first roller assembly portion 9100 and the second roller assembly portion 9200 each have a different number of pins. In yet a further example, the first roller assembly portion 9100 and the second roller assembly portion 9200 include a plurality of pins having different pin heights. For example, each of the first roller assembly portion 9100 and the second roller assembly portion 9200 may have pins with a longer pin height located closer to the center 9010 of the roller assembly 9000 and pins with a shorter pin height located at opposing ends 9012, 9014 of the roller assembly 9000. The height of the pins may gradually decrease from the center 9010 of the roller assembly 9000 toward the opposing ends 9012, 9014 of the roller assembly 9000.

[0194] Referring to FIG. 30, the roller assembly 9000 may include a first roller assembly portion 9100, a second roller assembly portion 9200. a third roller assembly portion 9300, and a fourth roller assembly portion 9400 that are each independently rotatable about an axis. In one example, the first roller assembly portion 9100, the second roller assembly portion 9200, the third roller assembly portion 93001, and the fourth roller assembly portion 9400 include an equal number of pins. In another example, the first roller assembly portion 9100, the second roller assembly portion 9200, the third roller assembly portion 93001, and the fourth roller assembly portion 9400 eachhave a different number of pins. In yet a further example, the first roller assembly portion 9100, the second roller assembly portion 9200, the third roller assembly portion 93001, and the fourth roller assembly portion 9400 include a plurality of pins having different pin heights. For example, each of the first roller assembly portion 9100, the second roller assembly portion 9200, the third roller assembly portion 93001, and the fourth roller assembly portion 9400 may have pins with a longer pin height located closer to the center 9010 of the roller assembly 9000 and pins with a shorter pin height located at opposing ends 9012, 9014 of the roller assembly 9000. The height of the pins may gradually decrease from the center 9010 of the roller assembly 9000 toward the opposing ends 9012, 9014 of the roller assembly 9000.

[0195] Referring to FIG. 31, the roller assembly 9000 is a single assembly rotatable bout an axis. As shown in FIG. 31, the plurality of pins located near the center 9010 of the roller assembly 9000 have a longer pin height closer to the center 9010 of the roller assembly 9000 and pins with a shorter pin height located at opposing ends 9012, 9014 of the roller assembly 9000. Specifically, the height of the pins gradually decreases from the center 9010 of the roller assembly 9000 toward the opposing ends 9012, 9014 of the roller assembly 9000.

[0196] As discussed above, refernng again to FIG. 19. the pin population density on the roller that created the perforation pattern 12230 has a pin population density that is different across the lateral width of the roller such that the perforation pattern 12230 has a perforation population density that is different across the width of the perforation pattern 12230. As also discussed above, the pin population density, and thus the perforation population density, is highest at the center of the roller and lowest at the lateral ends of the roller. As a result, a pin population gradient, and thus a perforation population gradient, exists between the center of the roller, and the pin perforation pattern 12230, and the lateral ends, or sides, of the roller and the pin perforation pattern 12230. In various embodiments, the pin population gradient decreases linearly between the center of the roller and the lateral ends of the roller. In such embodiments, the perforation population gradient will also decrease linearly between the centerline 12232 and the lateral sides 12231 of the pin perforation pattern 12230. In some embodiments, the pin population gradient decreases exponentially between the center of the roller and the lateral ends of the roller. In such embodiments, the perforation population gradient will also decrease exponentially between the centerline 12232 and the lateral sides 12231 of the pin perforation pattern 12230. That said, any suitable gradient can be used.EXAMPLES

[0197] The following Examples include aspects of the disclosure as further described below.

[0198] Reverberation Time

[0199] Acoustic panels in accordance with the disclosure were tested and compared to traditional drywall panels for reverberation time. Two rooms having identical size and configuration were used for the test. The rooms both included panels with mud applied to the j oints in the same method, and both rooms had panels that were painted with the same method. Table 1 below illustrates reverberation time calculated at various stages in the test.TABLE 1

[0200] The acoustic panel for the test exhibited excellent sound attenuation (reverberation time) even when coated with paint after being perforated in accordance with the disclosed method and perforation tool.

[0201] Acoustic Testing : NRC

[0202] Samples of the discloser were tested for acoustic performance. Samples were tested with pins having a blunt tip and pins having no tip and compared to a control with pins having a regular pointed / tapered pins.TABLE 2

[0203] The samples tested above were further reviewed for visual difference in the holes puncher by the different pin types. The control pin holes formed a large dent / crater around the punctured portion with material flared out at the punctured portion, the pin holes from the blunt tip samples formed a similarly-sized dent / crater around the punctured portion with slightly less material flared out at the punctured portion, and the pin holes from the no tip samples formed a significantly smaller dent with less material flared out over the punctured portion.

[0204] While the foregoing description and drawings represent exemplary embodiments of the present disclosure, it will be understood that various additions, modifications and substitutions may be made therein without departing from the spirit and scope and range of equivalents of the accompanying claims. In particular, it will be clear to those skilled in the art that the present invention may be embodied in other forms, structures, arrangements, proportions, sizes, and with other elements, materials, and components, without departing from the spirit or essential characteristics thereof. In addition, numerous variations in the methods / processes described herein may be made within the scope of the present disclosure. One skilled in the art will further appreciate that the embodiments may be used with many modifications of structure, arrangement, proportions, sizes, materials, and components and otherwise, used in the practice of the disclosure, which are particularly adapted to specific environments and operative requirements without departing from the principles described herein. The presently disclosed embodiments are therefore to be considered in all respects as illustrative and not restrictive. The appended claims should be construed broadly, to include other variants and embodiments of the disclosure, which may be made by those skilled in the art without departing from the scope and range of equivalents. In addition, all combinations of any and all of the features described in the disclosure, in any combination, are part of the invention.

Claims

What is claimed is:1 . A method for forming a wall covering system comprising: positioning a first substrate adjacent a second substrate such that a seam is defined between the first acoustic wall panel and the second acoustic wall panel; applying a seam-filling material to the seam; applying a coating composition over the first substrate, the second substrate, and the seamfilling material to define a first major exposed surface; and perforating at least a portion of the first maj or exposed surface.

2. The method according to claim 1. wherein the perforating comprises: positioning a perforation roller tool having a plurality of pins against the first maj or exposed surface; applying pressure to the perforation roller tool; and passing the perforation roller tool over at least a portion of the first major exposed surface to define a plurality of perforations.

3. The method according to claim 1 or 2, wherein the perforating comprises passing the perforation roller tool over the first maj or exposed surface at least two times, wherein each pass is performed at an offset position on the first major exposed surface such that none of the plurality of perforations overlap.

4. The method according to any one of claims 1 to 3, wherein the perforating comprises defining a plurality of perforations in the coating and at least a portion of one of the first substrate and the second substrate.

5. The method according to any one of claims 1 to 4, wherein the perforating comprises performing a series of offset passes over the first major surface to yield an irregular pattern of perforations across the first major surface.

6. The method according to any one of claims 1 to 5, wherein the perforating yields a plurality of perforations that are present in a perforation density ranging from about 10 perforation / in2to about 600 perforation / in2.

7. The method according to any one of claims 1 to 6, wherein the perforating yields a plurality of perforations having an average diameter ranging from about 0. 1mm to about 1mm.

8. The method according to any one of claims 1 to 7, wherein the seam-filling material comprises gypsum plaster.

9. The method according to any one of claims 1 to 8, wherein the seam-filling material is perforated.

10. A method for manufacturing an acoustic wall panel comprising: providing a substrate having a first major surface opposite a second major surface and a coating over the first major surface to define a first major exposed surface; positioning a perforation roller tool having a plurality of pins against the coating of the first major exposed surface; applying pressure to the perforation roller tool; and passing the perforation roller tool over at least a portion of the first major exposed surface to perforate the coating.

11. The method according to claim 10, wherein the passing comprises: performing a first pass over a first portion of the first major exposed surface; and performing a second pass over a second portion of the first major exposed surface that is offset from the first portion of the first major exposed surface.

12. The method according to any one of claims 10 or 11, wherein the passing yields a plurality’ of perforations that are present in a perforation density ranging from about 10 perforation / in2to about 600 perforation / in2.

13. The method according to any one of claims 10 to 12, wherein the passing yields a plurality' of perforations having an average diameter ranging from about 0. 1mm to about 1mm.

14. The method according to any one of claims 10 to 13, wherein the passing yields a plurality' of perforations having an average depth ranging from about 0. 1mm to about 4mm.

15. The method according to any one of claims 10 to 14, wherein the passing comprises performing a series of passes over first major exposed surface such that an irregular pattern of perforations is defined across the first major exposed surface.

16. A method for manufacturing an acoustic wall panel comprising: forming a blend by combining together a binder composition, an inorganic material, a recycled organic material, and water; shaping the blend to yield a substrate having a first major surface opposite a second major surface; applying a coating over the first major surface to define a first major exposed surface; and perforating the first major exposed surface to yield the acoustic wall panel.

17. The method according to claim 16, wherein the perforating comprises: positioning a perforation roller tool having a plurality' of pins against the coating of the first major surface; applying pressure to the perforation roller tool; and passing the perforation roller tool over at least a portion of the first major exposed surface.

18. The method according to claim 16 or 17, wherein the perforating comprises passing the perforation roller tool over the first major exposed surface at least two times, wherein each pass is performed at an offset position on the first major exposed surface such that none of the perforations overlap.

19. The method according to any one of claims 16 to 18, wherein the perforating comprises defining a plurality of perforations in the coating and at least a portion of the substrate.

20. The method according to any one of claims 16 to 19, wherein the perforating comprises performing a series of offset passes over the first major exposed surface to yield an irregular pattern of perforations across the first major surface.

21. The method according to any one of claims 16 to 20, wherein the acoustic wall panel has a length and a width, the length ranging from about 1 ft. to about 8ft and the width ranging from about 1 ft. to about 4 ft.

22. The method according to any one of claims 16 to 21, wherein the perforating yields a plurality of perforations that are present in a perforation density ranging from about 10 perforation / in2to about 600 perforation / in2.

23. The method according to any one of claims 16 to 22, wherein the perforating yields a plurality of perforations having an average diameter ranging from about 0. 1mm to about 1mm.

24. The method according to any one of claims 16 to 23, further comprising coupling a scrim to the first major surface of the substrate prior to applying the coating to the first major surface.

25. The method according to claim 24, wherein the scrim is comprised of afibrous material selected from one or more of fiberglass, mineral wool, and combinations thereof.

26. The method according to claim 24 or 25, wherein the scrim has an airflow resistance from about 30 inks ralys to about 200000 mks ralys, preferably from about 30 mks ralys to about 5000 mks ralys.

27. The method according to any one of claims 24 to 26, wherein the perforating comprises defining a plurality of perforations in the coating and at least a portion of the scrim.

28. The method according to any one of claims 16 to 27, wherein the substrate comprises: inorganic material present in an amount ranging from about 20 wt. % to about 80 wt. % based on the total dry -weight of the substrate; organic recycled material present in an amount ranging from about 5 wt. % to about 80 wt. % based on the total dry -weight of the substrate; and a binder present in an amount ranging from about 5 wt. % to about 15 wt. % based on the total dry-weight of the substrate, wherein the organic recycled material comprises a blend of two or more cellulosic materials.

29. The method according to any one of claims 16 to 28 , wherein the inorganic fiber comprises mineral wool.

30. The method according to any one of claims 16 to 29. wherein the inorganic material comprises clay present in an amount ranging from about 25 wt. % to about 55 wt. % based on the total dryweight of the substrate.

31. The method according to any one of claims 16 to 30, wherein the organic recycled material comprises starch material, cellulosic material, or combinations thereof.

32. The method according to any one of claims 16 to 31, wherein the organic recycled material comprises newsprint, refined paper, wood fiber, or combinations thereof.

33. The method according to any one of claims 16 to 32, wherein the organic recycled material comprises dry broke present in an amount ranging from about 15 wt. % to about 40 wt. % based on the total dr -weight of the substrate.

34. The method according to any one of claims 16 to 33, wherein the substrate exhibits an airflow resistance from about 30 mks ralys to about 200000 mks ralys.

35. A perforating roller tool comprising: a handle; a roller support; and a roller rotatably supported by the roller support, wherein the roller comprises: a cylinder comprising an outer surface; and pins extending from the cylinder.

36. The perforating roller tool of claim 35, wherein each pin has a pin length and a pin diameter.

37. The perforating roller tool of claim 36, wherein the pin diameters of the pins are between 0. 1 mm and 1 mm.

38. The perforating roller tool according to any one of claims 35 to 37, wherein the pins are arranged in a pin population density at the cylinder outer surface between 1 pin per square inch and 300 pins per square inch.

39. The perforating roller tool according to any one of claims 35 to 38, wherein the pins extend between 0. 1 mm and 4 mm from the outer surface of the cylinder.

40. The perforating roller tool according to any one of claims 35 to 39, wherein the pins extend orthogonally relative to the outer surface of the cylinder.

41. The perforating roller tool according to any one of claims 35 to 40. wherein the pins extend at an acute angle relative to the outer surface of the cylinder.

42. The perforating roller tool according to any one of claims 35 to 41, wherein the roller is replaceable.

43. The perforating roller tool according to any one of claims 35 to 42, wherein the roller comprises a first end, a second end, and an intermediate portion positioned intermediate the first end and the second end, wherein the pins extend a first height from the roller at the first end, wherein the pins extend a second height from the roller in the intermediate portion, and wherein the second height is different than the first height.

44. The perforating roller tool of claim 43, wherein the second height is taller than the first height.

45. The perforating roller tool according to any one of claims 43 to 44, wherein the pins extend the first height from the roller at the second end.

46. The perforating roller tool according to any one of claims 35 to 45, wherein the roller comprises a first end, a second end, and an intermediate portion positioned intermediate the first end and the second end, wherein the pins have a first diameter at the first end, wherein the pins have a second diameter in the intermediate portion, and wherein the second diameter is different than the first diameter.

47. The perforating roller tool of claim 46, wherein the second diameter is greater than the first diameter.

48. The perforating roller tool according to any one of claims 46 to 47, wherein the pins have the first diameter at the second end.

49. The perforating roller tool according to any one of claims 35 to 48, wherein the roller comprises a first end, a second end, and an intermediate portion positioned intermediate the first end and the second end, wherein the pins have a first population density at the first end, wherein the pins have a second population density in the intermediate portion, and wherein the second population density is different than the first population density.

50. The perforating roller tool of claim 49, wherein the second population density is greater than the first population density.

51. The perforating roller tool according to any one of claims 49 to 50, wherein the pins have the first population density at the second end.

52. The perforating roller tool according to any one of claims 35 to 51. wherein the handle extends along a longitudinal handle axis, wherein the roller extends along a transverse roller axis, and wherein the transverse roller axis extends transversely to the longitudinal handle axis.

53. The perforating roller tool of claim 52, wherein the transverse roller axis intersects the longitudinal handle axis.

54. The perforating roller tool of claim 52, wherein the transverse roller axis does not intersect the longitudinal handle axis.

55. The perforating roller tool according to any one of claims 52 to 54, wherein a portion of the handle comprises an offset shaft portion that is offset from the longitudinal handle axis.

56. The perforating roller tool according to any one of claims 35 to 55. wherein each pin comprises a column having a round cross-section and tapered pin tip extending radially from the column.

57. The perforating roller tool of claim 56, wherein the tapered pin tips of the pins extend outwardly from the outer surface of the cylinder but the columns of the pins do not extend outwardly from the outer surface of the cylinder.

58. A perforating roller tool system comprising: a handle; a first roller support; a second roller support; and a set of replaceable rollers, wherein each roller of the set of rollers is rotatably supportable between the first roller support and the second roller support, wherein the set of rollers comprises a first roller and a second roller, wherein the first roller comprises: a first cylinder comprising a first outer surface; and first pins extending a first height from the first cylinder; and wherein the second roller comprises: a second cylinder comprising a second outer surface; and second pins extending a second height from the second cylinder, wherein the first height is different than the second height.

59. A perforating roller tool system comprising: a handle; a first roller support; a second roller support; and a set of replaceable rollers, wherein each roller of the set of rollers is rotatably supportable between the first roller support and the second roller support, wherein the set of rollers comprises a first roller and a second roller, wherein the first roller comprises: a first cylinder comprising a first outer surface; and first pins extending from the first cylinder, wherein the first pins have a first diameter; and wherein the second roller comprises: a second cylinder comprising a second outer surface; and second pins extending from the second cylinder, wherein the second pins have a second diameter, and wherein the first diameter is different than the second diameter.

60. A perforating roller tool system comprising: a handle;a first roller support; a second roller support; and a set of replaceable rollers, wherein each roller of the set of rollers is rotatably supportable between the first roller support and the second roller support, wherein the set of rollers comprises a first roller and a second roller, wherein the first roller comprises: a first cylinder comprising a first outer surface; and an array of first pins extending from the first cylinder having a first pin density; and wherein the second roller comprises: a second cylinder comprising a second outer surface; and an array of second pins extending from the second cylinder having a second pin density, and wherein the first pin density is different than the second pin density.

61. A perforating roller tool comprising: a handle; a first roller support; a second roller support; a first roller rotatably supported between the first roller support and the second roller support, wherein the first roller comprises: a first cylinder; first pins extending from the first cylinder; and a second roller rotatably supported adjacent the first roller between the first roller support and the second roller support, wherein the first roller comprises: a second cylinder; and second pins extending from the second cylinder, wherein the first pins are different than the second pins.

62. The perforating roller tool of claim 61, wherein the first pins extend from the first cy linder a first distance, wherein the second pins extend from the second cylinder a second distance, and wherein the first distance is different than the second distance.

63. The perforating roller tool according to any one of claims 61 to 62, wherein the first pins have a first diameter, wherein the second pins have a second diameter, and wherein the first diameter is different than the second diameter.

64. The perforating roller tool according to any one of claims 61 to 63, wherein the first pins are arranged in an array having a first pin population density, wherein the second pins are arranged in an array having a second pin population density, and wherein the first pin population density is different than the second pin population density'.

65. The perforating roller tool according to any one of claims 61 to 64, wherein the first pins extend from the first cylinder at a first angle, wherein the second pins extend from the second cylinder at a second angle, and wherein the first angle is different than the second angle.

66. The perforating roller tool according to any one of claims 61 to 65, wherein the first roller comprises a first connector, wherein the second roller comprises a second connector engaged with the first connector such that the first roller and the second roller are rotatable together about a common axis of rotation.

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