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Publication numberUS3771213 A
Publication typeGrant
Publication dateNov 13, 1973
Filing dateDec 19, 1969
Priority dateDec 19, 1969
Publication numberUS 3771213 A, US 3771213A, US-A-3771213, US3771213 A, US3771213A
InventorsJ Peraro
Original AssigneeArmstrong Cork Co
Export CitationBiBTeX, EndNote, RefMan
External Links: USPTO, USPTO Assignment, Espacenet
Method of forming an embossed foil-covered ceiling panel
US 3771213 A
Abstract
A conventional ceiling panel covered with a metal foil which is adhered to the edges of the panel. The foil is drawn tight across the face of the panel by lightly embossing the foil face to mechanically shrink the foil over the face of the panel.
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Description  (OCR text may contain errors)

United States Patent [191 Peraro METHOD OF FORMING AN EMBOSSED FOIL-COVERED CEILING PANEL James S. Peraro, Lancaster, Pa.

Inventor:

Armstrong Cork Company, Lancaster, Pa.

Dec. 19, 1969 Assignee:

Filed:

Appl. No.:

U.S. Cl 29/480, 29/DIG. 42, 52/144, 52/599, 52/746, 156/219 Int. Cl. B23k 31/02 Field of Search 52/144, 599, 746; 156/71, 219-220, 216, 295; 161/119-120,

147; 29/480, DIG. 42

[56] References Cited UNITED STATES PATENTS 4/1928 Robinson 161/119 2/1936 Miller 52/144 6/1936 Pond 52/144 [111 3,771,213 [451 Nov. 13, 1973 Caprio et al. 156/219 Primary ExaminerFrank L. Abbott Assistant ExaminerLeslie A. Braun Attorney-Clifford B. Price [57] ABSTRACT A conventional ceiling panel covered with a metal foil which is adhered to the edges of the panel. The foil is drawn tight across the face of the panel by lightly embossing the foil face to mechanically shrink the foil over the face of the panel.

1 Claim, 2 Drawing Figures PATENTEDHUVIIB I975 3,771,213

INVENTOR JAMES S. PERARO ATTORNEY METHOD OF FORMING AN EMBOSSED FOIL-COVERED CEILING PANEL BACKGROUND OF THE INVENTION 1. Fieldof the Invention The invention relates generally to an improved acoustical panel and, more particularly, to an acoustical panel covered with a protective covering.

2. Description of the Prior Art U. S. Pat. No. 2,802,764 discloses a ceiling panel which has been covered with a plastic film. The film is drawn tight across the face of the panel by being exposed to heat which causes the plastic to shrink and draw itself tight across the face of the panel. U. S. Pat. No. 1,837,451 and U. S. Pat. No. 3,074,505 both disclose techniques wherein a metallic sheet is placed over a ceiling panel. The metallic sheet is fastened to the panel by being punched and having the edges of the punched openings in the metal grasp the ceiling panel to hold the metal covering to the face of the ceiling panel. It is also possible with a rigid enough piece of material to merely place the metal on the face of the ceiling panel and have the edges of the metal crimped into the edges of the panel to hold the metal relative to the panel.

The invention herein is directed to a technique that will permit the manufacture of a metal-faced ceiling panel. The technique permits the use of an extremely thim metal, or foil, and thus provides a saving in material cost. The foil is shrunk to the ceiling panel by mechanical embossing which provides the technique by which the foil is placed tightly adjacent the ceiling panel and yields a decorative aesthetic effect.

SUMMARY OF THE INVENTION The invention is directed to a ceiling panel formed of a basic conventional ceiling board to which there has been adhered a metal foil. The foil is secured, normally adhesively, to the edge of the panel and extends across the front face of the panel. The foil is drawn tight relative to the surface of the panel by being lightly mechanically embossed. This shrinks the foil and draws it tight and thereby provides a tight rigid metal surface extending across the front face of the ceiling panel. The foil is unpunched and the acoustical properties are obtained when the foil transmits sound to the prepunched board by vibration.

BRIEF DESCRIPTION OF THE DRAWING FIG. 1 is a perspective view of a metal foil ceiling panel, and

FIG. 2 is a cross-sectional view, enlarged, showing the ceiling panel and embossed metal covering.

DESCRIPTION OF THE PREFERRED EMBODIMENT Referring to FIG. 1, the metal foil ceiling panel 2 is composed of a vegetable fiber or asbestos fiber ceiling panel 4 which is conventional in the art. Normally this type of panel would be provided with a white paint coating and used with the paint coating facing downward. The invention involves the placing of a metal foil 6 over the front face of the ceiling panel. A good material to use would be an aluminum foil of 0.0025inch thickness. The metal foil extends across the front face and is adhered at the edges 8 by glue or other appropriate adhering means. Consequently, the metal foil is adhered around its perimeter to the perimeter of the ceiling panel, and the foil extends across the front face of the ceiling panel. There will be a slight tendency of the metal foil to sag relative to the center portion of the front face. Any tendency to sag would be eliminated by shrinking or drawing the metal foil tight across the face of the ceiling panel. This shrinking of the foil is accomplished by a low relief embossing roll providing a mechanical embossing to the metal foil on the front face of the ceiling panel. The mechanical embossing does not penetrate through the metal foil, but only distorts the foil to draw it tight between the edges which are fastened to the edge of the ceiling panel.

Referring to FIG. 2, there is shown the foil 6 extending across a portion of the ceiling panel 4. The foil extends around the corner of the ceiling panel and is fastened to edge 8 by an adhesive 10. The foil 6, which extends across the face 12 of the panel 4, is not adhered to the face 12 by any mechanical means. A shallow embossed area 14 is shown. It can be readily seen that when the foil is embossed, a forming of the impressions in the foil will tend to absorb any excess material that may exist between two opposite edges of the ceiling panel. Furthermore, these impressions place the foil under a tension which extends longitudinally through the foil. This is in effect a shrinking of the foil over the surface of the board. It may be more properly called a tensioning of the foil so that it tends to lay in a plane parallel and adjacent the face of the ceiling panel and not sag in a dish-shaped plane and hang away from the front face of the ceiling panel when it is mounted in position in a ceiling. The ceiling panel may be provided with punched holes, such as hole 16, for acoustical purposes. Sound waves striking against the foil will cause the foil to vibrate and the sound will be transmitted to the punched board by the vibration and absorbed within the holes within the board.

There is now provided a very decorative ceiling panel which will have an embossed effect. The ceiling panel will be relatively easy to clean and maintain plus it has a metallic coating which will not be stained or affected by grease or dirt. The panel is capable of having some acoustical properties, and the front surface of the panel is relatively durable as compared to conventional fiber panels.

What is claimed is:

1. The method of manufacturing a metal foil ceiling panel comprising the steps of placing a metal foil across the face ofa ceiling panel, adhering the metal foil to the ceiling panel only at the peripheral edge of the ceiling panel, embossing the portion of the metal foil which extends across the face of the ceiling panel to mechanically shrink the foil over the surface of the ceiling panel.

Patent Citations
Cited PatentFiling datePublication dateApplicantTitle
US1665222 *Jul 19, 1923Apr 10, 1928Anaconda Sales CoRoofing element and process of making same
US2031900 *Apr 7, 1933Feb 25, 1936Edward J MillerAcoustical wall surfacing
US2045099 *Jul 23, 1932Jun 23, 1936Johns ManvilleCellular material and method of making same
US2205466 *Sep 18, 1937Jun 25, 1940Celluloid CorpProcess for making decorative material
US2802764 *Oct 8, 1952Aug 13, 1957Owens Corning Fiberglass CorpAcoustical material
US2990027 *Jul 11, 1957Jun 27, 1961Celotex CorpComposite sound absorber
US3013626 *Jun 18, 1957Dec 19, 1961Armstrong Cork CoAcoustical material
US3380206 *Sep 29, 1965Apr 30, 1968Soundlock CorpLay-in acoustical ceiling panel with flexible diaphragms
US3510388 *Nov 1, 1965May 5, 1970Consolidated Aluminum CorpEmbossable sheet material
DD65652A * Title not available
IT531151A * Title not available
Referenced by
Citing PatentFiling datePublication dateApplicantTitle
US4248647 *Aug 7, 1979Feb 3, 1981Armstrong Cork CompanyMethod for producing acoustical ceiling tile faced with a smooth distortion free decorative thin plastic film
US4325177 *Jan 19, 1979Apr 20, 1982Depoorter Lieven LModular art wall systems
US4498390 *Sep 3, 1981Feb 12, 1985Philip Morris IncorporatedMethod and apparatus for embossing foil
US4642951 *Sep 25, 1985Feb 17, 1987Fam Tile Restoration Services, Ltd.Suspended ceiling tile system
US6299727 *Jun 13, 2000Oct 9, 2001Nitto Boseki Co., Ltd.Rock wool, beaten pulp, binder made of an organic resin, flocculating agent, natural mineral fiber and from carbon fibers
US20120021242 *Mar 29, 2010Jan 26, 2012Andrey Vilenovich LyubomirskiyWall facing panel
US20120028071 *Mar 29, 2010Feb 2, 2012Andrey Vilenovich LyubomirskiyWall facing panel
EP0368529A1 *Oct 30, 1989May 16, 1990Micropore International LimitedPanels of thermal insulating material
Classifications
U.S. Classification29/469.5, 156/219, 52/746.12, 29/DIG.420, 52/599, 52/144
International ClassificationE04C2/292, E04B9/04
Cooperative ClassificationE04C2/292, E04B9/0485, Y10S29/042, E04B9/045
European ClassificationE04B9/04G, E04B9/04L1, E04C2/292