Acoustical panel

Abstract

A method of making an acoustical panel includes providing a fiberglass substrate, applying an adhesive to the substrate, and applying a facing to the adhesive. The resulting acoustical panel laminate has a smooth exterior face. Further, an acoustical panel includes a rigid fiberglass board, an adhesive layer, and a fiberglass mat coupled to the fiberglass board by the adhesive layer.

What is claimed is:  
     
         1 . A method of making an acoustical panel with a smooth exterior face, comprising the steps of: 
 providing a fiberglass substrate having a first side and a second side;    providing an adhesive;    providing a flexible facing, the facing having an exterior surface;    applying the adhesive to the substrate;    heating the adhesive; and    applying the facing, whereby the facing is secured to the substrate by the adhesive.    
     
     
         2 . The method of  claim 1 , wherein the facing is a fiberglass mat.  
     
     
         3 . The method of  claim 1 , wherein the adhesive is air permeable.  
     
     
         4 . The method of  claim 3 , wherein the adhesive is a polymer resin tackifier mixture.  
     
     
         5 . The method of  claim 1 , wherein the adhesive is applied from a roll of cold adhesive.  
     
     
         6 . The method of  claim 1 , wherein the adhesive is heated after the application to the substrate.  
     
     
         7 . The method of  claim 1 , further comprising the steps of: 
 applying a second layer of adhesive to the second side of the substrate;    providing a second fiberglass facing; and    applying the second fiberglass facing to the opposite side of the substrate from the first facing.    
     
     
         8 . The method of  claim 7 , wherein the second facing is applied concurrently with the application of the first facing.  
     
     
         9 . The method of  claim 1 , further comprising the step of adding a decorative fabric layer to the panel.  
     
     
         10 . A method of making an office partition panel out of a rigid fiberglass board and a flexible fiberglass facing, comprising the steps of: 
 applying a cold adhesive to the fiberglass board;    heating the adhesive; and    applying the facing to the adhesive;    wherein the fiberglass board has surface imperfections that are filled in by the adhesive resulting in a smooth exterior surface of the facing.    
     
     
         11 . The method of  claim 10 , further comprising the step of adding a fabric layer.  
     
     
         12 . The method of  claim 10 , further comprising the steps of: 
 applying a second layer of adhesive to the fiberglass board; and    applying a second facing to the second layer of adhesive.    
     
     
         13 . An acoustical panel, comprising: 
 a rigid fiberglass board;    an adhesive layer; and    a first fiberglass mat coupled to the fiberglass board by the adhesive layer.    
     
     
         14 . The acoustical panel of  claim 13 , further comprising: 
 imperfections in the rigid fiberglass board;    wherein the adhesive fills in imperfections in the fiberglass board.    
     
     
         15 . The acoustical panel of  claim 13 , wherein the acoustical panel is used as a ceiling tile.  
     
     
         16 . The acoustical panel of  claim 13 , wherein the acoustical panel is used in a modular workstation.  
     
     
         17 . The acoustical panel of  claim 13 , wherein the adhesive is air permeable.  
     
     
         18 . The acoustical panel of  claim 13 , further comprising: 
 a second fiberglass mat coupled to the fiberglass panel with a second layer of adhesive, wherein the second fiberglass mat is applied to the side opposing the first fiberglass mat.    
     
     
         19 . The acoustical panel of  claim 13 , wherein the adhesive is attached by a heat treatment.  
     
     
         20 . The acoustical panel of  claim 13 , further comprising: 
 a decorative fabric disposed on the fiberglass mat.