Sound damping gypsum board and method of constructing a sound damping gypsum board

Patent metadata

Field	Value
Publication number	US-11772372-B2
Application number	US-202117338880-A
Country	US
Kind code	B2
Filing date	Jun 4, 2021
Priority date	Jun 5, 2020
Publication date	Oct 3, 2023
Grant date	Oct 3, 2023

Abstract

The present invention is directed to an improved gypsum board, such as an improved sound damping gypsum board, and a method of making such gypsum board. For instance, the method comprises: providing a first encasing layer and a first sound damping layer on the first encasing layer wherein the sound damping layer includes at least 50 wt. % of a first sound damping polymer; depositing a gypsum slurry comprising stucco and water on the sound damping layer to form a gypsum core; providing a second encasing layer on the gypsum slurry; and allowing the stucco to convert to calcium sulfate dihydrate.

First claim

The invention claimed is:

1. A method of forming a gypsum board, the method comprising:
providing a first encasing layer and a first sound damping layer on the first encasing layer wherein the sound damping layer includes at least 50 wt. % of a first sound damping polymer,
depositing a gypsum slurry comprising stucco and water on the sound damping layer to form a gypsum core,
providing a second encasing layer on the gypsum slurry, and
allowing the stucco to convert to calcium sulfate dihydrate.

2. The method of claim 1 , further comprising providing a second sound damping layer between the gypsum slurry and the second encasing layer.

3. The method of claim 1 , wherein the gypsum core includes a first gypsum layer and a second gypsum layer, the first gypsum layer having a density greater than the second gypsum layer.

4. The method of claim 1 , wherein the first sound damping polymer comprises a viscoelastic polymer.

5. The method of claim 1 , wherein the first sound damping layer includes rubber, cork, or a mixture thereof.

6. The method of claim 1 , wherein the first sound damping layer includes a cellulosic material, glycerin, or a mixture thereof.

7. The method of claim 1 , wherein the sound damping layer includes an additive also included in the gypsum slurry.

8. The method of claim 1 , wherein the first sound damping polymer comprises an acrylic polymer or copolymer.

9. The method of claim 1 , wherein the sound damping layer includes at least 90 wt. % of the first sound damping polymer.

10. The method of claim 1 , wherein the gypsum core further comprises a starch.

11. The method of claim 1 , wherein the first sound damping polymer is present in an amount of from 0.001 lbs/MSF to 150 lbs/MSF based on the weight of the gypsum board.

12. The method of claim 1 , wherein the gypsum slurry further includes a second sound damping polymer.

13. The method of claim 1 , wherein the sound damping layer is directly between the first encasing layer and the gypsum slurry.

14. The method of claim 1 , wherein the sound damping layer comprises gypsum.

15. The method of claim 1 , wherein the sound damping layer comprises a pigment.

16. The method of claim 1 , wherein the sound damping layer comprises calcium carbonate.

17. The method of claim 1 , wherein the sound damping layer comprises magnesium carbonate.

18. The method of claim 1 , wherein the sound damping layer comprises an inorganic particle.

19. The method of claim 1 , wherein the gypsum board exhibits a sound transmission loss of 20% or more in comparison to a board without the sound damping layer.

20. The method of claim 1 , wherein the first sound damping polymer is provided in a formulation having a viscosity of from 500 cps to 15000 cps.

Assignees

• Gold Bond Building Products Llc

Inventors

• Bailey Joseph J
• Weir Richard
• Iyer R G
• Stav Eli
• Busche Bradley J

Classifications

• B32B37/15 Primary

  with at least one layer being manufactured and immediately laminated before reaching its stable state, e.g. in which a layer is extruded and laminated while in semi-molten state · CPC title

• B32B7/12

  using interposed adhesives or interposed materials with bonding properties · CPC title

• B32B9/005

  comprising one layer of ceramic material, e.g. porcelain, ceramic tile (layered products with at least two ceramic layers composed mainly of ceramic B32B18/00) · CPC title

• G10K11/168 Primary

  Plural layers of different materials, e.g. sandwiches · CPC title

• B32B2255/26

  Polymeric coating · CPC title