Sound damping wallboard and method of constructing a sound damping wallboard

Patent metadata

Field	Value
Publication number	US-12270207-B2
Application number	US-202318454179-A
Country	US
Kind code	B2
Filing date	Aug 23, 2023
Priority date	Feb 5, 2015
Publication date	Apr 8, 2025
Grant date	Apr 8, 2025

Abstract

A sound damping wallboard for installation on an installed wallboard, a sound damping wallboard system, and a method of constructing a sound damping wallboard on a building structure are disclosed. The sound damping wallboard comprises a gypsum layer having a gypsum layer inner surface and a gypsum layer outer surface, a sound damping layer disposed at the gypsum layer inner surface for installation between the gypsum layer and an installed wallboard and having a sound damping layer inner surface, a first encasing layer disposed at the gypsum layer outer surface, and a second encasing layer disposed at the sound damping layer inner surface.

First claim

We claim:

1. A method for forming a sound damping wallboard, comprising: providing a gypsum layer having a gypsum layer inner surface and a gypsum layer outer surface, the gypsum layer having a first encasing layer disposed at the gypsum layer outer surface and a third encasing layer disposed at the gypsum layer inner surface; applying a sound damping layer to the third encasing layer such that the sound damping layer includes a sound damping layer inner surface opposite the gypsum layer inner surface; and providing a second encasing layer at the sound damping layer inner surface, wherein the second encasing layer is formed of a material comprising paper, fiberglass, foil, or a polymer; wherein, when attached to an installed wallboard, the sound damping layer is disposed between the gypsum layer and the installed wallboard.

2. The method of claim 1 , wherein the gypsum layer has a gypsum layer thickness that is about 5/16 inch or less.

3. The method of claim 1 , wherein the gypsum layer has a gypsum layer thickness that is about ¼ inch or less.

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

5. The method of claim 1 , wherein the sound damping layer comprises an elastomer.

6. The method of claim 5 , wherein the elastomer comprises an acrylic polymer.

7. The method of claim 5 , wherein the elastomer comprises an acrylic copolymer.

8. The method of claim 1 , wherein the sound damping layer comprises an adhesive.

9. The method of claim 1 , wherein the second encasing layer is a curable coating.

10. The method of claim 9 , wherein the curable coating is applied to the sound damping layer inner surface and then cured to form the second encasing layer.

11. The method of claim 9 , wherein the curable coating is applied to the sound damping layer inner surface by spraying.

12. The method of claim 1 , wherein the first encasing layer comprises paper.

13. The method of claim 1 , wherein the second encasing layer comprises paper.

14. The method of claim 1 , wherein the third encasing layer comprises paper.

15. The method of claim 1 , wherein the first encasing layer and the third encasing layer comprise paper.

16. The method of claim 1 , wherein at least one of the first encasing layer, the second encasing layer, or the third encasing layer comprise a plurality of sheets.

17. The method of claim 1 , wherein the first encasing layer and the third encasing layer comprise a plurality of sheets.

18. The method of claim 1 , wherein the sound damping wallboard further comprises a first edge encasing layer.

19. The method of claim 18 , wherein the sound damping wallboard further comprises a second edge encasing layer.

20. The method of claim 1 , wherein the method further comprises:
providing the first encasing layer;
depositing a gypsum slurry on the first encasing layer to form the gypsum layer; and
providing the third encasing layer to the gypsum layer inner surface before applying the sound damping layer to the third encasing layer.

21. The method of claim 1 , wherein the gypsum layer is the only gypsum layer of the sound damping wallboard.

Assignees

• Gold Bond Building Products Llc

Inventors

• Cusa Stephen A
• Blades Michael N
• Weir Richard P
• Mixson John W

Classifications

• E04B1/99

  Room acoustics, i.e. forms of, or arrangements in, rooms for influencing or directing sound (E04B1/82 takes precedence; acoustics in general G10K11/00; electric signal processing for producing a reverberation or echo sound G10K15/08) · CPC title

• E04F2290/043

  with a bottom layer for sound insulation · CPC title

• E04F13/14

  stone or stone-like materials, e.g. ceramics {concrete,}; of glass {or with an outer layer of stone or stone-like materials or glass (E04F13/0864 takes precedence; producing shaped elements from concrete, ceramic compositions or other stone-like materials B28B; prefabricated panels in general E04C2/00)} · CPC title

• E04F13/0875

  having a basic insulating layer and at least one covering layer · CPC title

• E04B2001/8461

  layered · CPC title