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

Patent metadata

Field	Value
Publication number	US-12296553-B2
Application number	US-202318507158-A
Country	US
Kind code	B2
Filing date	Nov 13, 2023
Priority date	Dec 6, 2018
Publication date	May 13, 2025
Grant date	May 13, 2025

Abstract

The present invention is directed to an improved gypsum board, such as an improved sound damping gypsum board. The gypsum board comprises a gypsum core including gypsum and a sound damping polymer. The gypsum core includes a first gypsum layer surface and a second gypsum layer surface opposing the first gypsum layer surface. In addition, a first encasing layer is disposed on the first gypsum layer surface and a second encasing layer is disposed on the second gypsum layer surface.

First claim

The invention claimed is:

1. A gypsum board comprising:
a gypsum core including a first gypsum layer surface and a second gypsum layer surface opposing the first gypsum layer surface, the gypsum core including a first gypsum layer comprising gypsum and a sound damping polymer and a second gypsum layer comprising gypsum,
a first encasing layer disposed on the first gypsum layer surface wherein the first gypsum layer is between the first encasing layer and the second gypsum layer, and
a second encasing layer disposed on the second gypsum layer surface.

2. The gypsum board of claim 1 , wherein the sound damping polymer comprises a viscoelastic polymer.

3. The gypsum board of claim 1 , wherein the sound damping polymer comprises an acrylic polymer or copolymer.

4. The gypsum board of claim 1 , wherein the first gypsum layer further comprises a plasticizer, a starch, or a mixture thereof.

5. The gypsum board of claim 1 , wherein the second gypsum layer further comprises a plasticizer, a starch, or a mixture thereof.

6. The gypsum board of claim 1 , wherein the sound damping polymer is present in an amount of from 0.001 wt. % to 10 wt. % based on the weight of gypsum.

7. The gypsum board of claim 1 , wherein the sound damping polymer is present in an amount of from 0.001 wt. % to 2.5 wt. % based on the weight of gypsum.

8. The gypsum board of claim 1 , wherein the sound damping polymer is present in an amount of from 0.1 wt. % to 1.5 wt. % based on the weight of gypsum.

9. The gypsum board of claim 1 , wherein the sound damping polymer is present in an amount of from 0.001 lbs/MSF to 150 lbs/MSF.

10. The gypsum board of claim 1 , wherein the sound damping polymer is present in an amount of from 0.1 lbs/MSF to 15 lbs/MSF.

11. The gypsum board of claim 1 , wherein the second gypsum layer further comprises the sound damping polymer.

12. The gypsum board of claim 1 , wherein the gypsum board is a composite board having a second gypsum board comprising a second gypsum core adjacent the first encasing layer.

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

14. The gypsum board of claim 1 , wherein the gypsum board exhibits a decay time of 1 second or less.

15. The gypsum board of claim 1 , wherein the gypsum board exhibits a decay time of 0.8 seconds or less.

16. A method of forming the gypsum board of claim 1 , the method comprising:
providing a first encasing layer,
depositing a first gypsum slurry comprising stucco, water, and the sound damping polymer on the first encasing layer for forming the first gypsum layer,
depositing a second gypsum slurry comprising stucco and water on the first gypsum slurry for forming the second gypsum layer,
providing a second encasing layer on the second gypsum slurry, and
allowing the stucco to convert to calcium sulfate dihydrate.

17. The method of claim 16 , wherein the first gypsum slurry further comprises a plasticizer, a starch, or a mixture thereof.

18. The method of claim 16 , wherein the second gypsum slurry further comprises a plasticizer, a starch, or a mixture thereof.

Assignees

• Gold Bond Building Products Llc

Inventors

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

Classifications

• E04B1/86

  slab-shaped · CPC title

• B32B2307/10

  having particular acoustical properties · CPC title

• E04C2/526

  with adaptations not otherwise provided for, for connecting, transport; for making impervious or hermetic, e.g. sealings · CPC title

• E04C2/288

  composed of insulating material and concrete, stone or stone-like material · CPC title

• B32B2419/04

  Tiles for floors or walls · CPC title