Building materials, compositions, and methods

Patent metadata

Field	Value
Publication number	US-9157242-B2
Application number	US-201314046314-A
Country	US
Kind code	B2
Filing date	Oct 4, 2013
Priority date	Dec 20, 2012
Publication date	Oct 13, 2015
Grant date	Oct 13, 2015

Abstract

Building materials include a dampening layer which contains a plaster, and hollow microspheres, such as polymeric microspheres. Methods of making a sound dampening material include providing a plaster mixture. The mixture may include hollow microspheres. The plaster mixture is combined with water to form a slurry. The slurry is applied to a surface so that it sets to form a sound dampening layer. Methods of dampening sound through a structure include disposing a dampening layer on a surface of or within a wall, door, floor, ceiling, roof, or floor/ceiling assembly.

First claim

What is claimed is:

1. A sound dampening material, comprising:
a dampening layer which comprises a plaster, hollow microspheres, and a barium salt selected from the group consisting of barium sulfate, barium oxide, barium chloride, barium fluoride, barium sulfide, barium carbonate, barium peroxide, barium hydride, and any combination thereof.

2. The sound dampening material of claim 1 , wherein the hollow microspheres comprise a polymeric shell encapsulating a gas.

3. The sound dampening material of claim 2 , wherein the polymeric shell comprises vinylidene chloride, acrylonitrile, methyl methacrylate, copolymers thereof, or any combination thereof.

4. The sound dampening material of claim 2 , wherein the gas comprises a hydrocarbon blowing agent.

5. The sound dampening material of claim 1 , wherein the hollow microspheres have an average diameter of about 20 μm to about 150 μm.

6. The sound dampening material of claim 1 , wherein the dampening layer further comprises a viscoelastic polymer.

7. The sound dampening material of claim 6 , wherein the viscoelastic polymer comprises polyvinyl butyral.

8. The sound dampening material of claim 6 , wherein the viscoelastic polymer is selected from the group consisting of polyvinyl butyral, acrylics, polyurethanes, vinyl ethers, ethylene vinyl acetates, styrene block copolymers, polyolefin copolymers, butyl rubber, natural rubber, silicones, nitriles, and any combination thereof.

9. The sound dampening material of claim 1 , wherein the plaster comprises alpha hemihydrate gypsum, beta hemihydrate gypsum, fine grind molding plaster, fly ash type C, Portland cement, dispersant, retarder, defoamer, boric acid, landplaster, or any combination thereof.

10. The sound dampening material of claim 1 , wherein the dampening layer further comprises a high atomic weight material or high molecular density material selected from the group consisting of barium sulfate, calcium silicate, zinc oxide, lead, zirconium dioxide, carbonyl iron powders, aluminum powder, iron powder, stainless steel powder, copper powder, bismuth powder, tungsten powder, bismuth oxide powder, niobium powder, tantalum powder, molybdenum powder, Borated high-density polyethylene, fly ash class C, and any combination thereof.

11. The sound dampening material of claim 1 , wherein the dampening layer comprises plaster in an amount from about 30 weight percent to about 95.5 weight percent, and hollow microspheres in an amount from about 0.5 weight percent to about 10 weight percent, wherein the weight percentages are measured on a dry basis.

12. The sound dampening material of claim 6 , wherein the dampening layer comprises plaster in an amount from about 30 weight percent to about 95.5 weight percent, viscoelastic polymer in an amount from about 1 weight percent to about 12 weight percent, and hollow microspheres in an amount from about 0.5 weight percent to about 10 weight percent, wherein the weight percentages are measured on a dry basis.

13. The sound dampening material of claim 1 , wherein the dampening layer comprises plaster in an amount from about 50 weight percent to about 95.5 weight percent, and hollow microspheres in an amount from about 5 weight percent to about 10 weight percent, wherein the weight percentages are measured on a dry basis.

14. The sound dampening material of claim 6 , wherein the dampening layer comprises plaster in an amount from about 50 weight percent to about 95.5 weight percent, viscoelastic polymer in an amount from about 5 weight percent to about 12 weight percent, and hollow microspheres in an amount from about 5 weight percent to about 10 weight percent, wherein the weight percentages are measured on a dry basis.

15. A method of making a sound dampening material, comprising:
combining water, hollow microspheres, a plaster, and a barium salt to form a slurry; and
applying the slurry to a surface so that the slurry sets to form a dampening layer,
wherein the barium salt is selected from the group consisting of barium sulfate, barium oxide, barium chloride, barium fluoride, barium sulfide, barium carbonate, barium peroxide, barium hydride, and any combination thereof.

16. The method of claim 15 , wherein the hollow microspheres comprise a polymeric shell encapsulating a gas, the polymeric shell comprising vinylidene chloride, acrylonitrile, methyl methacrylate, copolymers thereof, or any combination thereof.

17. The method of claim 15 , wherein the step of combining further comprises combining a viscoelastic polymer with the water, hollow microspheres, plaster, and barium salt to form the slurry.

18. The method of claim 17 , wherein the viscoelastic polymer is selected from the group consisting of polyvinyl butyral, acrylics, polyurethanes, vinyl ethers, ethylene vinyl acetates, styrene block copolymers, polyolefin copolymers, butyl rubber, natural rubber, silicones, nitriles, and any combination thereof.

19. The method of claim 15 , wherein the plaster comprises alpha hemihydrate gypsum, beta hemihydrate gypsum, fine grind molding plaster, fly ash type C, Portland cement, dispersant, retarder, defoamer, boric acid, landplaster, or any combination thereof.

20. The method of claim 15 , wherein the slurry comprises plaster in an amount from about 30 weight percent to about 95.5 weight percent, and hollow microspheres in an amount from about 0.5 weight percent to about 10 weight percent, wherein the weight percentages are measured on a dry basis.

21. The method of claim 17 , wherein the slurry comprises plaster in an amount from about 30 weight percent to about 95.5 weight percent, viscoelastic polymer in an amount from about 1 weight percent to about 12 weight percent, and hollow microspheres in an amount from about 0.5 weight percent to about 10 weight percent, wherein the weight percentages are measured on a dry basis.

22. The method of claim 15 , wherein the slurry comprises plaster in an amount from about 50 weight percent to about 95.5 weight percent, and hollow microspheres in an amount from about 5 weight percent to about 10 weight percent, wherein the weight percentages are measured on a dry basis.

23. The method of claim 17 , wherein the slurry comprises plaster in an amount from about 50 weight percent to about 95.5 weight percent, viscoelastic polymer in an amount from about 5 weight percent to about 12 weight percent, and hollow microspheres in an amount from about 5 weight percent to about 10 weight percent, wherein the weight percentages are measured on a dry basis.

24. A sound dampening material, comprising:
a dampening layer which comprises a plaster, hollow microspheres, and a high atomic weight material or high molecular density material selected from the group consisting of barium sulfate, calcium silicate, zinc oxide, lead, zirconium dioxide, carbonyl iron powders, aluminum powder, iron powder, stainless steel powder, copper powder, bismuth powder, tungsten powder, bismuth oxide powder, niobium powder, tantalum powder, molybdenum powder, Borated high-density polyethylene, fly ash class C, and any combination thereof.

25. The sound dampening material of claim 24 , wherein the hollow microspheres comprise a polymeric shell encapsulating a gas.

26. The sound dampening material of claim 25 , wherein the polymeric shell comprises vinylidene chloride, acrylonitrile, methyl methacrylate, copolymers thereof, or any combination thereof.

27. The sound

Assignees

• Georgia Pacific Gypsum Llc

Inventors

• Thomas Vincent B
• Fields Jeffrey Thomas

Classifications

• C04B22/0013

  Boron compounds · CPC title

• E04B1/82

  specifically with respect to sound only ({of floors or ceilings E04B9/001;} noise damping in ducts or channels E04F17/00; noise damping in general G10K11/16) · CPC title

• C04B2103/40

  Surface-active agents, dispersants · CPC title

• C04B28/145

  Calcium sulfate hemi-hydrate with a specific crystal form · CPC title

• C04B20/008

  Micro- or nanosized fillers, e.g. micronised fillers with particle size smaller than that of the hydraulic binder (colloidal silica C04B14/062 ; silica fume C04B18/146) · CPC title