Acoustical gypsum wallboard

Patent metadata

Field	Value
Publication number	US-9903116-B2
Application number	US-201615148035-A
Country	US
Kind code	B2
Filing date	May 6, 2016
Priority date	Sep 21, 2015
Publication date	Feb 27, 2018
Grant date	Feb 27, 2018

Abstract

This invention provides acoustical building panels and methods for imparting the acoustical property to wallboard with help of a compliant coating.

First claim

What is claimed is:

1. An acoustical wallboard comprising:
a wallboard comprising a gypsum core sandwiched between a first paper cover sheet and a second paper cover sheet, wherein the first paper cover sheet is the facer and the second paper cover sheet is the backer,
a compliant coating comprising a binder, a matrix of sound-compliant particles into which sound-stiff particles are incorporated, wherein the compliant coating is applied directly over the backer; and
a third paper sheet applied directly over the compliant coating, wherein the compliant coating and the third paper cover sheet create together a laminated structure.

2. The acoustical wallboard of claim 1 , wherein the laminated structure is repeated at least two times.

3. The acoustical wallboard of claim 1 , wherein at least one of paper cover sheets is replaced with a polymeric mat selected from the group consisting of a fiber mat and synthetic paper mat.

4. The acoustical wallboard of claim 1 , wherein the molar ratio of sound-compliant particles to sound-stiff particles is from 1:1 to 1:1,000.

5. The acoustical wallboard of claim 1 , wherein the molar ratio of sound-compliant particles to sound-stiff particles is from 1,000:1 to 1:1.

6. The acoustical wallboard of claim 1 , wherein the compliant coating comprises a binder selected from the group consisting of glue, starch, a latex polymer and any combination thereof.

7. The acoustical wallboard of claim 1 , wherein the compliant coating comprises a binder selected from the group consisting of polyvinyl-acetate based glue, cellulose-based glue and any combination thereof.

8. The acoustical wallboard of claim 1 , wherein the compliant coating comprises rubber particles and silica particles.

9. The acoustical wallboard of claim 1 , wherein the sound-compliant particles are selected from the group consisting of nitrile rubber, butyl rubber, ethylene propylene diene monomer (EPDM), natural rubber compounds, cotton fibers, organic fibers, inorganic fibers, polypropylene fibers, air-filled glass beads, polystyrene beads, polystyrene foam and any combination thereof.

10. The acoustical wallboard of claim 1 , wherein the sound-stiff particles are selected from the group consisting of silica particles, clay particles, calcium carbonate, perlite, gas-filled microspheres, hollow microspheres, cenospheres, inorganic glues and any combination thereof.

11. The acoustical wallboard of claim 1 , wherein the compliant coating comprises rubber tire scrap particles, wallpaper paste and water glass.

12. The acoustical wallboard of claim 1 , wherein the gypsum core is sandwiched between the facer and the compliant coating and wherein the compliant coating is applied directly over the gypsum core; and
a second paper sheet applied over the compliant coating.

13. The acoustical wallboard of claim 1 , wherein the sound transmission loss property of the acoustical wallboard is improved in the high-frequency range in comparison to the sound transmission loss property of the wallboard to which no compliant coating is applied.

14. A method of imparting sound-absorbing properties to a gypsum wallboard, the method comprising:
obtaining a gypsum wallboard;
applying a compliant coating comprising a binder and a combination of first sound-compliant particles and second sound-stiff particles; and
placing a paper cover sheet over the compliant coating.

15. A method of making a gypsum board, the method comprising:
formulating a gypsum slurry from at least water and calcined gypsum;
dispensing the gypsum slurry on a first paper cover sheet, the facer;
rolling a second paper cover sheet, the backer, over the gypsum slurry;
applying a compliant coating which comprises a binder, sound-compliant particles and sound-stiff particles over the backer sheet; and
rolling a third paper cover sheet over the compliant coating.

16. The method of claim 15 , wherein the compliant coating comprises rubber tire scrap particles, wallpaper paste and water glass.

17. The method of claim 15 , wherein the compliant coating comprises a binder selected from the group consisting of glue, starch, a latex polymer and any combination thereof.

18. The method of claim 15 , wherein the compliant coating comprises sound-compliant particles selected from the group consisting of nitrile rubber, butyl rubber, ethylene propylene diene monomer (EPDM), natural rubber compounds, cotton fibers, organic fibers, inorganic fibers, polypropylene fibers, air-filled glass beads, polystyrene beads, polystyrene foam and any combination thereof.

19. The method of claim 15 , wherein the compliant coating comprises the sound-stiff particles selected from the group consisting of silica particles, clay particles, calcium carbonate, perlite, gas-filled microspheres, hollow microspheres, cenospheres, inorganic glues and any combination thereof.

Assignees

• United States Gypsum Co

Inventors

• Ray Suman Sinha

Classifications

• B32B13/047

  made of particles · CPC title

• B32B2307/10

  having particular acoustical properties · CPC title

• B32B13/00

  Layered products comprising a {a layer of} water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material · CPC title

• E04B9/045

  being laminated · CPC title

• B32B13/042

  of natural rubber or synthetic rubber · CPC title