JP6093478B2 - Soundproof monolithic ceiling with plaster panel - Google Patents

Description

  The present invention relates to building materials and systems, and in particular, to a soundproof panel for constructing a monolithic ceiling and inner walls.

  Sound absorption in a building is generally achieved by ceiling tiles held on a suspended grid. In general, the sound absorbing capacity of a tile is achieved by material selection and / or properties of the room facing surface. Ceiling tile installations have the advantage of easy access to the space above the ceiling, but the partition between the tiles is still visible even when hiding the grid. Architects and interior designers have long sought an unobtrusive appearance with a one-piece structure, especially for soundproof ceilings when there is no need to access the space above the ceiling. Conventional gypsum panel drywall ceiling structures do not achieve a sufficiently high noise reduction factor (NRC) to qualify as soundproofing. Gypsum panels with punched holes can achieve acceptable NRC levels, but the appearance is not monolithic.

  The present invention resides in the discovery that conventional gypsum panels such as drywall sheets can be modified to construct soundproof ceilings or walls having a smooth surface with a monolithic structure and surprising soundproofing properties. Such a panel can achieve an NRC of 0.70 or higher.

  According to the present invention, the gypsum core is made by dispersing a number of punched holes or holes throughout the planar area of the gypsum core. The punched holes or holes are preferably limited on the front side by a painted non-woven porous scrim cloth or veil and optionally on the back side by a non-woven porous soundproofing cloth.

  A gypsum panel can be made, for example, by perforating a standard drywall sheet and then covering the punched hole side of the sheet with a further laminated sheet or layer. These drilling and laminating steps can be performed by the original manufacturer of the drywall sheet or by another entity independent of the original drywall manufacturer.

  Variations in the gypsum panel structure are possible. A common of these variants is a panel with a gypsum core and face with a punched hole, which is covered with a structure that appears to be essentially non-porous to the naked eye but is porous. .

  The disclosed gypsum-based panels can be installed in the same or similar manner as normal drywall. For ceiling applications, the soundproofing panel of the present invention is screwed into a “hat channel” supported on a grid tee, which is a conventional drywall suspension system, or a black iron channel typically used in commercial applications. It can be fastened or attached to a wooden framework that is used more frequently in residential construction. The soundproof wall can be constructed by attaching the soundproof panel of the present invention to a vertical member that acts as a spacing support element. It can be seen that the panels of the present invention can be easily taped and painted like regular drywalls using the same or similar materials, equipment, tools and skills to provide a smooth monolithic ceiling or wall. right.

It is a fragmentary schematic isometric view of a monolithic soundproof ceiling. FIG. 3 is a fragmentary cross-sectional view of a monolithic ceiling. It is a fragmentary scale sectional view of a modified form of the soundproof panel of the present invention. It is the figure of the corrected panel joint structure. FIG. 3 is a view of one embodiment of the present invention in which veils or scrims attached to one rectangular panel are interleaved and two adjacent panels and panel joints are superimposed. FIG. 6 is a view of the panel edge of FIG. 5. It is the figure of the several panel of FIG. 6 in the assembled | attached relationship. It is sectional drawing of the butt joint between a pair of soundproof panels comprised according to this invention. It is sectional drawing of a pair of contact | aural sound insulation panel which has the corrected edge part structure. FIG. 9B is a cross-sectional view of the panel of FIG. 9A in a fully installed state. It is sectional drawing of a pair of soundproof panel which joined the edge part, and the joined backing plate. 1 is a fragmentary cross-sectional view of a soundproof panel based on paper-coated gypsum board according to the present invention, the panel having a water resistant material applied to the edge area of the panel surface. FIG. 2 is a fragmentary cross-sectional view of a joint between two soundproof panels, each panel comprising a glass fiber / resin mat facing the gypsum core. FIG. 13 is a fragmentary cross-sectional view of one of the soundproof panels of FIG. 12.

  Next, referring to FIG. 1, a schematic partial view of the soundproof monolithic ceiling equipment 10 is shown. The layer portion of the ceiling 10 is removed to reveal details of the structure. The ceiling 10 is a suspension system that includes a dry wall grid 11 known in the art, the dry wall grid 11 having a main T-member 12 that is 4 feet from center to center and 16 inches from center to center or Intersects the intersecting T-shaped member 13 that is 2 feet apart. The dimensions used herein are typically nominal dimensions and are intended to include industry recognized metric equivalents. The main T-shaped member 12 that meshes with the intersecting T-shaped member 13 is suspended by a wire 14 attached to an upper structure (not shown). The outer periphery of the grating 11 is conventionally formed by channel forming portions 15 fixed to the respective walls 16.

  The soundproof panel 20 is attached to the lower side of the lattice T-shaped members 12 and 13 by self-drilling screws 21. The illustrated soundproof panel has a planar dimension of 4 feet x 8 feet, but may be longer, shorter and / or of different widths as required or practical. Due to the size of the panel 20 and the spacing of the grid T-shaped members 12 and 13, the panel edges can be under the grid T-shaped members and can be directly attached to them, providing sufficient support for the panel edges. Is guaranteed.

  Referring to FIG. 2, the soundproof panel 20 of the present invention is characterized by a gypsum core 24 having punched holes. One way to prepare the core 24 is to modify the dry wall sheet by perforating a commercially available standard dry wall sheet through the front paper surface 23, the gypsum core 24 and the back paper side or back paper surface 25. . The punched holes 28 can be formed by drilling, drilling or other known hole making techniques. The punched holes 28 are preferably spaced uniformly, and as an example, the punched holes can be 8 mm diameter round holes spaced 16 mm from center to center. This configuration results in a total punch hole area substantially equal to 20% of the total planar area of the panel 20. Other hole diameters, shapes, patterns and densities can be used. For example, tests have shown that a hole density of 9% of the total area can achieve good results. The edge region and the intermediate region corresponding to the center of the sheet support grid, beam or upright can be left without punching holes to maintain strength at the fastening point.

The sheets 29 and 30 are bonded to both sides of the dry wall sheet having the punching hole, thereby closing at least a part of both ends of the punching hole 28. On the back side of the drywall, the backing sheet or web 30 is preferably a sound-absorbing nonwoven fabric known in the soundproof ceiling panel field. By way of example, the backing fabric may be sold under the trade name SOUNDTEX® by Freudenberg Bergestoffe KG. The backing fabric has a nominal thickness of 0.2 to 0.3 mm and a nominal weight of 63 g / m ² . Specifically, the main components of this non-woven fabric example are cellulose and E-glass having a synthetic resin binder such as polyacrylic acid and poly (ethylene-CO-vinyl acetate). Alternatively, for example, the backing sheet 30 can be a porous paper layer. The sheet 30 may comprise a suitable adhesive to bond the sheet 30 to the backside paper side 25 of the modified drywall sheet 22.

On the front side of the drywall sheet 22, a sheet or web in the form of a nonwoven scrim layer 29 is attached with a suitable adhesive. The surface layer or sheet 29 is porous and materials suitable for this application are those that are used commercially as covers or surfaces for conventional soundproof ceiling panels. An example of this type of bale material is Owens Corning Veil Netherlands B.I. V. Sold under the product code A125 EX-CH02. This scrim fabric is composed of hydrated alumina glass fiber filaments, polyvinyl alcohol and acrylate copolymer. The unpainted scrim 29 has a nominal weight of 125 g / m ² and a porosity of 1900 l / m ² seconds at 100 Pa. The adhesive is first applied to the panel or sheet 22 so as not to block the face scrim 29. The face sheet 29 should be sufficiently sturdy to withstand the field finishing operations described below. Also, the topsheet 29 should be compatible with waterborne paints such as drywall joint compounds or similar materials and commercially available paints, typically those described below.

Other useful veils 29 include Owens-Corning Veil Netherlands B.I. V. By, A135EX-CY07 as (porous 600 l / ^{m 2} / sec at a nominal weight 180g ^/ m 2, 100Pa) (nominal weight 135 g ^/ m 2, porosity of 1050l / ^{m 2} / sec at 100 Pa) and A180EX-CX51 Includes non-woven fiberglass products for sale. All of the described veils are translucent and the punched holes 28 cannot be visually hidden unless painted or coated with a coating such as that disclosed herein.

  The other panel 20 having the same panel is suspended on the grid 11 in the same manner as installing a normal drywall. Similarly, as shown in FIG. 1, the joint 33 is taped in the same way that a normal drywall is taped. The drywall joint compound or similar material 34 is applied directly to the sheet 29 to adhere the tape or similar material 35 to the adjacent edges of the two abutting panels 20 and to hide the tape. Used to apply on top of 35. Typically, the long edge of the panel 20 tapers to receive the joint tape 35 below the plane of the main panel face. The joint compound 34 may be a conventional dry wall joint compound, and the tape 35 may be a conventional dry wallpaper or mesh tape. The screws 21 that secure the panel 20 to the spacing support elements 12 and 13 forming the grid 11 are countersunk as is conventionally done with a dry wall structure and are concealed with a joint compound 34, It is applied with a spatula or trowel in the same way as it is applied to drywall. The panel 20 can be attached to the vertical support with an adhesive when constructing the wall. After drying, the joint compound 34 can be integrated with the plane of the surface of the face sheet 29 by sanding or rubbing with a wet sponge.

  After sanding or smoothing the joint compound 34 with a sponge, the front side sheet 29 and the remaining joint compound are applied with a commercially available soundproof paint 31 used to paint a soundproof tile. An example of a suitable water-based paint, sometimes referred to as non-blocking paint, is available from ProCoat Products, Inc. of Maine, Maine, USA. And is sold under the trade name ProCoustic. An alternative non-blocking paint or non-bridging soundproof transparent paint or coating 31 can have the following formulation:

  The optimal pearlite flocculant particle size distribution for this coating is centered around 60-100% of its volume about 10-100 mesh and the packing density ranges from 6 to 8 pounds / cubic foot. be able to. The coating 31 can be applied in two layers at a total of 40 to 160 g / square foot, and a wet coating having a coverage of about 80 g / square foot is ideal.

  The fine particles of the coating formulation can provide a slightly textured appearance, which is equivalent to a moderate to coarse sandpaper appearance at about 30 to about 60 grit (on a CAMI and FEPA basis). This low level of texture can serve to effectively hide the joints between the panels from vision. To improve the finish uniformity of the ceiling appearance, the joints taped before painting can be covered with an elongated veil cloth 29, which is wide enough to cover the joint compound. is there. The coating should leave as much porosity as desired across layer 29, but should leave an appearance with a surface that appears essentially non-porous to the naked eye so that punched holes 28 are not visible. More specifically, the paint or coating 31 should be of non-bridging or non-blocking type, which can wet the fibers of the veil 29 but bridging between the fibers of the veil. The film which forms is not generated. Alternatively, if high NRC is not required, satisfactory results can be obtained through the use of conventional primer and one-layer indoor latex paint 31 to complete the installation of the ceiling 10. As used herein, the term monolithic structure indicates that the entire essentially visible surface of the ceiling or wall appears to be a seamless spread without joints.

  The 1/2 or 5/8 inch drywall-based panel 20 with the described punched hole configuration and the front sheet 29 and back sheet 30 and customary space behind the panel is the performance of a good grade soundproof ceiling tile NRC values exceeding 0.70 and 0.70 at the maximum can be exhibited.

In the present invention, the preferred properties of the gypsum-based core 24 are as follows:
Thickness: 0.5 to 0.625 inch, preferably 3/8 inch to 1 inch optionally.
Open area: 9.6-27.7%
Hole diameter: 6-12 mm.
Hole spacing: 15-25 mm.

  The following is the air flow characteristics of the non-woven SOUNDTEX® material backing layer 30 and the face layer 29 of the first non-woven scrim material before and after coating with a self-developed and ProCoustic soundproofing coating. It is.

  The following table shows NRC values for one or more boards of the present invention having other structures for comparison purposes. As noted in the table above, unless stated otherwise, the backing is a SOUNDTEX® material and the face is the first scrim identified above.

Test I:
* Panel with punched holes = punched holes with 3/8 inch diameter, 5/8 inch FC30 (dry wall) with 16 mm spacing from center to center-27.7% open area

Test II:
* Panel with punched holes = 6mm diameter punched holes, 15mm spacing from center to center, 1.5 inch boundary-hole pattern = 12.6% open area, overall panel = 9.6% open area Has a 1/2 inch ultralight (dry wall)

Test III:
Panel A (small hole) = round punched hole with a diameter of 8 mm, center-to-center 18 mm spacing and no border-1/2 inch Knauf 8 / 18R with 15.5% open area
Panel B (Large Hole) = 12 mm diameter round punched hole, center to center 25 mm spacing and no borders-1/2 inch Knauf 12 / 25R with 18.1% open area

Panel I of Test I had a heavy Manila paper surface with a nominal weight of 263.50 gm / m ² , a thickness of 17.22 millimeters, a density of 0.60 c / m ³ and a porosity of 58.97 seconds. This test sample shows that even though it is porous, the surface with too high air flow resistivity is not suitable for use in the present invention. Test I panel BB shows that a surface with higher air flow resistivity (see table above) than a painted scrim surface can achieve a satisfactory NRC.

  The soundproofing panel of the present invention can be manufactured by further methods and various structures, but maintains a limited punch hole on at least the surface side (room side) of the finished panel. For example, the backside layer 30 can be omitted if a high NRC value is not required. Perforated paper can be substituted for either of the nonwoven layers 29 and 30.

  It has further been discovered that NRC can be significantly increased by directing the punched holes at an angle to the plane of the panel. Such a structure is shown in FIG. The punching hole 28 can be oriented 20 degrees away from a line orthogonal to the panel plane, for example. One or more reasons for this improvement in sound insulation performance are currently not fully understood, but are more effective at larger punch hole volumes due to tilt angles and / or internal reflections of sound waves, and / or surfaces. This may be the result of a larger opening area.

  Referring to FIG. 4, there is shown an alternative joint structure showing in cross section the edges 36 of two adjacent panels 40. For the same elements, the same reference numerals used in FIG. 2 are used in FIG. The panel 40 is the same as the panel 20 except that it is of the “square edge” type, in which the edge of the panel long edge will receive the tape when the tape is on the panel 20. It has not decreased gradually. Glass fiber veil 29 is a trade name of ELMER's Products, Inc. Is adhered to the paper surface 23 with a suitable adhesive such as a polyvinyl acetate emulsion sold by the company. Veil 29 is sized such that bail 29 is spaced, for example, 1 inch from the panel edge and leaves edge 42. Any unavoidable or intentional narrow gaps 41 present between the panels 40 can be partially or substantially completely filled with the drywall joint compound 34, which is preferably: Curable, non-shrinkable or low-shrinkable types such as those disclosed in US Pat. No. 6,228,163; US Pat. No. 5,746,822; US Pat. No. 5,725,656; US Pat. No. 5,336,318; and US Pat. No. 4,661,161. The gap 41 is filled with the joint compound 34 flush with the outer surface of the front side paper surface 23. Alternatively, the gap 41 can be left partially unfilled or completely unfilled with the joint compound.

  Tape 43 made from the same material as the veil 29 can advantageously be used to span the joints or gaps 41 between the panels 40. The width of the tape 43 is smaller than the combined width of the panel edge regions 42. If the panel edge 42 not covered by the veil 29 is 1 inch wide, the bale tape 43 may be, for example, 1 to 1/4 inch wide. The tape 43 can be adhered, for example, with the same adhesive used to join the veil 29 to the paper surface 23, or can be adhered with a joint compound.

  The use of square edge drywall panels 40 and non-shrink curable joint compound reduces the time and effort to construct the ceiling or wall of the present invention. The space between the longitudinal edge of the tape 43 and the edge 44 of the panel veil 29 can be filled with a joint compound, preferably a fast-curing non-shrinkable joint compound. Next, the veils 29, 43 covering the panel 40 are preferably coated by spraying with one of the paints or coating materials 31 described above.

  5-7 show a modified sound insulation panel 50 that differs only in the size and position of the bail 29 of the panel 40 described in connection with FIG. The planar dimension of the veil 29 is slightly smaller than the corresponding planar dimension of the rectangular body or the remaining portion 51 of the panel 50 to be adhered to the panel 50. Furthermore, the veil 29 is offset from the body 51 along two intersecting edges 52, 53, so that these edges are cantilevered or free edges and are not glued directly to the body.

  The panels 50 are assembled from the same panel to constitute a wall, ceiling or similar soundproofing partition. Intersection joints joined to the edge 52 are interleaved in conjunction with adjacent panels joined at the edge 53. It can be seen that the cantilevers or edges 52 and 53 of the bail 29 rest on the actual joints that exist between the adjacent and abutting panel bodies 51. Prior to placing the panel 50 that would cover the veil edges 52, 53 from above, the edge region 54 of the previously placed panel 50 that is not covered by the veil 29 is a suitable adhesive such as those described above. Cover with. After placing the next panel 50, the free edges 52, 53 of the veil of the panel 50 can be pressed against the adhesive on the edge 54 of the previously placed panel 50. The configuration of shifting the veil of the panels 50 can eliminate the effort of tapering the joints between the panels and has the potential to result in joints that are invisible or nearly invisible to the viewer's eyes. There will be a very small gap between adjacent edges of the veil of the joined panel 50, which is generally equal to a selected small difference in the size of the veil 29 as compared to the body 51. While the various figures show a rectangular panel with one planar dimension larger than the orthogonal dimension, it should be understood that the intention is to include a square panel within the meaning of the term “rectangular”.

  For reasons of appearance and performance, it is desirable that the finish coating applied in the field to the installed and taped panel 20 is relatively smooth and has little or no texture. With regard to this smooth finish requirement, it may be difficult to hide the end joints between the panels 20, especially in the case of ceilings that are particularly exposed due to reflected light rays. Limiting the width of the joint compound at the joint requires additional constraints, so that the acoustic surface area of the panel 20 is not significantly covered by the joint compound, thereby reducing performance. Commercially available drywalls usually present a particularly difficult problem when there are no tapered portions at the end of the panel. Typically, drywall sheets (wallboards) are produced that have tapered portions along the long edges rather than on the short edges. When the end of the dry wall panel is brought into contact with each other, the dry wall panel forms what is referred to in the art as a “butt joint” with these non-decreasing short edges. In practice, it is impossible to hide the taped butt joints in a thin pattern of joint compound with a finish that has little or no texture. In one aspect of the invention, the drywall panels are modified at their butt joint ends to provide a recess in the outer surface that is coupled to the bail 29 to receive the joint tape 35 and joint compound 34. Several alternative structures are contemplated. The soundproof panel shown in FIGS. 8 to 10 has essentially the same structure as that described with reference to FIG. 2 except for the structure of the butt end portion. The panel, unlike the panel 20 previously described, has a taper on all four edges. For example, a recessed surface area that is at least about 1/32 inch and preferably about 5/64 inch in width, measured from the front side of the panel, with a width between about 1-3 / 4 inch and about 2 inches The taper is useful.

  One way to provide a taper at the butt end 71 of the panel 120 is by permanently compressing both ends of the panel to form a narrow recess or taper 72 along the length of the butt end. . This compression is essentially limited to the gypsum core 24 originally produced but having an air volume that allows the gypsum core to be compressed. The gypsum core 24 compressed in the depression or taper 72 has a correspondingly increased density compared to the rest of the gypsum in the core. The step of permanently compressing the butt end 71 of the panel 120 is performed when the veil 29 is bonded to the paper surface 23 or thereafter, or a punched hole or aperture 28 is drilled, drilled or otherwise formed in the panel. You can do it mechanically at the same time.

  Another fabrication method for forming a taper shape at the butt end 71 on the front side of the panel 20 is a gypsum core under the front side paper surface 23, in a manner that a tongue or kerf extends inwardly from the butt end. Part of the machine is removed by machine or otherwise, the paper and any gypsum applied to the paper are adhered, and the paper is not hindered by the tongue or kerf, Above the area on which the gypsum core 24 is based.

  FIGS. 9A and 9B show another manner of making a butt end having a dent or taper on the front side of the soundproof panel 220 of the present invention. Panel 220 is not the same structure as described in connection with panel 20 of FIG. Panel 220 is shown in the manufactured state in FIG. 9A. The deep kerf 81 is cut across the width of the back side of the panel 220 at both panel butt ends, and the chamfer 82 is cut from the kerf to the edge plane of the panel at both butt ends 71. FIG. 9B shows the panel 220 in the installed state, with the screw fastener 21 pulling the locally elongated portion of the panel toward the plane of the back side of the panel at the butt end. In the illustrated example, the butted ends 71 of the pair of panels 220 are under a support back plate 85 disposed between a lattice T-shaped member or other frame element (not shown), and the fasteners are placed in the support back plate 85. 21 is inserted so that the end of the panel is pulled against the plate. The result is a surface area 84 that gradually decreases from the front side plane to the back side plane of the panel 220 as it approaches the butt end 71.

  An alternative manner of providing a surface of the inner taper surface adjacent the butt end 71 of the gypsum drywall-based soundproof panel 320 is shown in FIG. The joint 86 between the two panels 320 is arranged to be suspended between two adjacent support elements or frame elements 13 rather than a single support element (shown at 13 in FIG. 1). A shallow U-shaped or V-shaped backing plate 87 is located on the back side of the panel 320. The illustrated backing plate 87 is a metal plate, but can be made of wood or other suitable material. A screw fastener 21 that attaches the panel 320 to the backing plate 87 bends the panel locally inward, thereby adjoining each abutting end 71 of the abutting panel from the plane of the major surface area of the panel 320. Resulting in an inner tapered surface region 88. As a result, a butt joint with a recessed area remains, which can fully receive the joint tape and joint compound.

  The drywall panel used to form the soundproofing panel of the present invention is first produced by pressing the gypsum core 24 and the paper surface 23 as a gypsum set in a dihydrate gypsum state in a certain region, and this region is finally formed. It is cut on a dry wall production line to become a butt end.

  A soundproofing panel similar to that described with reference to FIGS. 1 and 2 can be joined without the use of joint tape for the purpose of preventing conspicuous joints that have been taped. For example, the outer periphery of the drywall panel can be grooved on these outer surfaces, and the groove formed by the adjacent panel edge can be filled with a joint compound. File and fill the joints, and then re-seal one or more times to make the joints invisible between drywall panels with grooved edges, even after final painting Or it may be difficult to essentially hide. This difficulty in concealing joints is believed to be due, at least in part, to the swelling of the paper surface 23 of the drywall when exposed to water contained in the joint compound 34. If it is desirable to use a joint compound 34 containing water in the soundproof panel 20 of the present invention, it is advantageous to make the panel 20 with a surface 23 that does not readily swell when the surface 23 is exposed to the joint compound. Sometimes. Resistance to swelling caused by water can be achieved by treating the edge 56 (FIG. 11) of the front side paper surface 23 of the drywall sheet 22 (comprising the core 24 and the paper layers 23, 25) to be water resistant. . Since only the joints are of greatest interest, water resistance need only be applied to the face of the panel 20 or the room side edge 56. However, it is recognized that the entire front side paper surface 23 on the gypsum board core 24 can be treated or otherwise provided to be water resistant to resist the tendency to permanently swell upon application of the joint compound. Like. The face sheet 23 can be regarded as water resistant for the purposes of the present invention if the edge of the face sheet 23 does not swell beyond 0.005 inches when a joint compound containing water is applied.

  The edge area 56 (FIG. 11) of the paper plasterboard is coated with a suitable material 57 such as UV curable paint, siloxane, wax, silicone, solvent-based quick-drying binder, two-part coating system and polyurethane. Can be treated to make it water resistant, thereby providing swelling resistance. This list is exemplary and other useful materials exist. The water resistant material 52 can be roller-coated, sprayed or dipped on the paper surface or the sheet 23, for example.

  An alternative approach to reducing or eliminating the swelling of the front side paper surface 23 is the use of low water-absorbing manila paper or other types of waterproof paper made of special coatings or fibers that make the face sheet waterproof.

  These areas, which can be reduced by the edge area 57 of the panel 22, mean that it is intended or expected to be coated with a joint compound to hide the joint formed between the edges of adjacent panels. . The non-swelling waterproof panel described herein typically has the same through-hole pattern as described above herein, and the same nonwoven veil outer side layer 29 and nonwoven backside that are properly bonded. It has a layer 30.

  An alternative gypsum board structure is shown in FIGS. 12 and 12A. A fragmentary edge portion of the bonded gypsum-based soundproof panel 60 is shown in FIG. The panel 60 can be made using a ceiling board 61 such as that sold by the United States Gypsum Company under the trademark name SECUROCK®. The board 61 has a gypsum core 62 sandwiched between a pair of glass fiber mats or layers 63. Such ceiling boards 61 are available in 1/2 inch thick, 4 ft x 8 ft panels (or their industrial meter equivalents). All four edges of the panel 60 are grooved to form a tongue and groove 64 on the front side. As in the case of the panel 20 described above, the board 61 is penetrated by holes 28 that exist substantially over the entire surface area. As an example, the board 61 may have a punch hole pattern as follows: 3/8 diameter, approximately 3/4 inch spacing, and a 1.5 inch punch hole free boundary. The surface to which the tongue is attached is covered with the bale 29, and the surface without the tongue is covered with the backing sheet or web 30. The panel 60 is attached to the support structure already described with screws or the like. The joint between the panels 60 with a pair of adjacent ridges 64 is filled with a suitable joint compound 34 containing water. Do not use joint tape. The joint compound 34 can be a fast curing material such as an Easy-Sand brand joint compound sold by the United States Gypsum Company. The joint compound 34 can be applied in two layers and then lightly sanded.

  The layer 63 facing the gypsum core 62 of the board 61 is a non-woven glass fiber mat having a thickness of about 0.033 inches, impregnated with acrylic resin. These layers 63 are highly waterproof, almost impossible to absorb moisture, and are essentially impermeable to water. Therefore, as a result, there is no risk that the layer 63 absorbs water or obviously swells.

  The following is a non-cohesive, non-blocking coating that can be sprayed onto a soundproofing panel of the present invention to achieve a finish, conceal joints between panels, and conceal punch holes 28 that may normally be visible through the veil 29 Or it is a blend of paint. The coating can be applied twice and is lightly sanded after the first application.

  Fillers include but are not limited to carbonates (various particle sizes or forms), clays, delaminated clays, washed clays, nepheline syenite, TiO2, mica, talc, and other known fillers used in paints. Contains agents.

  Typically, the joint compound in the filed joint joint absorbs water to a different extent than the veil 29 and the underlying gypsum board surface layer 23. This difference in water absorption may result in different drying rates and may ultimately result in a final appearance difference in the water-based paint that covers the joint area and the rest of the soundproof panel from above. This effect is due to the fact that the joint area coated with the joint compound with sealant is first applied locally, such as by using a finish / paint on the joint area, and then the entire panel equipment is primed. Can be reduced. Subsequently, the entire facility is covered with one or more finish coatings.

  A second technique for reducing the difference between the finish on the joint filled with the joint compound and the finish on the main panel area is to paint the soundproofing panel with a primer in the factory. After the panel is installed with the other panels and the joints are finished, the system is completed by one or two finish paintings.

  The above disclosure includes, in part, a modification of the conventional drywall sheet to convert the conventional drywall sheet to the soundproof panel of the present invention. However, the soundproof panel of the present invention may be used during the original formation of the soundproof panel of the present invention, or immediately after the soundproof panel of the present invention is formed, and if there is one or both cover sheets or layers. Prior to attaching to the front and back sides, a perforated hole can be creatively produced in the gypsum core. The punched hole can be cast in a gypsum body, for example. The cross-section of the punch hole in the various disclosed embodiments may be needle-shaped if not punched.

  It should be apparent that the present disclosure is exemplary and that various changes can be made by adding, modifying, or excluding details without departing from the fair scope of the teachings contained in the present disclosure. Accordingly, the invention is not limited to the specific details of the disclosure except to the extent that the following claims are necessarily so limited.

Claims (3)

A rectangular sound insulation panel comprising a drywall sheet having a thickness of at least 12.7 mm for constituting a one-piece ceiling or inner wall ,
The drywall sheet has a gypsum-based core and a paper front side layer and a back side layer, and has a hole with a diameter of at least 3.2 mm through the gypsum base core and the paper front side layer and the back side layer. , Having holes drilled with holes that occupy at least 9% of the surface area of the panel,
The front side layer is covered with a porous nonwoven glass fiber veil having translucency that cannot completely hide the holes;
The porous nonwoven glass fiber veil is covered with a non-bridging coating;
The combination of the porous nonwoven glass fiber veil and the non-bridging coating is effective to conceal the hole, while providing sufficient porosity to the hole so that the panel is at least 0.55. To present NRC,
Short edges of the panels forming a pointed joint with the same panel, locally has a recessed area in the front surface of the panel, the joint tape and joint compound for front surface of the panel porous nonwoven A soundproof panel received between a glass fiber veil and the non-bridging coating. The soundproof panel according to claim 1, wherein the panel has a local depression region formed by permanently compressing a gypsum- based core on a front side surface of the panel. A rectangular soundproof panel comprising a drywall sheet having a thickness of at least 12.7 mm,
The drywall sheet has a gypsum-based core and a paper front side layer and a back side layer, and has a hole with a diameter of at least 3.2 mm through the gypsum base core and the paper front side layer and the back side layer. , Having holes drilled with holes that occupy at least 9% of the surface area of the panel,
The front side layer is covered with a porous nonwoven glass fiber veil having translucency that cannot completely hide the holes;
The porous nonwoven glass fiber veil is covered with a non-bridging coating;
The combination of the porous nonwoven glass fiber veil and the non-bridging coating is effective to conceal the hole, while providing sufficient porosity to the hole so that the panel is at least 0.55. To present NRC,
Short edges of the panels forming a pointed joint with the same panel, by machining, by pulling the realm adjacent the short edges of the panel to the panel support part on the back side surface of the panel, wherein the Oite the short edges of the panel, to the main area of the front surface of the same panel front surface is the main region and adjacent the front surface of the panel of the panel, in which as recessed locally A rectangular soundproof panel.

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