TWI611077B - Acoustical panels and combination thereof - Google Patents

Abstract

An acoustical panel for forming an integral ceiling or wall, the panel extending over a rectangular region and having a core made primarily of gypsum, the core being substantially coextensive with the panel region, thus The core has two opposite sides, each area being substantially equal to the area of the plate, the core having a plurality of perforations extending substantially between the sides thereof, the perforations being substantially evenly distributed over the entire area of the core and Opened on both sides of the core, the surface side of the core is covered by a porous layer, which is limited by the back side of one of the cores, on the surface of the core The porous layer at the side is suitable for adhering drywall bonding compounds and a water based non-blocking coating.

Description

Sound absorbing panels and combinations thereof

The present invention relates to building materials and systems, and more particularly to a sound absorbing panel for constructing integral ceilings and interior walls.

The sound absorbing effect in a building is usually achieved by a ceiling tile placed on a hanging grid. In general, the sound absorbing ability of bricks is achieved by the material selection and/or the characteristics of the room contact surface. The ceiling tile installation has the advantage of being able to easily access the space above the ceiling, but even when the grid is concealed, the boundary between the tiles can be seen. Architects and interior designers have been looking for a monolithic, untextured sound-absorbing ceiling, especially when there is no need to touch the space above the ceiling. Ordinary gypsum board drywall ceiling construction cannot achieve a sufficiently high noise reduction coefficient (NRC) that can be called sound absorption. The perforated gypsum board achieves an acceptable NRC level, but is non-integral in appearance.

The present invention is directed to the discovery that ordinary gypsum boards (e.g., drywall sheets) can be modified to create a sound absorbing ceiling or wall having an integral flat surface and excellent sound absorbing properties. These boards can achieve a noise reduction factor (NRC) of 0.70 or higher.

According to the invention, the gypsum board core is formed with a plurality of perforations or holes throughout its planar area. The perforations or holes are preferably exposed to a woven non-woven porous front side Restricted by non-woven porous scrim fabric or veil, and optionally limited by a nonwoven porous sound absorbing fabric on the back side.

For example, a gypsum board can be made by perforating a standard drywall sheet and then covering the perforated side of the sheet with additional laminated sheets or layers. These perforation or lamination steps can be performed by the original manufacturer of the drywall sheet or by a separate entity independent of the original drywall manufacturer.

A structural variant of the gypsum board is envisaged. In these variations, a common variant is a plate having a perforated gypsum core and having a surface covered by a porous structure, but the porous structure appears to the naked eye to be substantially non-porous.

The disclosed gypsum-based panels can be installed in the same or similar manner as conventional drywall. When used in a ceiling, the sound absorbing panel of the present invention can be screwed to a conventional drywall suspension system formed of a grille tee or a "slotted steel" on a black iron channel commonly used in commercial applications. (hat channel), or the sound absorbing panel of the present invention can be attached to a wooden frame commonly used in residential buildings. The sound absorbing wall can be constructed by attaching the sound absorbing panel of the present invention to a vertical stud, which is used as a spaced apart support member. It can be seen that the panels of the present invention can be easily taped and painted using the same or similar materials, equipment, tools and skills as conventional drywall to form a sleek monolithic ceiling or wall.

10‧‧‧Installation of sound-absorbing monolithic ceilings

11‧‧‧ Drywall grille

12‧‧‧Main T-piece

13‧‧‧Cross-shaped pieces

14‧‧‧Wire

15‧‧‧ Channel molding

16‧‧‧ wall

20‧‧‧Acoustic board

21‧‧‧ self drilling screws

23‧‧‧ Paper front

24‧‧‧Gypsum core

25‧‧‧paper side/back

28‧‧‧Perforation

29‧‧‧Sheet

30‧‧‧Sheet

31‧‧‧ Coating/Coating

34‧‧‧ joining compounds

35‧‧‧ strips

40‧‧‧ board

41‧‧‧ gap

42‧‧‧Edge area

43‧‧‧ strips

44‧‧‧ side

50‧‧‧Acoustic board

51‧‧‧ Subject

52‧‧‧ side

53‧‧‧ side

54‧‧‧Edge area

56‧‧‧ edge

57‧‧‧Materials

60‧‧‧Gypsum-based sound absorbing panels

61‧‧‧Deep panels

62‧‧‧ core

63‧‧‧Fiberglass mat/layer

64‧‧‧ notch

71‧‧‧Docking end

72‧‧‧Compressed area/tapered area

81‧‧‧Deep sawing

82‧‧‧Slope

84‧‧‧Surface area

85‧‧‧Support floor

86‧‧‧Connectors

87‧‧‧Backing board

88‧‧‧Surface area

120‧‧‧ boards

220‧‧‧Acoustic board

320‧‧‧Acoustic panels based on gypsum drywall

1 is a partial isometric view of an integral sound absorbing ceiling; FIG. 2 is a partial enlarged cross-sectional view of the integral ceiling; and FIG. 3 is a partially enlarged cross-sectional view showing a modification of one of the sound absorbing panels of the present invention; Figure 4 illustrates a modified plate joint configuration; Figure 5 illustrates an aspect of the invention in which the veil and the veneer attached to a rectangular plate are staggered to overlap the joints of the plates. Adjacent panels; Figure 6 is an edge view of the panel shown in Figure 5; Figure 7 shows a plurality of panels shown in Figure 6 assembled together; Figure 8 is a pair of sound absorbing panels constructed in accordance with the present invention. A cross-sectional view of a butt joint; a 9A is a cross-sectional view of a pair of butted sound absorbing panels having a modified end configuration; and a 9B is a panel shown in Fig. 9A in a fully installed state. Figure 10 is a cross-sectional view of a pair of end-contacting sound absorbing panels and an associated backer panel; Figure 11 is a plasterboard based on the sound absorbing panel of the present invention and covered with paper A partial cross-sectional view of the panel, the edge region of the surface of the gypsum board is coated with a water resistant material; and FIG. 12 is a partial cross-sectional view of a joint between the two sound absorbing panels, each of which includes a fiberglass/resin mat (mat) The facing gypsum core; and the 12A figure is shown in Figure 12 Wherein one of the partial enlarged sectional view of the sound board.

Referring now to Figure 1, a partial schematic view of a sound absorbing monolithic ceiling unit 10 is shown. Portions of the various layers of the ceiling 10 are stripped to reveal structural details. The ceiling 10 is a suspension structure that includes a drywall grille 11 as is known in the art. The drywall grill 11 includes a plurality of main T-pieces 12 having a center-to-center distance of 4 inches and a plurality of cross tees 13 having a center-to-center distance of 16 inches or 2 inches. The dimensions used herein are generally nominal dimensions and are intended to include equivalent dimensions in the metric industry. The main tee 12 interlocking with the cross member 13 is suspended by a plurality of wires 14 attached to an upper structure (not shown). The periphery of the grid 11 is typically formed by channel molding 15 secured to each wall 16.

The sound absorbing panel 20 is attached to the grille tee 12 and the underside of the cross member 13 by a self-drilling screw 21. The illustrated sound absorbing panels are 4 inches by 8 inches in planar size, but they may have longer or shorter dimensions and/or have different widths as needed or practical. The dimensions of the plate 20 and the spacing between the grid T-shaped member 12 and the cross member 13 are such that the sides of the plate are positioned below the grid tee and attached directly to the grid tee to ensure that the sides are well received. Support.

Referring to Fig. 2, the sound absorbing panel 20 of the present invention is characterized by having a perforated gypsum core 24. A method of providing a core 24 is by modifying a commercially available standard drywall sheet by passing through one of the paper front faces 23, the gypsum core 24, and a paper side or back 25 of the drywall sheet. The drywall sheet is perforated. The perforations 28 can be formed by drilling, punching, or other conventional hole making techniques. The perforations 28 are preferably uniformly spaced from each other; for example, the perforations may be circular holes having a diameter of 8 millimeters (mm) and a center-to-center distance of 16 mm. This arrangement is such that the total area of the perforations is substantially equal to 20% of the total planar area of the panel 20. Holes having other sizes, shapes, patterns, and densities can also 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 portion corresponding to the support grid, joist, or stud of the sheet may not be perforated to maintain the strength at the fastening point.

Sheets 29, 30 are laminated to both sides of the perforated drywall sheet to at least partially close the ends of the perforations 28. At the back of one of the drywalls, the backing sheet or web 30 is preferably one of the sound absorbing nonwoven fabrics known in the field of sound absorbing ceilings. For example, the backing fabric can be a fabric sold by Freudenberg Vliesstoffe KG under the trademark SOUNDTEX®. The backing fabric has a nominal thickness of from 0.2 mm to 0.3 mm and a nominal weight of 63 grams per square meter (g/m ² ). Specifically, the main component of this nonwoven fabric example is a cellulose resin having a synthetic resin binder (for example, polyacrylate, poly(ethylene-co-vinyl acetate)) and E-grade glass (E- Glass). Alternatively, for example, the backing sheet 30 can be a paper porous layer. The sheet 30 can be provided with a suitable adhesive to adhere to the paper back side 25 of the modified drywall sheet 22.

A sheet or web 29 in the form of a nonwoven fabric veneer layer is attached to the front side of one of the drywall sheets 22 by a suitable adhesive. The facing layer or sheet 29 is porous; one suitable material for this application is commercially used as a material for a cover or surface of a conventional acoustic ceiling. An example of this type of veil material is the material operated by Owens Corning Veil Netherlands BV (product code A125 EX-CH02). The scrim fabric comprises hydrated alumina fiber glass filaments, polyvinyl alcohol, and an acrylic copolymer. The unpainted scrim 29 has a nominal weight of 125 grams per square meter and an air porosity of 1900 liters per square meter per second (l/m ² /s) at 100 Pa. To avoid blocking the surface scrim 29, an adhesive can be applied to the sheet or sheet 22 initially. The contact sheet 29 should be sufficiently strong to withstand the finishing work described below. The contact sheet 29 should also be compatible with dry joint compounds or similar materials and commercially available coatings (typically water based coatings as described below).

Other available veiles 29 include Owens-Corning Veil Netherlands BV with product code A135 EX-CY07 (nominal weight 135 g/m2, porosity of 10050 liters at 100 Pa) / square meters / sec) and A180EX-CX51 (nominal weight of 180 g / m2, a porosity of 100 liters / 100 m / sec at 100 Pa) non-woven fiberglass products. The veil is translucent and does not visually conceal the perforations 28 unless it is painted or coated with a coating as described herein.

The plate 20 and other identical plates are suspended from the grid 11 in the same manner as the conventional drywall. Similarly, as shown in Figure 1, the strip is attached to the joint in the same manner as the strip is applied to the normal drywall. The strip or similar material 35 is adhered to the two butt plates 20 by dry coating or similar material 34 directly onto the sheet 29 and applied over the strip 35 using a drywall bonding compound or similar material 34. Adjacent edges to conceal strips. Typically, the long sides of the panel 20 are tapered to accommodate the engagement strips 35 below the plane of the major portion of the panel surface. The bonding compound 34 can be a conventional drywall bonding compound, and the strip 35 can be a conventional dry wallpaper or mesh strip. As in the conventional drywall construction, the screws 21 for securing the panel 20 to the spaced support members 12 and 13 forming the grid 11 are countersunk and in the same manner as applied to conventional drywall. A tapping knife or a trowel coats the bonding compound 34 so that the bonding compound 34 conceals the screw 21. When a wall is constructed, the panel 20 can be adhesively attached to the vertical stud support. When the bonding compound 34 is dried, the bonding compound 34 may be sanded with a sandpaper or wiped into the plane of the surface of the surface sheet 29 with a wet sponge.

After the bonding compound 34 is sanded or smoothed with a sponge, the front sheet 29 and the remaining bonding compound are painted using a commercially available sound absorbing coating 31 for absorbing the sound absorbing brick. An example of a suitable water based coating (sometimes referred to as a non-blocking coating) is commercially available from ProCoat Products, Inc., Holbrook, Maine, under the trademark ProCoustic. An alternative non-blocking or non-bridging sound absorbing clear coating or coating 31 can have the following formulation:

The best perlite aggregate particle size distribution for this coating is concentrated around 10 to 100 mesh (between 60% and 80% of its volume) and the bulk density can be 6 lbs/per cubic. Miles to 8 pounds per cubic foot. The coating 31 can be applied to the two coatings in a total of 40 grams per square inch to 160 grams per square inch, and a coverage of about 80 grams per square inch in the wet state is desirable.

The particles of the coating formulation can form a slightly textured appearance that is equivalent to sandpaper to coarse sandpaper having a particle size between about 30 and about 60 grit (CAMI and FEPA standards). This low texture can be used to visually effectively conceal the joint between the plates. In order to improve the consistency of the final appearance of the ceiling, a strip-attached joint may be covered with a strip of veil fabric 29 having a width sufficient to cover the bonding compound prior to painting. The application of the coating should Layer 29 is provided with sufficient porosity as desired, but with its appearance substantially visible to the naked eye as a non-porous surface so that perforations 28 are not visible. More specifically, the coating or coating 31 should be of a non-bridging or non-blocking type that can wet the fibers of the veil 29 but does not form a film between the fibers and the fibers that bridge the veil. Alternatively, when high NRC is not required, the ceiling 10 can be installed to achieve satisfactory results by coating with one of a conventional primer and an interior latex paint 31. When the term "integral" is used herein, it is used to mean that the entire visible surface of a ceiling or wall appears to be seamless and without any joints.

a 1/2 inch or 5/8 inch drywall based panel 20 having the perforated arrangement and front sheet 29 and back sheet 30, and a custom space behind the panel, the panel can be represented NRC values up to 0.70 and above, and their grades are equal to the performance of better grades of sound-absorbing ceiling tiles.

At present, the preferred characteristics of the gypsum-based core 24 are: thickness: preferably 0.5 inches to 0.625 inches.

3/8 inches to 1 inch as needed

Opening area: 9.6-27.7%

Hole diameter: 6-12 mm

Hole spacing: 15-25 mm

The following backing layer 30 of the above-mentioned non-woven SOUNDTEX® material, the surface layer 29 of the above-mentioned first nonwoven curtain material, before being painted, and after being coated with a proprietary sound absorbing coating and a sound absorbing ProCoustic coating, respectively Air flow characteristics.

The table below shows the NRC values for the panels of the present invention, as well as the NRC values for panels of other configurations for comparison purposes. Unless otherwise indicated, as in the previous table, the backing is a SOUNDTEX® material and the surface is the first veil described above.

Test I:

* Perforated plate = 5/8 inch, FC30 (dry wall), with 3/8 inch (3/8" diameter perforation, 16 mm center distance - 27.7% open area

Test II:

* Perforated plate = 1/2 inch, ultra light (dry wall), with 6 mm diameter perforation, 15 mm center distance, 1.5 inch plate - hole pattern = 12.6% open area, overall plate = 9.6% open area

Test III:

Plate A (small hole) = 1/2 inch, Knauf 8/18R, with a circular perforation of 8 mm diameter, 18 mm center distance & no plate - 15.5% open area

Plate B (large hole) = 1/2 inch, Knauf 12/25R, with circular perforations 12 mm in diameter, 25 mm center distance & no plate - 18.1% open area

Plate E of Test I has a heavy manila paper face having a basis weight of 263.50 grams per square meter (gm/m ² ), a thickness of 17.22 mils (caliper), 0.60. The density of grams per cubic centimeter (g/cm ³ ) and the porosity of 58.97 seconds. This test sample illustrates a surface having an excessively high air flow resistance, although it is porous and not suitable for use in the present invention. The board of Test I, BB, states that a surface with a higher air flow resistance (see table above) is a satisfactory NRC compared to the painted screen surface.

The sound absorbing panels of the present invention may be fabricated in other manners or may be fabricated in other configurations, but with the need to keep the perforations effectively confined to at least the surface (room) side of a finished panel. For example, the back layer 30 can be omitted when a high NRC value is not required. Any of the nonwoven layers 29, 30 can be replaced by porous paper.

It has further been found that the NRC can be moderately increased by orienting the perforations to be inclined relative to the plane of the panel. Such a configuration is illustrated in Fig. 3. For example, the perforations 28 can be oriented at an angle of 20 degrees to a line perpendicular to the plane of the panel. The reason for achieving such improved sound absorption performance is not fully understood, but may be an increase in the volume of the perforation, and/or an internal reflection of the acoustic wave due to the presence of the tilt angle, and/or an increase in the effective opening area on the surface. result.

Referring to Figure 4, an alternative joint configuration is illustrated in which the edges 36 of two adjacent panels 40 are shown in cross-section. The same reference numerals are used in Fig. 4 to denote the same elements. The plate 40 is identical to the plate 20 except that the plate 40 is a plate having a "square edge" type with the edges of the long sides not tapered as in the plate 20 to accommodate a strip. The adhesive to a suitable (e.g., an emulsion of a polyvinyl acetate) adhesive to the paper surface of the glass fiber veil 23 of 29 lines (Elmer 's Products, Inc. ) By the company logo ELMERS® Elmer product marketing of products. The veil 29 is sized such that it is placed, for example, 1 inch from the edge of a panel leaving the edge 42. Any narrow gap 41 that is inevitably or intentionally formed between the plurality of sheets 40 may be partially or substantially completely filled with the drywall joint compound 34, preferably as in the following patents. One of the disclosed, curable, non-shrinking or low-shrinkage, sand-abrasive-type compounds: US 6,228,163, US 5,746,822, US 5,725,656, US 5,336,318, and US 4,661,161. The gap 41 is filled with the bonding compound 34 and is flush with the outer surface of the paper front side 23. Alternatively, the gap 41 may not be partially or completely filled to join the compound.

A strip 43 made of the same material as the veil 29 can advantageously be used to span the joint or gap 41 between the panels 40. The width of the strip 43 is less than the combined width of the edge regions 42 of the panel. When the width of the panel edge 42 not covered by the veil 29 is 1 inch, the width of the veil strip 43 may be, for example, 1-1/4 inch. For example, the strip 43 can be adhered by the same adhesive used to bond the veil 29 to the paper surface 23, or by bonding compounds.

By using the square edge drywall 40 and the non-shrinking, curable joining compound, the time and labor required to construct the ceiling or wall of the present invention is reduced. The space between the longitudinal edges of the strips 43 and the sides 44 of the veil 29 can be filled with a bonding compound, preferably filled with a fast curing, non-shrinking type of bonding compound. The veil 29, 43 of the cover sheet 40 is then preferably applied by spraying one of the above coatings or coating materials 31.

Figs. 5 through 7 illustrate a modified sound absorbing panel 50 which differs from the panel 40 illustrated in Fig. 4 only in the size and position of the veil 29. The planar dimension of the veil 29 is slightly smaller than the corresponding planar dimension of the rectangular body or remaining portion 51 to which the panel 50 is adhered. In addition, the veil 29 is offset from the body 51 along the two intersecting edges 52, 53 such that the sides are cantilevered and do not directly adhere to the body.

The panels 50 are assembled with the same panels to construct a wall, ceiling or similar sound absorbing barrier. The cross joint associated with the edge 52 can be staggered with the adjacent plates joined at the edge 53. It can be seen that the cantilevered portion or sides 52 and 53 of the veil 29 are bridged adjacently, The actual joint between the main bodies 51 of the docking plate. The edge region 54 that is not covered by the veil 29 of a previously mounted panel 50 is coated with a suitable adhesive as described above prior to placing a panel 50 that will provide an overlying veil edge 52, 53. After the placement of the next panel 50, the unfixed veil edges 52, 53 can be pressed onto the adhesive on the edge region 54 of the previously placed panel 50. The offset veil setting of the panel 50 eliminates the need for the strap to be attached to the joint between the panels and has the potential to provide a joint that the viewer cannot see or barely see with the naked eye. Only a very small gap will be present between adjacent edges of the veil of the joined panels 50, the gap being substantially equal to the selected small difference between the size of the veil 29 and the body 51. Although a rectangular plate having a horizontal size larger than a vertical size is exemplified in the various figures described above, it should be understood that the square plate is intended to be encompassed within the meaning of the term "rectangular".

For aesthetic and performance reasons, it is desirable that the final coating applied to one of the panels 20 that are mounted and affixed in the field is relatively smooth and has little or no texture at all. Due to this smoothness requirement, it may be difficult to conceal the end joints between the panels 20, especially the brightly lit ceilings. A further limitation is that it is desirable to limit the width of the bonding compound at a joint such that the sound absorbing surface area of the sheet 20 is not covered by the bonding compound in a large amount, resulting in a decrease in potency. One of the tricky challenges of the generally commercially available drywall is that the end of the plate lacks a taper. The drywall sheet (wall sheet) usually produced has a taper along its long side and no taper on its short side. When the drywall panels are butted end to end, the panels will form "butt joints" known in the art at their short, non-tapered edges. In fact, it is not possible to conceal a butt joint with a strip by a non-textured or low-texture final coating in one of the narrow patterns of the bonding compound. In one aspect of the invention, the butt joint end of the drywall panel is modified to provide a recessed area at the outer surface associated with the veil 29 for receiving the joint strip 35 and the bonding compound 34. Several alternative configurations are envisaged. In addition to the butt end configuration Further, the sound absorbing panels shown in Figs. 8 to 10 have substantially the same configuration as those described in connection with Fig. 2. Unlike the previously described panels 20, the panels have a taper on all four sides. For example, the width is between about 1-3/4 inches to about 2 inches, and the dimension from the front of the panel to the deepest depression is at least about 1/32 inch (preferably about 5/64 inch).凹陷) One of the concave surface areas or taper systems is suitable.

A manner of providing a taper at the butted end 71 of a plate 120 is to permanently compress the ends of the plate to form a narrow recessed region or taper 72 along the length of the butted end. This compression is substantially limited to the gypsum core 24, which has an air content at the time of initial manufacture to enable it to be compressed. The density of the gypsum core 24 compressed at the compression zone or taper 72 is correspondingly increased relative to the remaining gypsum in the core. The step of permanently abutting the end portion 71 of the compression plate 120 may be performed while or after laminating the veil 29 to the paper surface 23, or may be formed in the plate 120 by perforation or hole 28 by punching, drilling, or otherwise. The step of permanently docking the end portion 71 of the compression plate 120 is performed in a machine.

Another method of forming a tapered geometry at the front face of the butted end 71 of the panel 20 is in the form of a rabbet or kerf extending inwardly from the butted end. Cutting or otherwise removing certain gypsum cores below the paper front side 23 and attaching the paper and any gypsum attached thereto to the gypsum core 24 undisturbed at the notch or kerf Underlying zone.

Figs. 9A and 9B illustrate another manner of fabricating a butt edge having a recessed area or a taper at the front surface of one of the sound absorbing panels 220 of the present invention. The plate 220 has the same configuration as the plate 20 described in connection with Fig. 2. Fig. 9A shows the manufacturing state of the board 220. A deep kerf 81 is cut across the entire width of the back of the plate 220 at the butt end of the plate and is at the two butt end 71 A chamfer 82 is cut from the kerf to the edge of the board. Figure 9B shows the plate 220 in a mounted state in which the screw fastener 21 has pulled a partial strip region of the plate toward the back side of the plate at the butt end. In the illustrated example, the butted ends 71 of the pair of plates 220 are located below a support floor 85 that is disposed between the invisible grille T-pieces or other frame members on which the support plate is In 85, the fastener 21 is driven to pull the end of the plate against the plate. As a result, it is obtained that the plane from which the front surface of the plate 220 is located is tapered toward the plane on which the back surface is located and gradually approaches the surface area 84 of the butted end portion 71.

Figure 10 illustrates an alternative to establishing an inwardly tapered surface adjacent a mating end of a drywall of gypsum based on the sound absorbing panel 320. One of the joints 86 between the two plates 320 is arranged to land between two adjacent supports or frame members 13 rather than at a single support member (as shown at 13 in Figure 1). A backing plate 87 in the form of a shallow U or shallow V is located at the back of the plate 320. As shown, the backing sheet 87 is a metal sheet, but it can be a board of wood or other suitable material. The screw fasteners 21 attaching the plate 320 to the backing plate 87 cause the plates to be partially bent inwardly, and thus adjacent to the abutting ends 71 of the respective abutting plates, forming a plane inward from the main surface area of the plate 320. One surface area 88 of the cone. This allows the butt joint to have a recessed area that can completely accommodate a bond strip and bond compound.

When the gypsum is cured in the dihydrate state at the region where it will eventually be cut into the butted ends, it can be originally produced for use by pressing the gypsum core 24 and the paper surface 23 on the drywall line. A drywall panel forming the sound absorbing panel of the present invention.

In order to avoid the formation of a butt joint that is clearly attached with a strip, the sound absorbing panels similar to those described in connection with Figures 1 and 2 can be joined to each other without the use of a joining strip. For example, the wiring around the drywall panel can be determined at the outer surface of the drywall panel, and the recess formed by the adjacent edge of the panel can be It is filled to join the compound. Even after the joint is sanded, filled, and sanded one or more times and finally painted, it is still difficult to form an invisible or substantially invisible joint between the dry panels that are determined to be wired. . It is believed that this difficulty in concealing a joint is due, at least in part, to the expansion of the paper surface 23 of the drywall upon exposure to moisture contained in the bonding compound 34. When it is desired to use a water-containing bonding compound 34 for the sound absorbing panel 20 of the present invention, it is advantageous to produce the sheet 20 having the surface 23 which does not easily expand when exposed to the bonding compound. The water-induced expansion can be achieved by treating the edge 56 (Fig. 11) of the paper front side 23 of the drywall sheet 22 (including the core 24 and the paper layers 23, 25) to impart water absorption resistance. Tolerance. Since only the joint is of the utmost concern, it is only necessary to make the surface of the panel 20 or the edge 56 of the room side water resistant. However, it will be appreciated that the entire paper front side 23 of the gypsum board core 24 can be treated to have water resistance to withstand the tendency to permanently expand after application of the joint compound. If the side of the surface sheet 23 does not expand more than 0.005 inch after application of the aqueous bonding compound, the surface sheet 23 can be considered to achieve the water resistance of the present invention.

Applying a suitable material 57 (eg, UV curable coating, siloxane, wax, polyoxymethylene, a solvent-based quick-drying adhesive, to the edge surface region 56 (Fig. 11) of a paper-coated gypsum board, The one-two component coating system and the polyurethane), the edge surface region 56 can be treated to have water resistance and thus have expansion resistance. The items listed herein are exemplary and other effective materials exist. For example, the water resistant material 57 can be rolled, sprayed, or immersed onto the paper or sheet 23.

An alternative method for reducing or eliminating the expansion of the paper front side 23 is to use a low water absorptive manila paper, or other type of waterproof paper made from a special coating and fibers to impart water resistance to the surface sheet.

The edge regions 56 of the panels 22 refer to regions that may be tapered and that are intended or desirably coated with a bonding compound to conceal one of the joints formed between the edges of adjacent panels. The non-expanded flashing sheets described herein generally have the same through-hole pattern as described above, as well as the same suitably adhered nonwoven outer surface layer 29 and nonwoven back layer 30.

Figures 12 and 12A illustrate an alternative gypsum board construction. Figure 12 shows a partial edge portion of the joined gypsum-based sound absorbing panel 60. A panel 60 can be made using a roof board 61 (e.g., a product run by the United States Gypsum Company under the trademark SECUROCK®). The plate 61 has a gypsum core 62 sandwiched between a pair of fiberglass mats or layers 63. Such roofing panels 61 may be obtained from panels having a thickness of 1/2 inch, 4 inches by 8 inches (or equivalent in the metric industry). The wiring of all four sides of the board 60 is determined to form a notch 64 at the front side. As in the case of the previously described plate 20, a plurality of holes 28 are formed in the plate 61, the holes 28 being substantially present over the entire surface area of the plate 61. For example, the plate 61 can have a perforation pattern of 3/8 inch diameter, approximately 3/4 inch apart, and a non-porous boundary of 1.5 inches. The notched face is covered by the veil 29, and the unopened face is covered by the backing sheet or web 30. The plate 60 is attached to one of the support structures as described above by screws or the like. A joint comprising a pair of adjacent slots 64 between the plurality of plates 60 is filled with a suitable aqueous joint compound 34. No straps are used. The bonding compound 34 can be a fast curing material such as an Easy-Sand brand bonding compound operated by American Gypsum Corporation. The bonding compound 34 can be applied to the two coatings and then subjected to a slight sanding.

The layer 63 of the gypsum core 62 facing the plate 61 is a non-woven fiberglass mat impregnated with acrylic resin having a thickness of about 0.033 inches. These layers 63 are highly water resistant, do not absorb large amounts of moisture, and are substantially impervious to water. Therefore, there is no need to worry about the layer 63 will absorb water or cause Absorbs water and swells significantly.

The following is a non-barrier non-blocking coating or coating formulation that can be sprayed onto the sound absorbing panels of the present invention to provide a finish layer, a joint between the concealed sound absorbing panels, and hidden through The veil 29 can be seen as a perforation 28. The coating can be used in two applications, the first of which is sanded with a slight sandpaper.

填充劑包括但不限於：碳酸酯(不同粒度或形態)、黏土、剝層黏土、水洗黏土、霞長石、TiO₂、雲母、滑石、及用於塗料中之其他已知填充劑。

Fillers include, but are not limited to, carbonates (different particle size or morphology), clay, delaminated clay, washed clay, celsian, TiO ₂ , mica, talc, and other known fillers used in coatings.

In general, the joint compound in a sandpaper-polished joint of a finished product has a degree of water absorption different from that of the veil 29 and the underlying surface layer 23 of the gypsum board. This different water absorption rate can lead This results in different drying rates and ultimately results in a different appearance of the water-based coating of the overlying joint area and the rest of the sound absorbing panel. This effect can be reduced by first painting the joint area covered by the joint compound by a sealer (for example by using the final coating/coating locally on the joint area) and then coating the entire board construction paint. The entire construction is then coated with one or two final coatings.

A second technique for reducing the difference between the final coating coating over the joint filled with one of the joint compounds and the area of the main board is a primer which is applied to the sound absorbing panel in the factory. After the panels are mounted with the other panels and their joints are completed, the system is completed with one or two final coatings.

The above disclosure relates in part to modifications to a conventional drywall sheet to convert it into a sound absorbing panel of the present invention. However, prior to attaching one or two cover sheets or layers (if present) to the front and back sides thereof, the sound absorbing panel of the present invention may be formed immediately upon its initial formation or immediately after it is formed. A perforation is first made in the core. For example, the perforations can be cast into the gypsum body. The cross-section of the perforations in the various disclosed embodiments may be non-circular when not drilled.

It is apparent that the present invention is described by way of example, and various changes may be made by the addition, modification or removal of certain details without departing from the scope of the invention. Therefore, the invention is not limited to the specific details disclosed herein, unless the scope of the claims

12‧‧‧Main T-piece

21‧‧‧ self drilling screws

23‧‧‧ Paper front

24‧‧‧Gypsum core

25‧‧‧paper side/back

28‧‧‧Perforation

29‧‧‧Sheet

30‧‧‧Sheet

34‧‧‧ joining compounds

35‧‧‧ strips

Claims (11)

A rectangular sound absorbing panel comprising a drywall sheet having a thickness of at least 1/2 inch or having a metric industry equivalent thickness, the drywall sheet having a gypsum-based core and a paper front layer and a paper back layer, the drywall sheet being perforated through the surface and the core, the diameter of the holes being at least 1/8 inch and the number of holes being sufficient to constitute at least 9% of a surface area of the sheet, The front side of the panel is covered with a porous nonwoven glass fiber veil which is translucent such that it cannot completely conceal the holes, the veil being covered with a non-bridged type (non -bridging), the combination of the veil and the coating effectively concealing the holes while providing sufficient porosity throughout the veil and the coating to cause the plate to exhibit a noise reduction factor of at least 0.55 (noise Reduction coefficient; NRC), the short side of the plate forms a butt joint with the same plate, the short side having a partially recessed area on the front side of the plate, the recessed area being receivable on the front side of the plate main Or less per a plane joining strip (joint tape), and a bonding compound. The sound absorbing panel of claim 1, wherein the partial recessed areas are the result of permanent compression of the gypsum-based core. A rectangular sound absorbing panel comprising a drywall sheet having a thickness of at least 1/2 inch or having a metric equivalent thickness, the drywall sheet having a gypsum-based core and a paper front layer and a paper back layer, the stem The wall sheet is perforated through its surface and core with a diameter of at least 1/8 inch and the number of holes is sufficient to constitute at least 9% of a surface area of the plate, the front side of the plate being covered with a porosity Non-woven glass fiber veil, the porous non-woven glass fiber veil is translucent to make it The method completely conceals the apertures, the veil being covered with a non-bridged coating, the combined veil and the coating are effective to conceal the apertures while providing sufficient porosity throughout the veil and the coating to The panel exhibits a noise reduction factor of at least 0.55, the short side of the panel forming a butt joint with the same panel, the short edge being machined such that the area of the panel adjacent the short edge is pulled at the back of the panel When the plate supports the plate, the front surface can be partially recessed at the short sides. A sound absorbing panel comprising a drywall sheet having a thickness of at least 1/2 inch or having a metric equivalent thickness, the drywall sheet having a gypsum-based core and a paper front layer and a paper back layer, the dry wall The sheet is perforated through its surfaces and core, the diameter of the holes being at least 1/8 inch and the number of holes being sufficient to constitute at least 9% of the surface area of one of the plates, the front side of the plate being covered with a porous non- Weaving a glass fiber veil having a translucency which makes it impossible to completely conceal the holes, the veil being covered with a non-bridged coating, the veil and the coating being effectively combined The apertures are concealed while providing sufficient porosity throughout the veil and the coating to enable the panel to exhibit a noise reduction factor of at least 0.55. The sound absorbing panel of claim 4, wherein the back layer is covered with a nonwoven sound absorbing fabric. The sound absorbing panel of claim 5, wherein the drywall sheet is of a square edge type. The sound absorbing panel of claim 4, wherein the panel is joined to the same panel that is closely adjacent or butted to form a wall or a ceiling, and the joint between the adjacent panels is covered with a strip, the strip being covered with the non- Bridge coating. A combination formed by a plurality of sound absorbing panels as claimed in claim 7, wherein the strip covering the joints is formed of the same material as the material of the veil. A combination formed by a plurality of sound absorbing panels as claimed in claim 7, wherein a region between the strip and the veil is filled with a bonding compound. A combination formed by a plurality of sound absorbing panels according to claim 7, wherein the coating is a water based product, the water based product comprising particles, the particles forming a medium texture when dried (moderate texture ). A combination of a plurality of sound absorbing panels as recited in claim 10, wherein the particles form a dry coating having a texture of sandpaper between 30 and 60 grit.