US20140273687A1 - Building Board with Acoustical Foam - Google Patents
Building Board with Acoustical Foam Download PDFInfo
- Publication number
- US20140273687A1 US20140273687A1 US13/837,109 US201313837109A US2014273687A1 US 20140273687 A1 US20140273687 A1 US 20140273687A1 US 201313837109 A US201313837109 A US 201313837109A US 2014273687 A1 US2014273687 A1 US 2014273687A1
- Authority
- US
- United States
- Prior art keywords
- slurry
- building panel
- polymer
- core
- thickness
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
- 239000006260 foam Substances 0.000 title claims abstract description 19
- 229910052602 gypsum Inorganic materials 0.000 claims abstract description 31
- 239000010440 gypsum Substances 0.000 claims abstract description 31
- 239000002002 slurry Substances 0.000 claims description 42
- 239000010410 layer Substances 0.000 claims description 33
- 229920000642 polymer Polymers 0.000 claims description 32
- 239000002131 composite material Substances 0.000 claims description 14
- 239000012792 core layer Substances 0.000 claims description 11
- 229920000877 Melamine resin Polymers 0.000 claims description 5
- 239000004640 Melamine resin Substances 0.000 claims description 5
- 239000012784 inorganic fiber Substances 0.000 claims description 3
- 229920001187 thermosetting polymer Polymers 0.000 claims description 2
- 238000007581 slurry coating method Methods 0.000 claims 3
- 230000000149 penetrating effect Effects 0.000 claims 2
- 238000004519 manufacturing process Methods 0.000 abstract description 15
- 238000010276 construction Methods 0.000 abstract description 8
- 238000010521 absorption reaction Methods 0.000 abstract description 6
- 238000010924 continuous production Methods 0.000 abstract description 2
- 230000008901 benefit Effects 0.000 description 9
- 229920005832 Basotect® Polymers 0.000 description 5
- 239000011521 glass Substances 0.000 description 4
- 230000015572 biosynthetic process Effects 0.000 description 3
- 238000010586 diagram Methods 0.000 description 3
- 238000009413 insulation Methods 0.000 description 3
- 238000000034 method Methods 0.000 description 3
- 230000004075 alteration Effects 0.000 description 2
- OSGAYBCDTDRGGQ-UHFFFAOYSA-L calcium sulfate Chemical compound [Ca+2].[O-]S([O-])(=O)=O OSGAYBCDTDRGGQ-UHFFFAOYSA-L 0.000 description 2
- 239000008187 granular material Substances 0.000 description 2
- 238000005192 partition Methods 0.000 description 2
- 239000011358 absorbing material Substances 0.000 description 1
- 239000000853 adhesive Substances 0.000 description 1
- 230000001070 adhesive effect Effects 0.000 description 1
- 230000002238 attenuated effect Effects 0.000 description 1
- 230000004888 barrier function Effects 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 238000000151 deposition Methods 0.000 description 1
- 239000003365 glass fiber Substances 0.000 description 1
- 230000006872 improvement Effects 0.000 description 1
- 239000003973 paint Substances 0.000 description 1
- 239000012254 powdered material Substances 0.000 description 1
- 230000008569 process Effects 0.000 description 1
- 238000000926 separation method Methods 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 238000006467 substitution reaction Methods 0.000 description 1
- 239000010409 thin film Substances 0.000 description 1
Images
Classifications
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/62—Insulation or other protection; Elements or use of specified material therefor
- E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
- E04B1/82—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to sound only
- E04B1/84—Sound-absorbing elements
- E04B1/86—Sound-absorbing elements slab-shaped
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
- E04C2/26—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
- E04C2/284—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating
- E04C2/288—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating composed of insulating material and concrete, stone or stone-like material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B13/00—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material
- B32B13/04—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material comprising such water setting substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material
- B32B13/045—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material comprising such water setting substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material of foam
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B13/00—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material
- B32B13/04—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material comprising such water setting substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material
- B32B13/08—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material comprising such water setting substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material of paper or cardboard
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B13/00—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material
- B32B13/14—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material next to a fibrous or filamentary layer
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form
- B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
- B32B3/266—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by an apertured layer, the apertures going through the whole thickness of the layer, e.g. expanded metal, perforated layer, slit layer regular cells B32B3/12
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
- B32B5/022—Non-woven fabric
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
- E04C2/26—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
- E04C2/284—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating
- E04C2/288—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating composed of insulating material and concrete, stone or stone-like material
- E04C2/2885—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating composed of insulating material and concrete, stone or stone-like material with the insulating material being completely surrounded by, or embedded in, a stone-like material, e.g. the insulating material being discontinuous
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
- B32B2262/10—Inorganic fibres
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2266/00—Composition of foam
- B32B2266/02—Organic
- B32B2266/0214—Materials belonging to B32B27/00
- B32B2266/0285—Condensation resins of aldehydes, e.g. with phenols, ureas, melamines
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2266/00—Composition of foam
- B32B2266/06—Open cell foam
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/10—Properties of the layers or laminate having particular acoustical properties
- B32B2307/102—Insulating
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2419/00—Buildings or parts thereof
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/62—Insulation or other protection; Elements or use of specified material therefor
- E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
- E04B1/82—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to sound only
- E04B1/84—Sound-absorbing elements
- E04B2001/8457—Solid slabs or blocks
- E04B2001/8461—Solid slabs or blocks layered
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/20—Coated or impregnated woven, knit, or nonwoven fabric which is not [a] associated with another preformed layer or fiber layer or, [b] with respect to woven and knit, characterized, respectively, by a particular or differential weave or knit, wherein the coating or impregnation is neither a foamed material nor a free metal or alloy layer
- Y10T442/25—Coating or impregnation absorbs sound
Definitions
- This disclosure relates to a building board construction. More specifically, the present invention relates to a building board with an acoustical foam.
- Building board also known as wallboard, plasterboard, or drywall, is one of the most commonly used building components in the world today. Building board is frequently used within the interior of a dwelling, where it functions both as a finished wall covering and as a structural room partition. Building board can also be used on the exterior of a dwelling, where it serves as a sheathing to provide weather protection and insulation. Building board can also be used as an interior facing for other structures as well, such as stairwells, elevator shafts, and interior ducting.
- Gypsum board is constructed by depositing a layer of cementitious gypsum slurry between two opposing paper liners.
- Gypsum slurry is the semi-hydrous form of calcium sulfate and has many physical characteristics that make it suitable for use as a building component.
- gypsum boards generally have a smooth external surface, a consistent thickness, and allow for the application of finishing enhancements, such as paint. Gypsum board is also desirable because it provides a degree of fire resistance and sound abatement.
- GSG glass reinforced gypsum
- An example of one such board is disclosed in U.S. Pat. No. 4,265,979 to Baehr et. al. Baehr discloses a building board constructed from opposing glass fiber mats with an intermediate gypsum core. This construction provides a hardened external surface and is an improvement over earlier paper faced boards.
- Pilgrim discloses a GRG board that is faced on one or both sides with a porous, nonwoven glass mat.
- the glass mat of Pilgrim is fully embedded into the slurry core. This is accomplished by vibrating the gypsum slurry to cause it to pass through the porous openings in the mat. Embedding the mat within the core as taught in Pilgrim results in a thin film of slurry being formed on the outer surface of the board. Building boards with this construction are referred to as embedded glass reinforced gypsum (EGRG) boards.
- EGRG embedded glass reinforced gypsum
- the building boards of the present disclosure have several important advantages.
- the disclosed building boards provide increase sound absorption without sacrificing any structural characteristics of the board.
- a further advantage is realized by providing increased acoustical properties via the inclusion of a polymer sheet within the core of the building board.
- Still yet another possible advantage of the present system is achieved by incorporating a polymer sheet via a continuous manufacturing method, thereby enabling the building board of the present disclosure to be manufactured quickly and inexpensively.
- Another advantage of the present system is attained by including a series of sound absorbing polymeric cubes within the core of the building board.
- Still yet another possible advantage of the present system is achieved by incorporating polymeric cubes or as a powdered material via a continuous manufacturing method, thereby enabling the building board of the present disclosure to be manufactured quickly and inexpensively.
- a further advantage is recognized by incorporating sound absorbing materials into a gypsum building board via a continuous manufacturing method.
- FIG. 1 is a diagram of one possible manufacturing process for the building boards of the present disclosure.
- FIG. 2 is a diagram of another possible manufacturing process for the building boards of the present disclosure.
- FIG. 3 is a diagram of another possible manufacturing process for the building boards of the present disclosure.
- FIG. 4 is a cross sectional view of an embodiment of the building board of the present disclosure.
- FIG. 5 is a cross sectional view of an alternative embodiment of the building board of the present disclosure.
- FIG. 6 is a cross sectional view of an alternative embodiment of the building board of the present disclosure.
- the present disclosure relates to a building board with enhanced acoustical properties.
- the board is a gypsum board with opposing facing sheets and an intermediate set gypsum core.
- An opened celled polymeric sheet is formed within the gypsum core and gives the resulting board enhanced sound absorption.
- individual pieces of polymeric foam are used in stead of the polymeric sheet.
- various manufacturing methods whereby boards with enhanced acoustical properties can be formed in a continuous process.
- FIGS. 1-3 illustrate various production lines ( 34 a , 34 b , and 34 c ) for constructing the building boards of the present disclosure.
- FIGS. 4-6 are cross sectional views of various board constructions ( 20 a , 20 b , 20 c ) of the present disclosure.
- the boards of the present disclosure are generally a core layer 22 of a set gypsum core and opposing paper of fibrous sheets 24 .
- board 20 a has upper and lower mats 24 which are formed from a series of non-woven, randomly aligned inorganic fibers. These mats are preferably porous with interior and exterior faces. Paper facing sheets can also be used and are likewise represented by element 24 .
- upper and lower mats 24 are each coated with a layer of dense set slurry 26 .
- Dense slurry 26 preferably penetrates the upper and lower mats 24 .
- Core layer 22 of set gypsum extends fully between and bonds with the upper and lower slurry layers 26 .
- core slurry layer 22 has a density that is less than the density of the upper and lower slurry layers 26 .
- sheet 28 is formed from a melamine resin and is formed into an opened cell foam.
- Melamine resin is a thermoset polymer.
- a suitable foam is Basotect® which is manufactured and sold by BASF Corporation. Basotect® foam preferred because it provides a three-dimensional network of slender and easily shaped webs. Basotect® foam also gives the resulting board sound absorption, and chemical and fire resistance.
- Basotect® foam also gives the resulting board sound absorption, and chemical and fire resistance.
- the use of other polymer foams is also within the scope of the present disclosures. For a 1 ⁇ 2 inch thick building board, a polymer sheet 28 of 1 ⁇ 8 inch is preferred.
- Polymer sheet 28 is design to be positioned within, but not penetrated by, the core slurry layer 22 . Because polymer sheet 28 does not absorb the slurry layer 22 , and because it preferably extends over the majority of the width of board 20 a , a series of apertures 32 must be formed through the thickness of sheet 28 . Apertures 32 permit the slurry 22 to extend through sheet 28 to thereby fully integrate building panel 20 a .
- the thickness of core layer 22 is substantially larger than the thickness of polymer sheet 28 .
- FIG. 1 illustrates a gypsum board production line 34 a that has been modified in accordance with the present disclosure.
- Production lines 34 a includes a series of forming tables 36 for supporting building panel 20 a during its formation.
- the mats that form panel are under tension by way of a series of downstream belts.
- panel Once panel has been formed, it is passed to a series of board dryers. Dryers function in driving out excess moisture and causing the gypsum slurry to set. This results in the formation of a dried composite panel.
- gypsum board 20 a is formed from first and second fibrous mats 24 which a volume of gypsum slurry being deposited from a mixer 38 .
- Paper mats can alternatively be used in place of fibrous mats.
- mats 24 are initially stored in large rolls 42 that are unwound in a continuous manufacturing method.
- a first roll 42 is unwound onto forming table at location 1a.
- a dense slurry layer 26 can optionally be deposited over the first mat 24 after it is unrolled beneath a first mixer outlet 44 . Rollers push the dense slurry layer through the mat at location 1b. Additional slurry is thereafter dispensed from mixer 38 at a second mixer outlet 46 to form core slurry layer 22 .
- a second roll 42 is ideally positioned downstream of first roll.
- a second mat 24 is unwound from this roll over top of the deposited gypsum core 22 to create sandwich or panel.
- the formed panel is noted at location 1c.
- Mixer 38 includes a third outlet 48 for supplying a dense slurry layer 26 over the second mat 24 .
- the polymer sheet 28 is initially stored in a wound roll 52 and is dispensed immediately downstream of second mixer outlet 46 . This positions sheet 28 in approximately the center of core 22 .
- FIG. 2 An alternative production line 34 b is disclosed in FIG. 2 .
- Line 34 b is the same in all respects to the production line of FIG. 1 ; however, the rolled polymer sheet 28 is replaced by a hopper 54 containing a plurality of polymer cubes 56 or a volume of a granulated polymer.
- cubes of approximately 1 ⁇ 2 inch are employed. Other shapes and sizes can also be used instead of 1 ⁇ 2 inch cubes.
- Basotect® foam can be used to produce polymer cubes 56 . Cubes 56 are dispensed from a hopper 54 to a chute to deliver cubes 56 into core slurry layer 22 .
- the Basotect® foam is added to the slurry in a grated or granular form.
- the resulting building board 20 b has a cross section as illustrated in FIG. 5 .
- Each of the polymer cubes 56 or granulated material includes an opened cell foam. Cubes 56 or granules are randomly distributed within slurry layer 22 ; however, slurry 22 does not penetrate the individual pieces or cubes 56 .
- the composite board 20 b is fully integrated as core layer 22 extends about the individual polymer cubes 56 .
- the polymer foam can be grated to form very small bits of foam that agglomerate into a foam fluff. This foam fluff can then be distributed into slurry core 22 .
- FIG. 3 A further embodiment of the production line 34 c is depicted in FIG. 3 .
- This embodiment uses a polymeric sheet 28 , which may have the same construction as the sheet described in connection with FIG. 1 . However, instead of sheet 28 being delivered into slurry core 22 , it is secured to the lower mat 24 via an adhesive. More specifically, a roll 58 of the polymeric sheet is dispensed over top of mat 24 prior to the mat being delivered to the forming table 36 .
- the cross sectional view of the resulting building board 20 c is depicted in FIG. 6 . As illustrated, sheet 28 is now oriented in facing relation with the first mat 26 . It is also within the scope of the present invention to apply sheet 28 directly to one of the upper or lower dense slurry layers. This would avoid sheet 28 being secured to mat 24 . Either of these embodiments may be used in connection with either of the previously described embodiments.
Abstract
Disclosed is a building board construction that provides enhanced acoustical properties. In one possible embodiment, the board is a gypsum board with opposing facing sheets and an intermediate set gypsum core. An opened celled polymeric sheet is formed within the gypsum core and gives the resulting board enhanced sound absorption. In an alternative embodiment, individual pieces of polymeric foam are used in stead of the polymeric sheet. Also disclosed are various manufacturing methods whereby boards with enhanced acoustical properties can be formed in an continuous process. The various components of the present disclosure, and the manner in which they interrelate, are described in greater detail hereinafter.
Description
- This disclosure relates to a building board construction. More specifically, the present invention relates to a building board with an acoustical foam.
- Building board, also known as wallboard, plasterboard, or drywall, is one of the most commonly used building components in the world today. Building board is frequently used within the interior of a dwelling, where it functions both as a finished wall covering and as a structural room partition. Building board can also be used on the exterior of a dwelling, where it serves as a sheathing to provide weather protection and insulation. Building board can also be used as an interior facing for other structures as well, such as stairwells, elevator shafts, and interior ducting.
- One particularly popular form of building board is known as gypsum board. Gypsum board is constructed by depositing a layer of cementitious gypsum slurry between two opposing paper liners. Gypsum slurry is the semi-hydrous form of calcium sulfate and has many physical characteristics that make it suitable for use as a building component. For example, gypsum boards generally have a smooth external surface, a consistent thickness, and allow for the application of finishing enhancements, such as paint. Gypsum board is also desirable because it provides a degree of fire resistance and sound abatement.
- An example of a paper-covered gypsum board is disclosed in U.S. Pat. No. 2,806,811 to Von Hazmburg. Von Hazmburg discloses a board that primarily consists of a thick gypsum core that is encased in a fibrous envelope consisting of both a manila sheet and a newsprint sheet. These sheet layers can be made from a conventional multi-cylinder paper making process.
- Another popular form of building board is known as glass reinforced gypsum (GRG) board. An example of one such board is disclosed in U.S. Pat. No. 4,265,979 to Baehr et. al. Baehr discloses a building board constructed from opposing glass fiber mats with an intermediate gypsum core. This construction provides a hardened external surface and is an improvement over earlier paper faced boards.
- Yet another type of gypsum board is disclosed in commonly owned U.S. Pat. No. 4,378,405 to Pilgrim. Pilgrim discloses a GRG board that is faced on one or both sides with a porous, nonwoven glass mat. The glass mat of Pilgrim is fully embedded into the slurry core. This is accomplished by vibrating the gypsum slurry to cause it to pass through the porous openings in the mat. Embedding the mat within the core as taught in Pilgrim results in a thin film of slurry being formed on the outer surface of the board. Building boards with this construction are referred to as embedded glass reinforced gypsum (EGRG) boards.
- These various building board constructions offer many beneficial characteristics. However, none of these constructions provide for increased acoustical properties. As a result, these boards offer little, if any sound absorption or insulation, they act as a sound barrier. Sound absorption and insulation are especially important when the building board is used as a room partition or even as an exterior building component. Thus, there exists a need in the art for building boards with increased acoustical properties. More specifically, there is a need in the art for a board that absorbs sound waves. The present invention is aimed at achieving these and other objectives.
- The building boards of the present disclosure have several important advantages. In particular, the disclosed building boards provide increase sound absorption without sacrificing any structural characteristics of the board.
- A further advantage is realized by providing increased acoustical properties via the inclusion of a polymer sheet within the core of the building board.
- Still yet another possible advantage of the present system is achieved by incorporating a polymer sheet via a continuous manufacturing method, thereby enabling the building board of the present disclosure to be manufactured quickly and inexpensively.
- Another advantage of the present system is attained by including a series of sound absorbing polymeric cubes within the core of the building board.
- Still yet another possible advantage of the present system is achieved by incorporating polymeric cubes or as a powdered material via a continuous manufacturing method, thereby enabling the building board of the present disclosure to be manufactured quickly and inexpensively.
- A further advantage is recognized by incorporating sound absorbing materials into a gypsum building board via a continuous manufacturing method.
- Various embodiments of the invention may have none, some, or all of these advantages. Other technical advantages of the present invention will be readily apparent to one skilled in the art.
- For a more complete understanding of the present disclosure and its advantages, reference is now made to the following descriptions, taken in conjunction with the accompanying drawings, in which:
-
FIG. 1 is a diagram of one possible manufacturing process for the building boards of the present disclosure. -
FIG. 2 is a diagram of another possible manufacturing process for the building boards of the present disclosure. -
FIG. 3 is a diagram of another possible manufacturing process for the building boards of the present disclosure. -
FIG. 4 is a cross sectional view of an embodiment of the building board of the present disclosure. -
FIG. 5 is a cross sectional view of an alternative embodiment of the building board of the present disclosure. -
FIG. 6 is a cross sectional view of an alternative embodiment of the building board of the present disclosure. - The present disclosure relates to a building board with enhanced acoustical properties. In one possible embodiment, the board is a gypsum board with opposing facing sheets and an intermediate set gypsum core. An opened celled polymeric sheet is formed within the gypsum core and gives the resulting board enhanced sound absorption. In an alternative embodiment, individual pieces of polymeric foam are used in stead of the polymeric sheet. Also disclosed are various manufacturing methods whereby boards with enhanced acoustical properties can be formed in a continuous process. The various components of the present disclosure, and the manner in which they interrelate, are described in greater detail hereinafter.
-
FIGS. 1-3 illustrate various production lines (34 a, 34 b, and 34 c) for constructing the building boards of the present disclosure.FIGS. 4-6 are cross sectional views of various board constructions (20 a, 20 b, 20 c) of the present disclosure. The boards of the present disclosure are generally acore layer 22 of a set gypsum core and opposing paper offibrous sheets 24. In the particular embodiment illustrated inFIG. 4 , board 20 a has upper andlower mats 24 which are formed from a series of non-woven, randomly aligned inorganic fibers. These mats are preferably porous with interior and exterior faces. Paper facing sheets can also be used and are likewise represented byelement 24. - With continuing reference to
FIG. 4 , upper andlower mats 24 are each coated with a layer ofdense set slurry 26.Dense slurry 26 preferably penetrates the upper andlower mats 24. As a result the exterior surface of eachmat 24 is substantially covered by set slurry.Core layer 22 of set gypsum extends fully between and bonds with the upper and lower slurry layers 26. In one embodiment,core slurry layer 22 has a density that is less than the density of the upper and lower slurry layers 26. - The enhanced acoustical properties are achieved via the inclusion of a
polymer sheet 28 intocore slurry layer 22. In the preferred embodiment,sheet 28 is formed from a melamine resin and is formed into an opened cell foam. Melamine resin is a thermoset polymer. A suitable foam is Basotect® which is manufactured and sold by BASF Corporation. Basotect® foam preferred because it provides a three-dimensional network of slender and easily shaped webs. Basotect® foam also gives the resulting board sound absorption, and chemical and fire resistance. However, the use of other polymer foams is also within the scope of the present disclosures. For a ½ inch thick building board, apolymer sheet 28 of ⅛ inch is preferred. - Sound waves entering the cells of the foam are subsequently attenuated and dissipated, thereby giving
sheet 28 its sound absorbing characteristics. As such, it is important that the cells of the foam remain free to gypsum slurry during the formation of the board.Polymer sheet 28 is design to be positioned within, but not penetrated by, thecore slurry layer 22. Becausepolymer sheet 28 does not absorb theslurry layer 22, and because it preferably extends over the majority of the width of board 20 a, a series ofapertures 32 must be formed through the thickness ofsheet 28.Apertures 32 permit theslurry 22 to extend throughsheet 28 to thereby fully integrate building panel 20 a. In the absence ofapertures 32, building panel 20 a would be prone to separation along the boundary ofsheet 28. In the event thatpolymer sheet 28 could absorbslurry layer 22, apertures could be eliminated 32. In the preferred embodiment, the thickness ofcore layer 22 is substantially larger than the thickness ofpolymer sheet 28. -
FIG. 1 illustrates a gypsum board production line 34 a that has been modified in accordance with the present disclosure. Production lines 34 a includes a series of forming tables 36 for supporting building panel 20 a during its formation. As is known in the art, the mats that form panel are under tension by way of a series of downstream belts. Once panel has been formed, it is passed to a series of board dryers. Dryers function in driving out excess moisture and causing the gypsum slurry to set. This results in the formation of a dried composite panel. - As further noted in
FIG. 1 , gypsum board 20 a is formed from first and secondfibrous mats 24 which a volume of gypsum slurry being deposited from amixer 38. Paper mats can alternatively be used in place of fibrous mats. In either event,mats 24 are initially stored inlarge rolls 42 that are unwound in a continuous manufacturing method. Afirst roll 42 is unwound onto forming table atlocation 1a. Adense slurry layer 26 can optionally be deposited over thefirst mat 24 after it is unrolled beneath afirst mixer outlet 44. Rollers push the dense slurry layer through the mat atlocation 1b. Additional slurry is thereafter dispensed frommixer 38 at asecond mixer outlet 46 to formcore slurry layer 22. Asecond roll 42 is ideally positioned downstream of first roll. Asecond mat 24 is unwound from this roll over top of the depositedgypsum core 22 to create sandwich or panel. The formed panel is noted atlocation 1c.Mixer 38 includes athird outlet 48 for supplying adense slurry layer 26 over thesecond mat 24. Thepolymer sheet 28 is initially stored in awound roll 52 and is dispensed immediately downstream ofsecond mixer outlet 46. This positionssheet 28 in approximately the center ofcore 22. - An alternative production line 34 b is disclosed in
FIG. 2 . Line 34 b is the same in all respects to the production line ofFIG. 1 ; however, the rolledpolymer sheet 28 is replaced by ahopper 54 containing a plurality ofpolymer cubes 56 or a volume of a granulated polymer. In the preferred embodiment, cubes of approximately ½ inch are employed. Other shapes and sizes can also be used instead of ½ inch cubes. Basotect® foam can be used to producepolymer cubes 56.Cubes 56 are dispensed from ahopper 54 to a chute to delivercubes 56 intocore slurry layer 22. In still yet additional embodiments, the Basotect® foam is added to the slurry in a grated or granular form. - The resulting
building board 20 b has a cross section as illustrated inFIG. 5 . Each of thepolymer cubes 56 or granulated material includes an opened cell foam.Cubes 56 or granules are randomly distributed withinslurry layer 22; however,slurry 22 does not penetrate the individual pieces orcubes 56. Thecomposite board 20 b is fully integrated ascore layer 22 extends about theindividual polymer cubes 56. In still yet another embodiment, the polymer foam can be grated to form very small bits of foam that agglomerate into a foam fluff. This foam fluff can then be distributed intoslurry core 22. - A further embodiment of the production line 34 c is depicted in
FIG. 3 . This embodiment uses apolymeric sheet 28, which may have the same construction as the sheet described in connection withFIG. 1 . However, instead ofsheet 28 being delivered intoslurry core 22, it is secured to thelower mat 24 via an adhesive. More specifically, a roll 58 of the polymeric sheet is dispensed over top ofmat 24 prior to the mat being delivered to the forming table 36. The cross sectional view of the resulting building board 20 c is depicted inFIG. 6 . As illustrated,sheet 28 is now oriented in facing relation with thefirst mat 26. It is also within the scope of the present invention to applysheet 28 directly to one of the upper or lower dense slurry layers. This would avoidsheet 28 being secured tomat 24. Either of these embodiments may be used in connection with either of the previously described embodiments. - Although this disclosure has been described in terms of certain embodiments and generally associated methods, alterations and permutations of these embodiments and methods will be apparent to those skilled in the art. Accordingly, the above description of example embodiments does not define or constrain this disclosure. Other changes, substitutions, and alterations are also possible without departing from the spirit and scope of this disclosure.
Claims (12)
1. A composite, multi-layered building panel with enhanced acoustical properties, the panel comprising:
coplanar opposed upper and lower mats formed from non-woven, randomly aligned inorganic fibers, the mats being porous and having interior and exterior faces;
upper and lower layers of a set slurry coating the upper and lower mats, the upper and lower layers penetrating the upper and lower mats, whereby the exterior surface of each mat is substantially covered by set slurry;
a core layer of set gypsum having a thickness extending between the upper and lower layers, the core slurry layer having a density that is less than the density of the upper and lower slurry layers;
a polymer sheet have a thickness, the polymer sheet positioned within but not penetrated by the core slurry layer, the sheet being formed from a melamine resin and containing a plurality of opened cells throughout its thickness, the polymer sheet having sound-absorbing characteristics, a series of apertures formed through the thickness of the polymer sheet to allow the polymer sheet to bond to the core layer, the thickness of the core layer being larger than the thickness of the polymer sheet.
2. A composite, multi-layered building panel with enhanced acoustical properties, the panel comprising:
coplanar opposed upper and lower paper sheets, the sheets having interior and exterior faces;
a core layer of set gypsum having a thickness extending between the upper and lower paper sheets;
a polymer sheet have a thickness, the polymer sheet positioned within but not penetrated by the core slurry layer, the sheet containing a plurality of opened cells throughout its thickness.
3. The composite building panel as described in claim 2 wherein the sheet is formed from a thermoset polymer.
4. The composite building panel as described in claim 2 wherein the sheet is formed from a melamine resin.
5. The composite building panel as described in claim 2 wherein the opened celled foam enhances the sound-absorbing characteristic of the building panel.
6. The composite building panel as described in claim 2 further comprising a series of apertures formed through the thickness of the polymer sheet to allow the polymer sheet to bond to the core layer.
7. The composite building panel as described in claim 2 further comprising upper and lower layers of a set slurry coating the upper and lower paper sheets, wherein the upper and lower layers of set slurry have a greater density than the core slurry layer.
8. A composite, multi-layered building panel with enhanced acoustical properties, the panel comprising:
coplanar opposed upper and lower mats having interior and exterior faces;
upper and lower layers of a set slurry coating the upper and lower mats;
a core layer of set gypsum having a thickness extending between the upper and lower layers, the core slurry layer having a density that is less than the density of the upper and lower slurry layers;
a plurality of polymer pieces, the polymer pieces distributed within the core slurry layer, each polymer piece containing a plurality of opened cells, the core layer extending around but not penetrating the polymer pieces.
9. The composite building panel as described in claim 8 wherein the upper and lower mats are porous mats formed from non-woven, randomly aligned inorganic fibers.
10. The composite building panel as described in claim 9 wherein the upper and lower layers of set slurry penetrate the upper and lower mats, whereby the exterior surface of each mat is substantially covered.
11. The composite building panel as described in claim 8 wherein the pieces are formed from a melamine resin.
12. The composite building panel as described in claim 8 wherein the opened cells of the polymer pieces give the building board sound-absorbing characteristics.
Priority Applications (17)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US13/837,109 US20140273687A1 (en) | 2013-03-15 | 2013-03-15 | Building Board with Acoustical Foam |
KR1020157029289A KR20150143491A (en) | 2013-03-15 | 2014-03-14 | Building board with acoustical foam |
AU2014228801A AU2014228801B2 (en) | 2013-03-15 | 2014-03-14 | Building board with acoustical foam |
BR112015023768A BR112015023768A8 (en) | 2013-03-15 | 2014-03-14 | construction board with acoustic foam |
RU2015144110A RU2643393C2 (en) | 2013-03-15 | 2014-03-14 | Construction slab with acoustic foam material |
JP2016503013A JP2016516146A (en) | 2013-03-15 | 2014-03-14 | Building board with soundproof foam |
SG11201507680WA SG11201507680WA (en) | 2013-03-15 | 2014-03-14 | Building board with acoustical foam |
NZ712480A NZ712480A (en) | 2013-03-15 | 2014-03-14 | Building board with acoustical foam |
CA2906759A CA2906759C (en) | 2013-03-15 | 2014-03-14 | Building board with acoustical foam |
CN201480022413.8A CN105143571B (en) | 2013-03-15 | 2014-03-14 | Composite multi-story building panel with enhanced sound damping |
EP14763771.4A EP2971398A4 (en) | 2013-03-15 | 2014-03-14 | Building board with acoustical foam |
PCT/US2014/029206 WO2014144688A1 (en) | 2013-03-15 | 2014-03-14 | Building board with acoustical foam |
ZA2015/06988A ZA201506988B (en) | 2013-03-15 | 2015-09-18 | Building board with acoustical foam |
US16/031,444 US10731337B2 (en) | 2013-03-15 | 2018-07-10 | Building board with acoustical foam |
JP2019212182A JP2020041413A (en) | 2013-03-15 | 2019-11-25 | Board for construction including soundproof foam |
US16/984,716 US11536022B2 (en) | 2013-03-15 | 2020-08-04 | Building board with acoustical foam |
US18/089,258 US20230139624A1 (en) | 2013-03-15 | 2022-12-27 | Building Board with Acoustical Foam |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US13/837,109 US20140273687A1 (en) | 2013-03-15 | 2013-03-15 | Building Board with Acoustical Foam |
Related Child Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US16/031,444 Continuation US10731337B2 (en) | 2013-03-15 | 2018-07-10 | Building board with acoustical foam |
Publications (1)
Publication Number | Publication Date |
---|---|
US20140273687A1 true US20140273687A1 (en) | 2014-09-18 |
Family
ID=51529134
Family Applications (4)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US13/837,109 Abandoned US20140273687A1 (en) | 2013-03-15 | 2013-03-15 | Building Board with Acoustical Foam |
US16/031,444 Active US10731337B2 (en) | 2013-03-15 | 2018-07-10 | Building board with acoustical foam |
US16/984,716 Active US11536022B2 (en) | 2013-03-15 | 2020-08-04 | Building board with acoustical foam |
US18/089,258 Pending US20230139624A1 (en) | 2013-03-15 | 2022-12-27 | Building Board with Acoustical Foam |
Family Applications After (3)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US16/031,444 Active US10731337B2 (en) | 2013-03-15 | 2018-07-10 | Building board with acoustical foam |
US16/984,716 Active US11536022B2 (en) | 2013-03-15 | 2020-08-04 | Building board with acoustical foam |
US18/089,258 Pending US20230139624A1 (en) | 2013-03-15 | 2022-12-27 | Building Board with Acoustical Foam |
Country Status (13)
Country | Link |
---|---|
US (4) | US20140273687A1 (en) |
EP (1) | EP2971398A4 (en) |
JP (2) | JP2016516146A (en) |
KR (1) | KR20150143491A (en) |
CN (1) | CN105143571B (en) |
AU (1) | AU2014228801B2 (en) |
BR (1) | BR112015023768A8 (en) |
CA (1) | CA2906759C (en) |
NZ (1) | NZ712480A (en) |
RU (1) | RU2643393C2 (en) |
SG (1) | SG11201507680WA (en) |
WO (1) | WO2014144688A1 (en) |
ZA (1) | ZA201506988B (en) |
Cited By (8)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US9903116B2 (en) * | 2015-09-21 | 2018-02-27 | United States Gypsum Company | Acoustical gypsum wallboard |
US9909304B2 (en) | 2015-02-05 | 2018-03-06 | National Gypsum Properties, Llc | Sound damping wallboard and method of forming a sound damping wallboard |
US20180171626A1 (en) * | 2016-12-15 | 2018-06-21 | Certainteed Gypsum, Inc. | Plaster boards and methods for making them |
US20210180322A1 (en) * | 2019-12-12 | 2021-06-17 | National Gypsum Properties, Llc | Wallboard with Foam Material Layer |
US11124965B2 (en) | 2017-09-26 | 2021-09-21 | Certainteed Gypsum, Inc. | Plaster boards having internal layers and methods for making them |
US11559968B2 (en) | 2018-12-06 | 2023-01-24 | Gold Bond Building Products, Llc | Sound damping gypsum board and method of constructing a sound damping gypsum board |
US11772372B2 (en) | 2020-06-05 | 2023-10-03 | Gold Bond Building Products, Llc | Sound damping gypsum board and method of constructing a sound damping gypsum board |
US20230374785A1 (en) * | 2022-05-23 | 2023-11-23 | Klrh, Llc | Non-Combustible, Net-Zero Energy Building Systems |
Families Citing this family (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN107447915A (en) * | 2016-02-24 | 2017-12-08 | 张日龙 | A kind of building panel |
WO2023129617A1 (en) * | 2021-12-29 | 2023-07-06 | Certainteed Gypsum, Inc. | Plaster boards and methods for making them |
Citations (14)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4045268A (en) * | 1974-07-25 | 1977-08-30 | Bell Fibre Products Corporation | Mastic composition and composite structural panels formed therefrom |
US4390642A (en) * | 1981-02-26 | 1983-06-28 | Thermocell Development, Ltd. | Flame-retardant, thermosetting foam product and method of preparing same |
US5104715A (en) * | 1987-07-06 | 1992-04-14 | Cruz Francisco A | Tile formed of composite sheet with insulating board |
DE4446968A1 (en) * | 1993-12-28 | 1995-06-29 | Platres Lafarge S A De Droit F | Gypsum-based slurry-forming dry material |
US5923002A (en) * | 1997-11-12 | 1999-07-13 | Owens Corning Fiberglas Technology, Inc. | Acoustical room paneling and method of installation |
US20050066618A1 (en) * | 2002-07-11 | 2005-03-31 | Tucker Mark Irvine | Panel and related wall structure |
US6941720B2 (en) * | 2000-10-10 | 2005-09-13 | James Hardie International Finance B.V. | Composite building material |
KR20080027177A (en) * | 2006-09-21 | 2008-03-26 | 주식회사 엘지화학 | Interfloor noise proofing material and floor execution method using the same |
US20080299413A1 (en) * | 2007-05-31 | 2008-12-04 | Song W David | Acoustical gypsum board panel and method of making it |
US20090011203A1 (en) * | 2006-03-10 | 2009-01-08 | Basf Aktiengesellschaft | Multilayer foam composite element with recesses |
US20100055431A1 (en) * | 2008-08-29 | 2010-03-04 | Certainteed Gypsum, Inc. | Plastic Coated Composite Building Boards and Method of Making Same |
US20100143682A1 (en) * | 2008-10-30 | 2010-06-10 | United States Gypsum Company | Mat-Faced Cementitious Article and Method for Preparing Same |
US20100273907A1 (en) * | 2006-01-12 | 2010-10-28 | BASF SE Carl-Bosch-Strasse; GVX -C006 | Modified open-cell foams and process for their production |
US20100331434A1 (en) * | 2007-11-09 | 2010-12-30 | Shin Soon-Ok | mortar for concrete having polyurethane foam and method of thereof |
Family Cites Families (22)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US2806811A (en) | 1954-12-31 | 1957-09-17 | United States Gypsum Co | Paper-covered gypsum board |
JPS5251719A (en) * | 1975-10-20 | 1977-04-25 | Kanebo Ltd | Fireeproof heat insulating structure material |
JPS5355329A (en) * | 1976-10-28 | 1978-05-19 | Taku Yamada | Insulatinggmateriallincorporated lighttweight nonnflammable gypsum board and apparatus for production thereof |
US4265979A (en) | 1978-06-05 | 1981-05-05 | United States Gypsum Company | Method for the production of glass fiber-reinforced gypsum sheets and gypsum board formed therefrom |
IE49483B1 (en) | 1979-05-30 | 1985-10-16 | Bpb Industries Ltd | Production of building board |
US4861642A (en) * | 1987-03-13 | 1989-08-29 | Bpco Inc. | Reinforcement of phenolic foams composite |
GB8811033D0 (en) | 1988-05-10 | 1988-06-15 | A Foam Co Ltd | Foam composite & method of forming same |
CA2211984C (en) * | 1997-09-12 | 2002-11-05 | Marc-Andre Mathieu | Cementitious panel with reinforced edges |
CN2344468Y (en) * | 1997-11-14 | 1999-10-20 | 重庆市建筑科学研究院 | New type composite light wall panel |
DE19803915C1 (en) | 1998-02-02 | 1999-06-10 | Infra Folienkabel Gmbh | Production of constructional board for ceilings, etc. |
EP0965701A1 (en) * | 1998-06-19 | 1999-12-22 | Dow Deutschland Inc. | Sound insulating panel |
BE1012250A3 (en) | 1998-10-27 | 2000-08-01 | Wheeltech Bvba | Attachment for light metal wheel rims. |
US6244378B1 (en) * | 1998-12-11 | 2001-06-12 | Owens Corning Fiberglas Technology, Inc. | Dual sonic character acoustic panel and systems for use thereof |
AU2002314925B2 (en) | 2001-06-06 | 2006-07-20 | Bpb Limited | Glass reinforced gypsum board and method of manufacture |
TWI265087B (en) * | 2002-03-27 | 2006-11-01 | Yoshino Gypsum Co | Plaster board and method of fabricating the plaster board |
US20050176833A1 (en) | 2002-06-03 | 2005-08-11 | Tay Chong H. | Fire resistant insulation material |
CN2564642Y (en) * | 2002-07-04 | 2003-08-06 | 谢峰 | Environmental protection light partition plate |
US7049251B2 (en) * | 2003-01-21 | 2006-05-23 | Saint-Gobain Technical Fabrics Canada Ltd | Facing material with controlled porosity for construction boards |
JP4290545B2 (en) * | 2003-12-25 | 2009-07-08 | 共同印刷株式会社 | Glossy decorative board |
KR100874212B1 (en) | 2007-12-04 | 2008-12-15 | 엠에프엘 앤드 아이티(주) | Anti-sagged melamine acoustic panel unit for ceiling and wall and method constructing the melamine acoustic panel unit to ceiling and wall |
US8409391B2 (en) * | 2010-06-07 | 2013-04-02 | Certainteed Gypsum, Inc. | Method for constructing composite building boards using dissolvable films |
CN102127935A (en) * | 2011-01-20 | 2011-07-20 | 家得润生态房屋有限公司 | Composite sandwich partition board and preparation method thereof |
-
2013
- 2013-03-15 US US13/837,109 patent/US20140273687A1/en not_active Abandoned
-
2014
- 2014-03-14 NZ NZ712480A patent/NZ712480A/en not_active IP Right Cessation
- 2014-03-14 CN CN201480022413.8A patent/CN105143571B/en not_active Expired - Fee Related
- 2014-03-14 JP JP2016503013A patent/JP2016516146A/en not_active Ceased
- 2014-03-14 AU AU2014228801A patent/AU2014228801B2/en not_active Ceased
- 2014-03-14 BR BR112015023768A patent/BR112015023768A8/en active Search and Examination
- 2014-03-14 WO PCT/US2014/029206 patent/WO2014144688A1/en active Application Filing
- 2014-03-14 KR KR1020157029289A patent/KR20150143491A/en not_active Application Discontinuation
- 2014-03-14 SG SG11201507680WA patent/SG11201507680WA/en unknown
- 2014-03-14 EP EP14763771.4A patent/EP2971398A4/en active Pending
- 2014-03-14 RU RU2015144110A patent/RU2643393C2/en not_active IP Right Cessation
- 2014-03-14 CA CA2906759A patent/CA2906759C/en active Active
-
2015
- 2015-09-18 ZA ZA2015/06988A patent/ZA201506988B/en unknown
-
2018
- 2018-07-10 US US16/031,444 patent/US10731337B2/en active Active
-
2019
- 2019-11-25 JP JP2019212182A patent/JP2020041413A/en not_active Withdrawn
-
2020
- 2020-08-04 US US16/984,716 patent/US11536022B2/en active Active
-
2022
- 2022-12-27 US US18/089,258 patent/US20230139624A1/en active Pending
Patent Citations (14)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4045268A (en) * | 1974-07-25 | 1977-08-30 | Bell Fibre Products Corporation | Mastic composition and composite structural panels formed therefrom |
US4390642A (en) * | 1981-02-26 | 1983-06-28 | Thermocell Development, Ltd. | Flame-retardant, thermosetting foam product and method of preparing same |
US5104715A (en) * | 1987-07-06 | 1992-04-14 | Cruz Francisco A | Tile formed of composite sheet with insulating board |
DE4446968A1 (en) * | 1993-12-28 | 1995-06-29 | Platres Lafarge S A De Droit F | Gypsum-based slurry-forming dry material |
US5923002A (en) * | 1997-11-12 | 1999-07-13 | Owens Corning Fiberglas Technology, Inc. | Acoustical room paneling and method of installation |
US6941720B2 (en) * | 2000-10-10 | 2005-09-13 | James Hardie International Finance B.V. | Composite building material |
US20050066618A1 (en) * | 2002-07-11 | 2005-03-31 | Tucker Mark Irvine | Panel and related wall structure |
US20100273907A1 (en) * | 2006-01-12 | 2010-10-28 | BASF SE Carl-Bosch-Strasse; GVX -C006 | Modified open-cell foams and process for their production |
US20090011203A1 (en) * | 2006-03-10 | 2009-01-08 | Basf Aktiengesellschaft | Multilayer foam composite element with recesses |
KR20080027177A (en) * | 2006-09-21 | 2008-03-26 | 주식회사 엘지화학 | Interfloor noise proofing material and floor execution method using the same |
US20080299413A1 (en) * | 2007-05-31 | 2008-12-04 | Song W David | Acoustical gypsum board panel and method of making it |
US20100331434A1 (en) * | 2007-11-09 | 2010-12-30 | Shin Soon-Ok | mortar for concrete having polyurethane foam and method of thereof |
US20100055431A1 (en) * | 2008-08-29 | 2010-03-04 | Certainteed Gypsum, Inc. | Plastic Coated Composite Building Boards and Method of Making Same |
US20100143682A1 (en) * | 2008-10-30 | 2010-06-10 | United States Gypsum Company | Mat-Faced Cementitious Article and Method for Preparing Same |
Non-Patent Citations (5)
Title |
---|
DE 4446968 English Machine Translation. Espacenet, retrieved 18 Nov 2016. * |
KR 20080027177 English Machine Translation. Espacenet, retrieved 17 Nov 2016. * |
Parallel, Defintion of. Merriam-Webster, http://www.merriam-webster.com/dictionary/parallel. retrieved 17 November 2016. * |
Planar, Defintion of. Merriam-Webster, http://www.merriam-webster.com/dictionary/planar. retrieved 17 November 2016. * |
Sheet. Merriam-Webster. retrieved 16 May 2016. * |
Cited By (16)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US9909304B2 (en) | 2015-02-05 | 2018-03-06 | National Gypsum Properties, Llc | Sound damping wallboard and method of forming a sound damping wallboard |
US10519650B2 (en) | 2015-02-05 | 2019-12-31 | National Gypsum Properties, Llc | Sound damping wallboard and method of forming a sound damping wallboard |
US11519167B2 (en) | 2015-02-05 | 2022-12-06 | Gold Bond Building Products, Llc | Sound damping wallboard and method of forming a sound damping wallboard |
US11939765B2 (en) | 2015-02-05 | 2024-03-26 | Gold Bond Building Products, Llc | Sound damping wallboard and method of forming a sound damping wallboard |
US9903116B2 (en) * | 2015-09-21 | 2018-02-27 | United States Gypsum Company | Acoustical gypsum wallboard |
US20180171626A1 (en) * | 2016-12-15 | 2018-06-21 | Certainteed Gypsum, Inc. | Plaster boards and methods for making them |
RU2771539C2 (en) * | 2016-12-15 | 2022-05-05 | Сертейнтид Джипсем, Инк. | Plasterboard sheets and methods for their production |
US11753817B2 (en) * | 2016-12-15 | 2023-09-12 | Certainteed Gypsum, Inc. | Plaster boards and methods for making them |
US11124965B2 (en) | 2017-09-26 | 2021-09-21 | Certainteed Gypsum, Inc. | Plaster boards having internal layers and methods for making them |
US11655635B2 (en) | 2017-09-26 | 2023-05-23 | Certainteed Gypsum, Inc. | Plaster boards having internal layers and methods for making them |
US11845238B2 (en) | 2018-12-06 | 2023-12-19 | Gold Bond Building Products, Llc | Sound damping gypsum board and method of constructing a sound damping gypsum board |
US11559968B2 (en) | 2018-12-06 | 2023-01-24 | Gold Bond Building Products, Llc | Sound damping gypsum board and method of constructing a sound damping gypsum board |
US20210180322A1 (en) * | 2019-12-12 | 2021-06-17 | National Gypsum Properties, Llc | Wallboard with Foam Material Layer |
US11772372B2 (en) | 2020-06-05 | 2023-10-03 | Gold Bond Building Products, Llc | Sound damping gypsum board and method of constructing a sound damping gypsum board |
US20230374785A1 (en) * | 2022-05-23 | 2023-11-23 | Klrh, Llc | Non-Combustible, Net-Zero Energy Building Systems |
US11885132B2 (en) * | 2022-05-23 | 2024-01-30 | Klrh, Llc | Non-combustible, net-zero energy building systems |
Also Published As
Publication number | Publication date |
---|---|
NZ712480A (en) | 2018-06-29 |
BR112015023768A8 (en) | 2020-03-17 |
BR112015023768A2 (en) | 2017-07-18 |
CA2906759C (en) | 2023-10-03 |
SG11201507680WA (en) | 2015-10-29 |
EP2971398A1 (en) | 2016-01-20 |
ZA201506988B (en) | 2017-01-25 |
US20180320369A1 (en) | 2018-11-08 |
CN105143571B (en) | 2017-05-31 |
EP2971398A4 (en) | 2016-08-10 |
US11536022B2 (en) | 2022-12-27 |
US10731337B2 (en) | 2020-08-04 |
WO2014144688A1 (en) | 2014-09-18 |
KR20150143491A (en) | 2015-12-23 |
JP2016516146A (en) | 2016-06-02 |
AU2014228801B2 (en) | 2017-10-26 |
CN105143571A (en) | 2015-12-09 |
US20230139624A1 (en) | 2023-05-04 |
JP2020041413A (en) | 2020-03-19 |
US20200362555A1 (en) | 2020-11-19 |
AU2014228801A1 (en) | 2015-10-08 |
RU2015144110A (en) | 2017-04-21 |
RU2643393C2 (en) | 2018-02-01 |
CA2906759A1 (en) | 2014-09-18 |
Similar Documents
Publication | Publication Date | Title |
---|---|---|
US11536022B2 (en) | Building board with acoustical foam | |
US7829488B2 (en) | Non-woven glass fiber mat faced gypsum board and process of manufacture | |
US7842629B2 (en) | Non-woven glass fiber mat faced gypsum board and process of manufacture | |
US8128767B2 (en) | Process for manufacturing gypsum board faced with non-woven glass fiber mat | |
US6443257B1 (en) | Acoustical panel having a calendered, flame-retardant paper backing and method of making the same | |
US6983821B2 (en) | Acoustical panel having a honeycomb structure and method of making the same | |
US20080003903A1 (en) | Coated nonwoven mat | |
US20070148430A1 (en) | Perforated, coated nonwoven mat | |
US20070149078A1 (en) | Perforated non-woven fiberglass mat | |
CN207032561U (en) | A kind of sound-proof wall body structure | |
CN103971670A (en) | Noise absorption and insulation composite board | |
US11951712B2 (en) | Multilayer facer | |
US1943757A (en) | Soundproof board and process of making same | |
TWI748946B (en) | Plaster-based acoustic board and process for manufacturing the same | |
EP3453507B1 (en) | Multilayer facer manufacturing system | |
US1926509A (en) | Sound absorbing and deadening material | |
CN205604627U (en) | Cracked not broken compound furred ceiling board | |
CA2010250C (en) | Acoustic construction panel | |
JP2000129815A (en) | Sound insulation panel | |
CN102658683A (en) | Light flexible noise reduction non-woven composite material, preparation method and application | |
JPH0330666B2 (en) | ||
LV14909B (en) | Finishing acoustic plate and method for its production |
Legal Events
Date | Code | Title | Description |
---|---|---|---|
AS | Assignment |
Owner name: CERTAINTEED GYPSUM, INC., FLORIDA Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:ATHARI, CHRISTOPHER K.;GARVEY, THOMAS;SHINKODA, PAMELA;SIGNING DATES FROM 20131025 TO 20131028;REEL/FRAME:031772/0234 |
|
STCB | Information on status: application discontinuation |
Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION |