U.S. patent application number 11/322986 was filed with the patent office on 2007-08-02 for board construction assembly for reducing sound transmission and method.
Invention is credited to Francis John JR. Babineau, Maylene Kay Hugh, Philippe M. Scheerlinck, Timothy G. Swales.
Application Number | 20070175173 11/322986 |
Document ID | / |
Family ID | 37887916 |
Filed Date | 2007-08-02 |
United States Patent
Application |
20070175173 |
Kind Code |
A1 |
Babineau; Francis John JR. ;
et al. |
August 2, 2007 |
Board construction assembly for reducing sound transmission and
method
Abstract
An underlayment for supplementing one or more mechanical
properties of conventional wall, ceiling, or floor board is used to
in a wall, ceiling, or floor assembly that may be fabricated on
site. The assembly includes a first and second wall, ceiling, or
floor boards which each have mechanical properties, and the
underlayment which has at least one supplemental mechanical
property for supplementing the physical properties of the first and
second boards. The second board is secured to the first board with
the underlayment sandwiched between the second and first boards to
form a wall, ceiling, or floor assembly with the supplemental
physical property or properties of the underlayment. The
supplemental physical property or properties of the underlayment
may include, but are not limited to, sound transmission
reduction.
Inventors: |
Babineau; Francis John JR.;
(Parker, CO) ; Hugh; Maylene Kay; (Westminster,
CO) ; Swales; Timothy G.; (Aurora, CO) ;
Scheerlinck; Philippe M.; (Lakewood, CO) |
Correspondence
Address: |
JOHNS MANVILLE
10100 WEST UTE AVENUE
LITTLETON
CO
80127
US
|
Family ID: |
37887916 |
Appl. No.: |
11/322986 |
Filed: |
December 30, 2005 |
Current U.S.
Class: |
52/745.05 |
Current CPC
Class: |
B32B 5/022 20130101;
B32B 2262/101 20130101; B32B 13/14 20130101; B32B 2315/085
20130101; E04B 1/8409 20130101; B32B 7/12 20130101; B32B 38/0004
20130101; B32B 13/00 20130101; B32B 37/223 20130101; E04B 1/86
20130101; B32B 21/02 20130101; B32B 37/12 20130101; E04B 2/7457
20130101; E04F 15/206 20130101; B32B 2309/105 20130101; B32B
2419/00 20130101; E04B 2001/8461 20130101; B32B 2607/00 20130101;
E04B 2/7409 20130101; B32B 2305/20 20130101; B32B 21/10 20130101;
B32B 2471/00 20130101; B32B 2309/10 20130101; B32B 17/02 20130101;
B32B 2307/102 20130101; E04F 15/20 20130101 |
Class at
Publication: |
052/745.05 |
International
Class: |
E04B 1/00 20060101
E04B001/00 |
Claims
1. A method for on-site fabrication of a wall, ceiling, or floor
construction component/underlayment assembly, comprising: providing
a first wall, ceiling or floor construction component; the first
construction component having a length, a width, and a thickness;
the first construction component having first and second major
surfaces that are each defined by the length and the width of the
first construction component; the first construction component
having mechanical properties; providing a second wall, ceiling or
floor construction component; the second construction component
having a length, a width, and a thickness; the second construction
component having first and second major surfaces that are each
defined by the length and the width of the second construction
component; the second construction component having mechanical
properties; providing an underlayment means having a supplemental
mechanical property for supplementing the mechanical properties of
the first and second construction components; applying the
underlayment means to the first major surface of the first
construction component and securing the underlayment means to the
first major surface of the first construction component to form an
underlayment layer; overlaying the underlayment means and the first
major surface of the first construction component with the second
construction component; and securing the second construction
component to the first construction component with the underlayment
means sandwiched between the second and first construction
components to form a wall, ceiling or floor assembly with the
supplemental mechanical property of the underlayment means.
2. A method according to claim 1, wherein the underlayment layer
formed by the underlayment means substantially overlies the entire
first major surface of the first construction component.
3. A method according to claim 2, wherein the thickness of the
underlayment layer is between about 3.0 mm and about 30.0 mm.
4. A method according to claim 1, wherein the underlayment means is
flexible and a roll good.
5. A method according to claim 1, wherein the first and second
construction components are gypsum boards, cement boards, or wood
fiber boards.
6. A method according to claim 5, wherein the first and second
construction components are gypsum boards.
7. A method according to claim 6, wherein the first and second
construction components are gypsum wallboards.
8. A method according to claim 1, wherein the underlayment means
comprises a nonwoven fiberglass mat.
9. A method according to claim 8, wherein the nonwoven fiberglass
mat has a thickness of between about 3.0 mm and about 30.0 mm.
10. A method according to claim 9, wherein the nonwoven fiberglass
mat has a thickness of about 6.5 mm.
11. A method according to claim 1, wherein the supplemental
mechanical property of the underlayment means increases sound
transmission reduction.
12. A method according to claim 11, wherein the supplemental
mechanical property of the underlayment means increases sound
transmission reduction by 1 to 21 percent (1-21%).
13. A method according to claim 12, wherein the supplemental
mechanical property of the underlayment means increases sound
transmission reduction by 10 to 21 percent (10-21%).
14. A method according to claim 1, wherein the supplemental
mechanical property of the underlayment means increases a Sound
Transmission Class (hereinafter "STC") value by about 1 to about 21
percent (1-21%).
15. A method according to claim 14, wherein the supplemental
mechanical property of the underlayment means increases the STC
value by about 10 to about 21 percent (10-21%).
16. A method according to claim 1, wherein the supplemental
mechanical property of the underlayment means satisfies a STC value
for multi-family housing as determined by the U.S. Department for
Housing and Urban Development for sound transmission from living
unit to living unit, in an average noise environment, where the
corridor floors are carpeted.
17. A method according to claim 1, wherein the means used to secure
the second construction component to the first construction
component with the underlayment means sandwiched between the second
and first construction components to form the wall, ceiling or
floor assembly also secures the second construction component to a
structural support member.
18. A method according to claim 1, wherein the means used to secure
the second construction component to the first construction
component with the underlayment means sandwiched between the second
and first construction component to form the wall, ceiling or floor
assembly is an adhesive.
19. A construction component/underlayment assembly, comprising: a
first wall, ceiling or floor construction component; the first
construction component having a length, a width, and a thickness;
the first construction component having first and second major
surfaces that are each defined by the length and the width of the
first construction component; the first construction component
having mechanical properties; a second wall, ceiling or floor
construction component; the second construction component having a
length, a width, and a thickness; the second construction component
having first and second major surfaces that are each defined by the
length and the width of the second construction component; the
second construction component having mechanical properties; an
underlayment including a phase change material that for
supplementing the mechanical properties of first and second wall,
ceiling, or floor construction components; and the underlayment and
first and second construction components forming a layered
construction with the underlayment being located between the first
and second construction components.
20. A construction assembly according to claim 19, wherein: the
first and second construction components are wall, ceiling, or
floor construction boards; and the first and second construction
components and the underlayment are permanently secured
together.
21. A construction assembly according to claim 20, wherein the
first and second construction components are a first and second
wall construction components.
22. A construction assembly according to claim 21, wherein the
first and second wall construction components comprises gypsum
wallboard.
23. A construction assembly according to claim 21, wherein at least
one of the first or second wall construction components comprises
gypsum wallboard.
24. A construction assembly according to claim 23, wherein the
underlayment includes a sound deadening material for supplementing
the mechanical properties of the first and second construction
components to reduce sound transmission through the assembly.
25. A construction assembly according to claim 24, wherein the
underlayment means comprises a nonwoven fiberglass mat.
26. A construction assembly according to claim 25, wherein the
nonwoven fiberglass mat has a thickness of between about 3.0 mm and
about 30.0 mm.
27. A construction assembly according to claim 26, wherein the
nonwoven fiberglass mat has a thickness of about 6.5 mm.
28. A construction assembly according to claim 24, wherein the
supplemental mechanical property of the underlayment means
increases sound transmission reduction by 1 to 21 percent
(1-21%).
29. A construction assembly according to claim 28, wherein the
supplemental mechanical property of the underlayment means
increases sound transmission reduction by 10 to 21 percent
(10-21%).
30. A construction assembly according to claim 24, wherein the
supplemental mechanical property of the underlayment means
increases a STC value by about 1 to about 21 percent (1-21%).
31. A construction assembly according to claim 30, wherein the
supplemental mechanical property of the underlayment means
increases the STC value by about 10 to about 21 percent
(10-21%).
32. A construction assembly according to claim 24, wherein the
supplemental mechanical property of the underlayment means
satisfies a STC value for multi-family housing as determined by the
U.S. Department for Housing and Urban Development for sound
transmission from living unit to living unit, in an average noise
environment, where the corridor floors are carpeted.
33. A construction assembly according to claim 19, wherein the
means used to secure the second construction component to the first
construction component with the underlayment means sandwiched
between the second and first construction components to form the
wall, ceiling or floor assembly also secures the second
construction component to a structural support member.
34. A construction assembly according to claim 19, wherein the
means used to secure the second construction component to the first
construction component with the underlayment means sandwiched
between the second and first construction component to form the
wall, ceiling or floor assembly is an adhesive.
Description
BACKGROUND
[0001] The subject matter disclosed herein relates to an
underlayment for supplementing one or more mechanical properties of
conventional wall, ceiling, and/or floor boards; to the wall,
ceiling, and/or floor assemblies that include the underlayment
disclosed herein; and to the method of fabricating and installing
such assemblies.
[0002] Current practices for constructing walls, ceilings, and
floors of residential and commercial buildings (hereinafter
sometimes referenced as "horizontal and/or vertical building
components") typically utilize conventional wall, ceiling, and
floor boards, such as, but not limited to, gypsum boards, cement
boards, and wood fiber boards (e.g., OSB boards, particle boards,
and plywood). While horizontal and vertical building components
constructed with these conventional wall, ceiling, and floor boards
meet the basic requirements for residential and commercial
horizontal and/or vertical building components, certain
applications arise where it is necessary or desirable to provide
horizontal and vertical building components with mechanical
properties not provided by these conventional construction boards
or not provided by these conventional construction boards to the
extent required or desired for the applications. A mechanical
property necessary or desirable for certain applications and not
provided or only partially provided by conventional construction
boards includes, but is not limited to, sound transmission
reduction. For example, it might be necessary or desirable to have
the external walls of a living portion of a home or working areas
of a commercial building or walls between the living portion of a
home or working areas of a commercial building and an attached
garage that have greater sound transmission reduction when compared
to walls made of conventional wallboards. It might also be
necessary or desirable to have ceilings and/or floors of a home or
commercial building that have greater sound transmission reduction
when compared to walls made of conventional wallboards.
[0003] In addition to being able to supplement the mechanical
properties (enhance the existing mechanical properties and/or add
new mechanical properties) of conventional wall, ceiling, and/or
floor boards used in new building construction and enhance the
performance of these construction boards and the horizontal and
vertical building components made with these construction boards,
it would also be advantageous to be able to enhance the performance
of horizontal and/or vertical building components in existing
building structures without having to remove the existing wall,
ceiling, and/or floor boards forming the walls, ceilings, and
floors of these existing structures.
[0004] Accordingly, there is a need for wall, ceiling, and floor
boards having improved mechanical performance characteristics,
including greater sound transmission reduction, when compared to
horizontal and/or vertical building components made of conventional
wallboards.
[0005] The foregoing examples of the related art and limitations
related therewith are intended to be illustrative and not
exclusive. Other limitations of the related art will become
apparent to those of skill in the art upon a reading of the
specification and a study of the drawings.
SUMMARY
[0006] The following embodiments and aspects thereof are described
and illustrated in conjunction with systems, tools, and methods
which are meant to be exemplary and illustrative, not limiting in
scope. In various embodiments, one or more of the above-described
problems have been reduced or eliminated, while other embodiments
are directed to other improvements.
[0007] The subject matter disclosed herein provides an underlayment
for supplementing one or more mechanical properties of horizontal
and/or vertical building components and especially for
supplementing one or more mechanical properties of conventional
wall, ceiling, and floor construction components. The underlayment
may be used to enhance the performance of horizontal and/or
vertical building components in the construction of new buildings
and in the renovation of existing buildings without having to
remove existing horizontal and/or vertical building components
forming the walls, ceilings and/or floors of existing buildings.
Wall, ceiling, and floor assemblies that include the underlayment
and the method of fabricating and installing such assemblies on
site are disclosed herein.
[0008] The underlayment disclosed herein is a compliant material
that exhibits one or more mechanical properties that can enhance
the performance of horizontal and/or vertical building components,
especially walls, ceilings, and floors made with conventional wall,
ceiling, and floor construction components. These wall, ceiling,
and floor construction components include, but are not limited to,
wall, ceiling, and floor construction boards such as, but not
limited to, 4.times.8, 4.times.9, 4.times.10, and 4.times.12 foot
gypsum boards; cement boards; and wood fiber boards (e.g., OSB
boards, particle boards, and plywood); concrete walls, ceilings,
and floors; decorative wall and ceiling construction components,
such as, but not limited to, laminates with decorative surface
layers (e.g. hardwood or simulated hardwood surface layers, fabric
layers, etc.); and decorative floor construction components, which
may be a permanent component of a floor or an unattached or readily
removable floor construction component that overlies conventional
permanent floor construction components, such as, but not limited
to carpeting, cushioned carpeting, rugs, cushioned rugs, vinyl
flooring, cushioned vinyl flooring, tiles, flexible or vinyl tiles,
and flooring laminates with decorative surface layers (e.g.
hardwood or simulated hardwood surface layers, tile or simulated
tile surface layers, etc.). The underlayment disclosed herein
enhances one or more mechanical properties of these wall, ceiling,
and/or floor construction components by supplementing the
mechanical properties of these wall, ceiling, and/or floor
construction components. For example, when the underlayment is
combined with a wall, ceiling, or floor component to form a wall,
ceiling, or floor construction component/underlayment assembly, the
underlayment can supplement the mechanical properties of the
construction component by enhancing one or more existing mechanical
properties of the construction component and/or by adding one or
more new mechanical properties to those of the construction
component. The supplemental mechanical properties imparted to a
construction component/underlayment assembly by the underlayment
disclosed herein include mechanical properties such as, but not
limited to, enhanced sound transmission reduction.
[0009] In one embodiment, the horizontal and/or vertical building
component/underlayment assembly for use in a horizontal and/or
vertical building component includes a first and second horizontal
and/or vertical building component which each have mechanical
properties and the underlayment component which has at least one
supplemental mechanical property for supplementing the mechanical
properties of the first and second horizontal and/or vertical
building component. The components of this construction
component/underlayment assembly are permanently affixed to each
other for the service life of the assembly. The first and second
wall, ceiling, or floor construction components of this
construction component/underlayment assembly may have the same or
different mechanical properties and may be made from the same type
of construction component or a different type of construction
component. For example, the assembly may include first and second
construction components that are each wall, ceiling, or floor
construction boards. The assembly may include first and second
construction components where one construction component is a wall,
ceiling, or floor construction board and the second construction
component is a decorative wall, ceiling, or floor construction
component. The first and second construction components are
permanently secured to each other with the underlayment component
sandwiched between the first and second construction components to
form a wall, ceiling, or floor construction component/underlayment
assembly with the supplemental mechanical property or properties of
the underlayment.
[0010] In one embodiment, the underlayment component is first
secured, e.g., with an adhesive or mechanical fasteners such as
staples, to one of the construction components and the construction
components are then permanently secured to each other to form the
construction component/underlayment assembly. Typically, one of the
construction components is already secured to structural members of
a wall, ceiling, or floor that may be a wall, ceiling or floor of a
building under construction or under renovation. However, fasteners
securing the first and second construction components together can
also be used to secure the underlayment component to the
construction components and/or to secure the entire construction
component/underlayment assembly to structural members of the wall,
ceiling, or floor.
[0011] In another embodiment, a floor construction
component/underlayment assembly of the subject invention for use in
floor construction includes a first and second floor construction
components which each have mechanical properties and the
underlayment component which has at least one supplemental
mechanical property for supplementing the mechanical properties of
the first and second floor construction components. The components
of this construction component/underlayment assembly are not
permanently affixed to each other for the service life of the
assembly. The first and second floor construction components of
this embodiment of the construction component/underlayment assembly
typically have different mechanical properties and are typically
made from different types of construction components. For example,
the assembly typically includes a first construction component that
is a floor construction board, a concrete floor construction
component, etc., and a second construction component that is a
decorative floor construction component that overlies, but is
unattached to or readily removable from the first construction
component. Such decorative floor construction components include,
but are not limited to, carpeting, cushioned carpeting, rugs,
cushioned rugs, vinyl flooring, cushioned vinyl flooring, tiles,
flexible or vinyl tiles, and flooring laminates with decorative
surface layers (e.g. hardwood or simulated hardwood surface layers,
tile or simulated tile surface layers, etc). The underlayment is
sandwiched between the first and second floor construction
components to form a floor construction component/underlayment
assembly with the supplemental mechanical property or properties of
the underlayment component.
[0012] In one embodiment, either the underlayment component is laid
over the construction board component, concrete floor construction
component, etc., and then the decorative floor construction
component is laid over the underlayment component or the
underlayment component and the decorative floor construction
component are an integral subassembly that is laid over the
construction floor construction component, etc. Where the
underlayment component, the underlayment component and the
decorative floor construction component, or the underlayment
component and decorative floor construction component subassembly
are secured to the floor construction board component, the concrete
floor construction component, etc., they are removably secured with
an adhesive, staples, or other fastening means that enables the
underlayment component, the decorative floor construction
component, or the underlayment component and the decorative floor
construction component (held in place primarily by gravity) to be
easily removed from the floor construction board component, the
concrete floor construction component, etc.
[0013] In general, the underlayment is a compliant material and the
construction component/underlayment assemblies disclosed herein can
be manufactured by incorporating the underlayment to provide
contractors a product available for purchase. Furthermore, the
compliant material and the construction component/underlayment
assemblies disclosed herein can be made at the job site by
incorporating the underlayment to provide contractors a product
with great flexibility and cost savings. In one embodiment,
contractors would only need to stock and utilize standard
relatively low cost construction components when constructing or
renovating buildings. Where select portions of a building require
construction components with mechanical properties that are not
provided by standard construction components, rather than having to
purchase and stock relatively expensive construction components to
meet these application requirements, the contractors could utilize
construction component/underlayment assemblies that are made with
standard building components.
[0014] For example, in multi-occupant buildings, such as apartment
buildings, the walls separating the rooms of an apartment typically
can be constructed with standard gypsum board. However, the walls
between apartments utilizing only standard gypsum board in the wall
construction transmit sound at undesirable levels. With the on site
fabrication of construction component/underlayment assemblies as
described herein, which are made with standard gypsum board and an
underlayment that provides reduced sound transmission properties,
contractors would improve the overall acoustical properties of the
resulting apartment units and reduce overall sound transmission
from one apartment unit to another.
[0015] The foregoing has outlined rather broadly the features and
technical advantages of the present invention in order that the
detailed description of the invention that follows may be better
understood. Additional features and advantages of the methods and
compositions disclosed herein will be described hereinafter which
form the subject of the claims of the invention. It should be
appreciated that the conception and specific embodiment disclosed
may be readily utilized as a basis for modifying or designing other
structures for carrying out the same purposes of the methods and
compositions disclosed herein. It should also be realized that such
equivalent constructions do not depart from the methods and
compositions disclosed herein. The novel features which are
believed to be characteristic of the methods and compositions
disclosed herein, both as to its organization and method of
operation, together with further aspects and advantages will be
better understood from the following description.
[0016] In addition to the exemplary aspects and embodiments
described above, further aspects and embodiments will become
apparent by reference to the drawings and tables and by study of
the following descriptions.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] Exemplary embodiments are illustrated in the referenced
figures of the drawings. It is intended that the embodiments and
figures disclosed herein are to be considered illustrative rather
than limiting.
[0018] FIG. 1 is a cross sectional view of a conventional wall
structure showing a conventional gypsum wallboard construction.
[0019] FIG. 2 depicts one embodiment where a compliant material or
underlayment is positioned between two layers of gypsum
wallboard.
[0020] FIG. 3 is a cross sectional view of a wall structure
incorporating the gypsum wallboard--compliant material--gypsum
wallboard configuration as shown in FIG. 2.
[0021] FIG. 4 depicts the results of a standardized airborne sound
transmission test comparing a conventional 0.625 inch gypsum
wallboard and a 1/4 inch gypsum--compliant material--1/4 inch
gypsum wallboard configuration.
[0022] FIG. 5 is a schematic perspective view of a compliant
material/underlayment supplied as a roll good.
DETAILED DESCRIPTION
[0023] In traditional construction applications, it is known in the
art to reduce the mechanical connection between layers of gypsum
wallboard to increase sound transmission loss. For example, it is
known that staggered use of wood studs or the use of resilient
metal furring strips to serve as supports for the gypsum wallboard
layers independent one to another are effective in increasing sound
transmission loss. Multiple layers of gypsum wallboard is also
known to increase sound transmission loss. As shown in FIG. 1, the
addition of sound absorbing material in a wall system 10 is used to
provide thermal and acoustical properties. However, there exists a
need for improved materials and methods for increasing sound
transmission loss in residential and commercial construction.
[0024] Referring still to FIG. 1, conventional lightweight
construction in North America typically consists of framing
materials 11, made from wood or steel, oriented vertically and
arranged in a regular periodic manner so as to define a framed
structure (such as a wall). This frame structure is typically
covered with gypsum wallboard 12 to provide structure, fire
protection, aesthetics, and sound insulation to the rooms of a
building. The gypsum wallboard is typically attached to the framing
11 by the use of nails or screws 13. Occasionally, insulating
material 14 may be added to the cavity defined by the framing and
the gypsum wallboard for thermal or sound insulating purposes. The
entire structure comprises a wall system 10.
[0025] Referring now to FIG. 2, it has been discovered that
disposition of underlayment 23 between two construction components
22 in a conventional (standard) wall construction increased sound
transmission loss at sound frequencies typically encountered in an
average building and increased the Sound Transmission Class ("STC")
of the composite wall structure. Similarly, other wall, ceiling,
and floor construction components, including, but not limited to,
wall, ceiling, and floor construction boards, such as, but not
limited, to 4.times.8, 4.times.9, 4.times.10, and 4.times.12 foot
gypsum boards, cement boards, and wood fiber boards (e.g. OSB
boards, particle boards, and plywood); concrete block walls,
ceilings, and floors; decorative wall and ceiling construction
components, such as but not limited to laminates with decorative
surface layers (e.g. hardwood or simulated hardwood surface layers,
fabric layers, etc.); and decorative floor construction components,
which may be a permanent component of a floor or an unattached or
readily removable floor construction component that overlies
conventional permanent floor construction components, such as but
not limited to carpeting, cushioned carpeting, rugs, cushioned
rugs, vinyl flooring, cushioned vinyl flooring, tiles, flexible or
vinyl tiles, and flooring laminates with decorative surface layers
(e.g. hardwood or simulated hardwood surface layers, tile or
simulated tile surface layers, etc.), could be fabricated to take
advantage of the increased sound transmission loss and increased
STC of the composite wall structure described herein. These
construction component/underlayment assemblies have supplemental
mechanical properties provided by the underlayment 23 that are not
present in the construction components of the conventional
assemblies and/or have supplemental mechanical properties provided
by the underlayment 23 that enhance the mechanical properties of
the construction components of the assemblies, such as, but not
limited to, enhanced sound transmission reduction.
[0026] As shown in FIG. 2, the underlayment 23 includes a single
layer provided between a first layer of gypsum wallboard 21 and a
second layer of gypsum wallboard 22 to supplemental the mechanical
properties of the wall structure 20. The thicknesses of the two
layers of gypsum wallboard and of the compliant material are
selected such that total thickness of the three assembled layers of
the wallboard structure 20 is equivalent to that of standard gypsum
wallboard construction. In one embodiment, the total thickness is
approximately 0.625 inches (15.875 mm). Underlayment 23 could
include one or more layers. Preferably, the underlayment 23 is a
single layer of compliant material, such as a nonwoven mat of
fiberglass. In one preferred embodiment, the underlayment 23 is
ECOMAT TYPE G 600 glass fiber insulation mat (Johns Manville,
Denver, Colo.). Type G 600 is a binderless, nonwoven textile
insulation mat having a thickness of about 0.25 inches (6.5 mm).
Alternate preferred embodiments could include glass fiber mats
having thicknesses of between about 0.118 inches and about 1.18
inches (3.0 mm and 30.0 mm) (ECOMAT, Johns Manville, Denver,
Colo.).
[0027] Without being bound by one particular theory, it is thought
that the compliant layer 23 in the composite wallboard structure 20
allows for minute amounts of relative motion between the two layers
of gypsum wallboard 21, 23 and provides a vibration break that
prevents the transmission of vibrational energy through the wall
structure 30 (FIG. 3). In a standardized airborne sound
transmission loss test (ASTM E90), replacing one 0.625 inch layer
of gypsum wallboard 12, with the composite wallboard structure 32,
as shown in FIG. 3, resulted in an increase of sound transmission
loss at nearly all frequencies of interest (see FIG. 4) and an
increase in the Sound Transmission Class ("STC"), the typical
single-number rating used to classify building constructions for
sound insulation performance.
[0028] The passage of sound transmission from one room of a
building into another room or source within or outside the building
is known as "sound transmission." Sound transmission loss measures
the effectiveness of a structural component, such as door, wall,
floor, or other barrier, in restricting the passage of sound and
varies with frequency. Typically, sound transmission loss is
greater at higher frequencies. As referenced above, a sound
transmission loss measurement test has been defined and
standardized by the American Society for Testing and Materials
(ASTM E90). Under ASTM E90, a test opening is created between two
isolated reverberation rooms. A test specimen comprising a wall or
floor/ceiling construction is mounted and sealed within the test
opening. Measurements are made in both rooms at sixteen frequencies
in 1/3 octave bands from 125 to 4000 cycles per second (cps) (also
expressed as "Hertz" or "Hz"). Sound transmission loss is taken as
the difference, at each measurement frequency, of the measured
sound pressure levels in each room, adjusted for absorption in the
second, or "receive" room. The unit of sound transmission loss is
the decibel (dB). Higher transmission loss values of a wall
component equate to an improved ability to act as a barrier to the
passage of unwanted or undesirable sound or noise.
[0029] STC is a single number rating determined from the ASTM E90
test method sound transmission loss data. An STC rating is
calculated by comparing the measurements of transmission loss made
at the frequencies proscribed by ASTM E90 with a standardized
reference contour. The sum of deficiencies below the reference
contour cannot be greater than 32 dB and a maximum deficiency at a
single test point cannot exceed 8 dB. When the contour is at its
highest value that meets the deficiency requirements outlined
above, the STC for the article being tested is the transmission
loss corresponding to the intersection of the counter and the 500
Hz ordinate. STC ratings are calculated in accordance with ASTM
designation E413.
[0030] Common internal partition walls used in residential
dwellings with gypsum wallboard attached directly to both sides of
wood studs have an STC rating of about 32-35. The addition of sound
absorbing material 14, as shown in FIG. 1, in a wall cavity between
a first and second layers of gypsum wallboard generally increases
the STC rating to about 35-38. When tested according to ASTM E90,
the composite wall structure employing underlayment 23 as shown in
FIG. 2 increased the STC rating to about 46 (see FIG. 4), a
measured increase in sound transmission reduction of about 21
percent (21%). An STC rating of 46 exceeded the minimum STC value
acceptable for multi-family housing as determined by the U.S.
Department for Housing and Urban Development (sound transmission
from living unit to living unit, in an average noise environment,
where the corridor floors are carpeted require an minimum STC
rating of 45).
[0031] Referring now to FIG. 5, preferably, the underlayment 23 of
the subject invention is flexible or pliable, such as the
embodiment shown in FIG. 5, so that the underlayment can be
packaged, stored, shipped, and handled in roll form. The
underlayment 23 has first and second major surfaces 25 and 27 that
are each defined by the length and the width of the underlayment.
The underlayment 23 may be provided in different lengths, but would
typically be at least about 164 feet in length (50 meters). As a
practical matter, when the underlayment 23 is provided in roll
form, the length of the underlayment 23 is only limited by the size
and weight of the roll, which should have a size and weight that
facilitates the packaging, storage, shipment, handling, and
application of the underlayment. Preferably, the underlayment 23
can be easily severed to desired lengths at the job site with a
knife or other conventional cutting tool for application to wall,
ceiling, and/or floor construction components and/or may be
transversely separable by hand e.g. through the use of
longitudinally spaced-apart transverse lines of weakness (such as
but not limited to lines of perforations) that are located a
standard eight feet or some other standard construction board
dimension apart along the length of the underlayment.
[0032] The underlayment 23 may be provided in different widths with
the underlayment typically being between about 1.0 and about 2.2
meters in width (3.28 and 7.22 feet). However, for applications
where the underlayment 23 is to be applied to a series of
construction boards, such as but not limited to wall boards, it may
be beneficial to have an underlayment about 8 feet to about 10 feet
in width (2.44 and 3.05 meters) so that the underlayment could be
applied in one continuous operation from floor to ceiling over a
plurality of wall boards such as the wall boards of an entire
wall.
[0033] In one preferred embodiment, one major surface of the
underlayment 23 has an adhesive (e.g. a pressure sensitive or
rewettable adhesive) thereon so that the underlayment can be easily
and quickly secured to one of the construction components of a
wall, ceiling, or floor construction component/underlayment
assembly as the assembly is being fabricated on site. Preferably,
the underlayment 23 is a self-adhering underlayment and the
adhesive is a pressure sensitive adhesive that is overlaid, until
application, by a release sheet that is surface treated with
silicone or another suitable release agent and protects the
adhesive from degradation prior to application. The adhesive may be
a continuous coating that is substantially coextensive with the
major surface of the underlayment 23 or may be discontinuous (e.g.
spaced apart lines of adhesive, dots of adhesive, etc.) and both
major surfaces of the underlayment 23 may have an adhesive thereon
for bonding the underlayment 23 to both of the construction
components.
[0034] Where it is desired to reduce sound transmission through a
wall, ceiling, and/or floor, an underlayment 23 can be used in the
construction component/underlayment assembly of the subject
invention that is or includes one or more layers of sound-deadening
material of the same or differing thicknesses.
[0035] Preferably, the construction component/underlayment assembly
20 as shown in FIG. 2 is fabricated at the job site and may be used
to enhance the performance of walls, but could be used in ceilings,
and/or floors in both new building construction and the upgrading
of existing building structures. FIG. 3 shows a wall 30 constructed
with the construction component/underlayment assembly 32 wherein
the construction components are gypsum boards. Insulating material
35 can be added to the cavity for thermal or sound insulating
purposes. Preferably, the wall is constructed by first securing a
first layer of gypsum board with nails, screws and/or adhesive. A
layer of underlayment 23 is then bonded, stapled or otherwise
secured to a major surface of the gypsum board. The underlayments
23 can be applied in vertically extending strips (e.g. strips
extending from floor to ceiling) that preferably are between about
1 and about 2.2 meters (3.28 and about 7.22 feet wide) and the
height of the wall. When the strips of underlayment 23 are applied
in a vertical direction, these vertically extending strips of the
underlayment 23 may abut or overlap adjacent strips of the
underlayment so that the underlayments form a layer within the wall
that is coextensive or substantially coextensive with the first
layer of construction boards. The underlayments 23 can also be
applied in horizontally extending strips (e.g. strips extending for
part or all of the length of the wall) that preferably are between
about 1 and about 2.2 meters wide (3.28 and about 7.22 feet) and
have a length to overlay at least two construction boards and
preferably all of the construction boards of the wall. When the
strips of underlayment 23 are applied in a horizontal direction,
these horizontally extending strips of the underlayment 23 may abut
or overlap adjacent strips of the underlayment so that the
underlayments form a layer within the wall that is coextensive or
substantially coextensive with the first layer of construction
boards and thus the wall. The construction boards of the second
layer of construction boards are then secured to the studs 31 with
nails or screws to complete the fabrication of the construction
component/underlayment assemblies 32 and the wall 30 or, where the
application will permit, the construction boards are then bonded to
the underlayment 23 to complete the fabrication of the construction
component/underlayment assemblies 20 and the wall 30. The wall 30
may then be taped, mudded and finished, e.g. with texture or
paint.
[0036] While the on-site fabrication of the construction
component/underlayment assemblies 20 has been described in
connection with wall 30, the fabrication of construction
component/underlayment assemblies of a floor and/or ceiling would
be the same with the strips of underlayment 23 extending lengthwise
or widthwise of the construction boards and abutting or overlapping
to form a layer within the floor and/or ceiling that is coextensive
with or substantially coextensive with the floor and/or
ceiling.
[0037] While a number of exemplary aspects and embodiments have
been discussed above, those of skill in the art will recognize
certain modifications, permutations, additions, and subcombinations
thereof. It is therefore intended that claims hereafter introduced
are interpreted to include all such modifications, permutations,
additions, and sub-combinations as are within their spirit and
scope.
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