U.S. patent application number 13/837109 was filed with the patent office on 2014-09-18 for building board with acoustical foam.
This patent application is currently assigned to CERTAINTEED GYPSUM, INC.. The applicant listed for this patent is CERTAINTEED GYPSUM, INC.. Invention is credited to Christopher K. Athari, Thomas J. Garvey, Pamela Shinkoda.
Application Number | 20140273687 13/837109 |
Document ID | / |
Family ID | 51529134 |
Filed Date | 2014-09-18 |
United States Patent
Application |
20140273687 |
Kind Code |
A1 |
Garvey; Thomas J. ; et
al. |
September 18, 2014 |
Building Board with Acoustical Foam
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.
Inventors: |
Garvey; Thomas J.;
(Oakville, CA) ; Athari; Christopher K.; (St.
Petersburg, FL) ; Shinkoda; Pamela; (Oakville,
CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
CERTAINTEED GYPSUM, INC. |
Tampa |
FL |
US |
|
|
Assignee: |
CERTAINTEED GYPSUM, INC.
Tampa
FL
|
Family ID: |
51529134 |
Appl. No.: |
13/837109 |
Filed: |
March 15, 2013 |
Current U.S.
Class: |
442/120 |
Current CPC
Class: |
B32B 2419/00 20130101;
B32B 13/08 20130101; B32B 2266/0285 20130101; B32B 2266/06
20130101; B32B 5/022 20130101; B32B 2307/102 20130101; B32B 2262/10
20130101; B32B 3/266 20130101; E04B 1/86 20130101; B32B 13/14
20130101; Y10T 442/25 20150401; B32B 13/045 20130101; E04B
2001/8461 20130101; B32B 7/02 20130101 |
Class at
Publication: |
442/120 |
International
Class: |
E04B 1/86 20060101
E04B001/86; B32B 13/14 20060101 B32B013/14 |
Claims
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.
Description
TECHNICAL FIELD
[0001] This disclosure relates to a building board construction.
More specifically, the present invention relates to a building
board with an acoustical foam.
BACKGROUND OF THE INVENTION
[0002] 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.
[0003] 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.
[0004] 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.
[0005] 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.
[0006] 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.
[0007] 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.
SUMMARY OF THE INVENTION
[0008] 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.
[0009] A further advantage is realized by providing increased
acoustical properties via the inclusion of a polymer sheet within
the core of the building board.
[0010] 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.
[0011] Another advantage of the present system is attained by
including a series of sound absorbing polymeric cubes within the
core of the building board.
[0012] 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.
[0013] A further advantage is recognized by incorporating sound
absorbing materials into a gypsum building board via a continuous
manufacturing method.
[0014] 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.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] 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:
[0016] FIG. 1 is a diagram of one possible manufacturing process
for the building boards of the present disclosure.
[0017] FIG. 2 is a diagram of another possible manufacturing
process for the building boards of the present disclosure.
[0018] FIG. 3 is a diagram of another possible manufacturing
process for the building boards of the present disclosure.
[0019] FIG. 4 is a cross sectional view of an embodiment of the
building board of the present disclosure.
[0020] FIG. 5 is a cross sectional view of an alternative
embodiment of the building board of the present disclosure.
[0021] FIG. 6 is a cross sectional view of an alternative
embodiment of the building board of the present disclosure.
DETAILED DESCRIPTION OF THE DRAWINGS
[0022] 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.
[0023] FIGS. 1-3 illustrate various production lines (34a, 34b, and
34c) for constructing the building boards of the present
disclosure. FIGS. 4-6 are cross sectional views of various board
constructions (20a, 20b, 20c) 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. In the
particular embodiment illustrated in FIG. 4, board 20a 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.
[0024] With continuing reference to FIG. 4, 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. As a result
the exterior surface of each mat 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.
[0025] The enhanced acoustical properties are achieved via the
inclusion of a polymer sheet 28 into core 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.RTM. which is manufactured and
sold by BASF Corporation. Basotect.RTM. foam preferred because it
provides a three-dimensional network of slender and easily shaped
webs. Basotect.RTM. 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 1/2 inch thick building board, a polymer sheet
28 of 1/8 inch is preferred.
[0026] 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, 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 20a, 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 20a. In the absence of
apertures 32, building panel 20a would be prone to separation along
the boundary of sheet 28. In the event that polymer sheet 28 could
absorb slurry layer 22, apertures could be eliminated 32. In the
preferred embodiment, the thickness of core layer 22 is
substantially larger than the thickness of polymer sheet 28.
[0027] FIG. 1 illustrates a gypsum board production line 34a that
has been modified in accordance with the present disclosure.
Production lines 34a includes a series of forming tables 36 for
supporting building panel 20a 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.
[0028] As further noted in FIG. 1, gypsum board 20a 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. In either event, 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.
[0029] An alternative production line 34b is disclosed in FIG. 2.
Line 34b 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. In the preferred embodiment, cubes of
approximately 1/2 inch are employed. Other shapes and sizes can
also be used instead of 1/2 inch cubes. Basotect.RTM. 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.
In still yet additional embodiments, the Basotect.RTM. foam is
added to the slurry in a grated or granular form.
[0030] The resulting building board 20b 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 20b is fully integrated as core layer 22 extends about the
individual 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 into slurry core 22.
[0031] A further embodiment of the production line 34c 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
20c 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.
[0032] 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.
* * * * *