HK1177629A - Sound attenutation building material and system - Google Patents

Description

sound attenuating building materials and systems

The application is a divisional application of a patent application with the application number of 200880129305.5, the application date of the original application is 2008, 9 and 25, and the name of the application is 'sound attenuation building material and system'.

RELATED APPLICATIONS

This application claims the benefit of U.S. patent application No.12/077,951 filed on day 21, 3.2008, which claims the benefit of U.S. provisional patent application No.60/919,509 filed on day 21, 3.2007, U.S. provisional patent application No.60/961,130 filed on day 17, 7.2007, and U.S. provisional patent application No.61/002,367 filed on day 7, 11.2007, all of which are incorporated herein by reference. This application also claims the benefit of U.S. provisional patent application No.61/081,949 filed on day 18, 7/2008 and U.S. provisional patent application No.61/081,953 filed on day 18, 7/2008.

Technical Field

The present invention relates to building materials, and more particularly to wallboard and other building materials that include sound attenuation properties.

Background

Many building materials are designed with sound attenuation or absorption characteristics in mind, as it is often desirable to minimize or at least reduce the amount of sound transmitted through the partition. With respect to building structures, building materials such as wallboard, insulation, and paint are considered materials that can help reduce sound transmission.

Wallboard is a conventional utility or building material that has many different types, designs and sizes. The wall panels may be configured to have a number of different characteristics or features, such as different sound absorption, heat transfer, and/or fire protection characteristics. To date, the most common type of wallboard is drywall or gypsum board. Dry wallboard comprises a gypsum core that is calcium sulfate hemihydrate (CaSO)₄·¹/₂ H₂O) arranged between two facing membranes, typically paper or fibreglass mats. Drywall panels can include various additives and fillers to modify their properties.

The most commonly used drywall panels are one-half inch thick, but the thickness can range from one-quarter inch (6.35 mm) to one inch (25 mm). For sound insulation or fire protection, two layers of drywall are sometimes placed at right angles to each other. Drywall panels provide a thermal resistance or R-value of 0.32 for three-eighths of an inch panels, an R-value of 0.45 for half an inch panels, an R-value of 0.56 for five-eighths of an inch panels, and an R-value of 0.83 for one inch panels. Thicker drywall has a slightly higher Sound Transmission Class (STC) rating, in addition to an increase in R-value.

STC is part of ASTM international classifications E413 and E90 and is a widely used standard for identifying the degree to which building materials attenuate airborne sound. The STC number is derived from acoustic attenuation values measured at sixteen standard frequencies from 125Hz to 4000 Hz. These transmission loss values are then plotted on a sound pressure level plot and the resulting curve is compared to a standard reference profile. The acoustic engineer fits these values to an appropriate TL (or transmission loss) curve to determine the STC rating. STC can be considered to be the decibel drop in noise that a wallboard or other partition can provide. dB is logarithmic, wherein the human ear can perceive a 10dB reduction in sound when the volume is roughly halved. Thus, any reduction in dB (magnitude) is evident. The reduction in dB (magnitude) for the same material depends on the sound transmission frequency. The higher the STC rating, the more effective the barrier is in reducing the transmission of the most common audio.

Interior walls, as is common in houses or buildings, have opposing pieces of drywall mounted on a stud frame or stud/wall. In this arrangement, the STC of the interior wall is about 33 with a drywall panel thickness of 1/2 inches. The addition of fiberglass insulation helps, but only increases STC to 36-39, depending on the type and quality of insulation and stud to stud spacing. Since wallboard is typically made up of several panels or panels, the small gaps or spaces between the panels or any other gap or space in the wall structure are referred to as "side channels" which will allow sound to be transmitted more freely, thus resulting in a lower overall STC rating. It is therefore critical to eliminate or reduce as much as possible all potential side passages.

Similarly, the outdoor-indoor transmission class (OITC) is a widely used standard for indicating a sound transmission level between an outdoor space and an indoor space. The OITC test typically considers frequencies as low as 80Hz and places more emphasis on lower frequencies.

Disclosure of Invention

Accordingly, the present invention provides sound attenuating building materials, systems, and methods for attenuating sound. In one aspect, for example, a sound attenuating building material is provided. Such building materials may include a core matrix (core matrix) disposed on the facing material, wherein the core matrix includes a plurality of microparticles and a binder configured to support the microparticles, and wherein one side of the core matrix is exposed to form an at least substantially exposed face of the building material to increase acoustic attenuation by reducing reflection of acoustic waves impinging on the building material as compared to a control building material lacking the exposed face. The construction material may also include an acoustically transparent material disposed on an exposed surface of the construction material. Such acoustically transparent materials may include mesh or net-like materials. Further, in certain aspects, the building material may also include a rigid material associated with the core matrix. In a particular aspect, the rigid material is disposed within the core matrix.

It is contemplated that a variety of different microparticles may be included in the core matrix of the present invention. In one aspect, the microbeads are hollow. On the other hand, the microbeads are filled with an inert gas. In yet another aspect, the microbeads are made of fly ash.

The exposed face of the building material may include a variety of configurations, from a relatively planar configuration to a significantly non-planar configuration. For example, in one aspect, the substantially exposed face has a plurality of projections extending from the core matrix. Such projections may vary depending on the desired properties of the building material, but in one aspect, the projections are spaced apart in a predetermined pattern.

The present invention also provides a system for attenuating sound using a building material. Such a system may include a first building material, a second building material disposed in an orientation substantially parallel to the first building material such that the first building material and the second building material are separated by a distance to form a sound trap space, and wherein the first building material includes a core matrix disposed on a facing material. The core matrix may include a plurality of particulates, and a binder configured to support the particulates, wherein a side of the first building material core matrix facing the second building material is exposed to form an at least substantially exposed face of the first building material to increase acoustic attenuation by reducing reflections of acoustic waves impinging on the first building material as compared to a control building material lacking the exposed face. In a more particular aspect, the building structure may be located within the sound trap space. In another more particular aspect, the first building material is supported about/near a first side of the building structure and the second building material is supported about a second side of the building structure. In yet another more particular aspect, the first building material, the second building material, and the building structure form a partition. In certain aspects, a barrier/isolation material may be disposed within the sound trap between the first building material and the second building material.

Many configurations for the second building material are contemplated. For example, in one aspect, a second building material includes a core matrix disposed on a facing material, wherein the core matrix includes a plurality of beads and a binder configured to support the beads. In a particular aspect, a side of the second building material core matrix facing the first building material is exposed to form an at least substantially exposed face of the second building material to increase sound attenuation by reducing reflection of sound waves impinging on the second building material as compared to a control building material lacking the exposed face. Alternatively, the side of the second building material core matrix facing the first building material may be substantially covered.

The invention also provides a method of attenuating sound using the building material. Such a method may include introducing acoustic waves into a sound trap as described herein, whereby the acoustic waves are attenuated by passing at least partially through at least one of the first building material core matrix and the second building material core matrix. In yet another aspect, the acoustic waves are attenuated by passing at least partially through both the first building material core matrix and the second building material core matrix. In yet another aspect, the sound wave is at least partially attenuated due to a reduced reflection of the sound wave impinging on the exposed face of the first building material as compared to a control building material lacking the exposed face.

Drawings

The present invention will become more fully apparent from the following description and appended claims, taken in conjunction with the accompanying drawings. It is appreciated that these drawings depict only exemplary embodiments of the invention and are therefore not to be considered limiting of its scope. It will be readily understood that the components of the present invention, as generally described and illustrated in the figures herein, could be arranged and designed in a wide variety of different configurations. The invention will be described and explained with additional specificity and detail through the use of the accompanying drawings, in which:

FIG. 1 shows a detailed perspective view of a construction material according to an exemplary embodiment of the present invention;

FIG. 2 shows a detailed perspective view of a construction material according to another exemplary embodiment of the present invention;

FIG. 3 illustrates a partial side cross-sectional view of an exemplary sound attenuation system in the form of a partition formed in accordance with one exemplary embodiment, wherein the partition is formed of an opposing exemplary building material, and wherein the partition forms and defines a sound trap;

FIG. 4 illustrates a partial side cross-sectional view of an exemplary sound attenuation system in the form of a partition formed in accordance with another exemplary embodiment, wherein the partition is formed of an opposing exemplary building material, and wherein the partition forms and defines a sound trap;

FIG. 5 illustrates a partial side cross-sectional view of an exemplary sound attenuation system in the form of a partition formed in accordance with yet another exemplary embodiment, wherein the partition is formed of an opposing exemplary building material, and wherein the partition forms and defines a sound trap;

figure 6 shows a detailed perspective view of a wallboard building material according to an exemplary embodiment of the present invention, wherein the building material includes a particulate-based core matrix, a multi-protrusion (multi-elevation) surface configuration formed in one surface of the core matrix, and a facing sheet disposed on an opposite surface of the core matrix;

FIG. 7-A shows a detailed perspective view of a wallboard building material in accordance with another exemplary embodiment of the present invention, wherein the building material includes a particulate-based core matrix, laths (lath) disposed or sandwiched within the core matrix, a multi-lobed surface configuration formed in one surface of the core matrix, and a facing sheet disposed on an opposite surface of the core matrix;

FIG. 7-B shows a detail view of the building material of FIG. 7-A;

FIG. 8 shows a top view of a building material according to yet another exemplary embodiment of the invention, wherein the building material includes a patterned pillow-like (multi-protrusion) surface configuration formed in an exposed surface of a core matrix;

FIG. 9 shows a cross-sectional side view of the building material of FIG. 8;

FIG. 10 shows a cross-sectional end view of the building material of FIG. 8;

FIG. 11 shows a detailed side view of the building material of FIG. 6;

FIG. 12 shows a detailed side view of a building material having a multi-projection surface configuration, according to another exemplary embodiment;

FIG. 13 shows a detailed side view of a building material having a multi-projection surface configuration, according to another exemplary embodiment;

FIG. 14 shows a cross-sectional side view of a building material according to another exemplary embodiment, wherein the building material includes a plurality of strategically formed and located cavities or voids; and

fig. 15 illustrates a building material configured for use as a trim material on the exterior of a structure.

Detailed Description

The following detailed description of exemplary embodiments of the invention refers to the accompanying drawings, which form a part hereof, and which show by way of illustration exemplary embodiments in which the invention may be practiced. Although these exemplary embodiments are described in sufficient detail to enable those skilled in the art to practice the invention, it should be understood that other embodiments may be realized and that various changes to the invention may be made without departing from the spirit and scope of the present invention. Thus, the following more detailed description of the embodiments of the present invention is not intended to limit the scope of the invention as claimed, but is presented for purposes of illustration only and not limitation to describe the features and characteristics of the present invention, to set forth the best mode of operation of the invention, and to sufficiently enable one skilled in the art to practice the invention. Accordingly, the scope of the invention is to be limited only by the following claims.

In the description and claims of the present invention, the corresponding terms are used according to the following definitions.

Reference to "a" and "the" in the singular includes plural referents unless the context clearly dictates otherwise. Thus, for example, reference to "a wallboard" includes one or more such wallboards, and reference to "the adhesive" includes one or more such adhesives.

For the purposes of describing and interpreting the claims set forth herein, the term "building material" as used herein should be understood to mean a wide variety of different types of products or materials that incorporate a matrix of microparticles (e.g., microbeads) that are adhered or bound together with one or more ingredients, such as a binder of some type. The building material may include other additives, ingredients or components such as hardeners, foaming agents or surfactants, water soluble polymers, and others. The building material may include many different types, embodiments, etc., and may be used in many different applications.

As used herein, the term "microparticle" is understood to mean any naturally occurring, manufactured or synthetic particle having an outer surface, and in some cases a hollow interior. Generally, reference herein to microparticles includes spherical or substantially spherical geometries having a hollow interior, referred to as microbeads. Other types of particulates may include those made from wood, reclaimed rubber powder, ground plastic, sawdust, and the like.

As used herein, the term "core matrix" is understood to mean the combination of particulates and other ingredients used to form the support matrix of the building material. The microparticles may be combined with one or more binders, additives, hardeners, and the like.

The term "multi-projection" should be understood to describe at least one surface of a core matrix of a building material in which a series of peaks and valleys (or projections and depressions) are formed to provide an overall surface configuration having different surfaces located at different heights and/or orientations. The surface configuration of the multiple protrusions may be randomly formed or patterned. Further, the multi-lobed surface may be defined by any or geometrically shaped composition of projections and recesses.

As used herein, the term "substantially" refers to the completion or near completion of an action, feature, characteristic, state, structure, article, or result. For example, an object that is "substantially" enclosed means that the object is completely enclosed or nearly completely enclosed. The exact allowable degree of deflection versus absolute completion may depend on the particular context in some cases. However, in general, the approach to completion will have the same overall result as absolute and complete completion. The use of "substantially" when used in a negative sense is also intended to mean the complete or near complete absence of an action, feature, characteristic, state, structure, item, or result. For example, a composition that is "substantially free" of particles will lack particles entirely, or nearly so, that the effect is the same as if the particles were completely absent. In other words, a composition that is "substantially free" of components or elements may still actually contain such an item so long as there is no measurable effect thereof.

As used herein, the term "about" is used to provide flexibility to a given value by allowing that value to be "slightly above" or "slightly below" the end point of a range of values.

As used herein, a large number of items/products, structural elements, compositional elements, and/or materials may be listed in a common list for convenience. However, these lists should be construed as: each element of the list is individually identified as a separate, unique element. Thus, no individual member of such list should be construed as a de facto equivalent of any other member of the same list solely based on their presentation in a common group without indications to the contrary.

Concentrations, amounts, and other numerical data may be expressed or presented herein in a range format. It is to be understood that such range format is used merely for convenience and brevity and thus should be interpreted flexibly to include not only the numerical values explicitly recited as the limits of the range, but also to include all the individual numerical values or sub-ranges encompassed within that range as if each numerical value and sub-range is explicitly recited. By way of example, a numerical range of "about 1 to about 5" should be interpreted to include not only the explicitly recited values of about 1 to about 5, but also include individual values and sub-ranges within the indicated range. Thus, included in this range of values are individual values such as 2,3, and 4 and sub-ranges such as from 1 to 3, from 2 to 4, and from 3 to 5, etc., as well as individual values of 1, 2,3, 4, and 5. The same principle applies to ranges reciting a numerical value as either a minimum or maximum value. Moreover, such interpretation should apply regardless of the breadth of the range and the characteristics being described.

The present invention proposes a variety of practical materials constructed using a large number of particles. The present invention also provides various methods for producing or manufacturing different utility materials, and various applications of such utility materials. The utility materials, related wallboard embodiments, and related methods of making and using such utility materials disclosed herein have several significant advantages over utility materials in the prior art, such as wallboard products, particularly drywall, some of which are noted herein and throughout the following more detailed description. First, the wallboard building material provides improved thermodynamic performance. For example, in one aspect, the wallboard building material has a much greater resistance to heat transfer. Second, in another aspect, the wallboard building material has improved acoustic performance. For example, the wallboard building materials disclosed herein have significantly better Sound Transmission Class (STC) ratings. Third, the wallboard building material of the present invention is stronger and lighter. These advantages are not limiting in any way. Moreover, those skilled in the art will appreciate that other advantages may be realized, other than those specifically recited herein, upon practicing the present invention.

The utility materials disclosed herein are adaptable to a variety of different applications. The utility material, by virtue of its composition or composition, can be controlled to achieve different performance characteristics depending on the intended use. For example, the porosity and density of the microparticles can be controlled to achieve any desired level. This is beneficial in many applications, for example when sound or heat insulating utility materials are required.

For example, in one aspect, the present invention provides a building material having an improved sound transmission rating level and other beneficial properties (e.g., high heat transfer resistance) compared to conventional drywall panels. The building materials may be constructed as shear panels or as wallboard panels, each comprising a core matrix comprising a plurality of microbeads and at least one binder or binder solution, the microbeads being hollow or solid, inert, lightweight, naturally occurring or synthetic, configured to support (e.g., bind or adhere) the microbeads together and form a plurality of voids throughout the core matrix. The particles are thus dispersed and suspended in a composition comprising at least a binder and possibly other ingredients such as surfactants or foaming agents. The binder may comprise an inorganic binder solution, an organic or latex binder solution, or a mixture of an inorganic binder solution and an organic binder solution. The core matrix may also include various additives, fillers, reinforcing materials, and the like. Depending on the selected composition, the practical material may be configured to have specific physical and performance characteristics, such as strength, flexibility, hardness, as well as thermodynamic properties, fire protection characteristics, and the like, in addition to acoustic attenuation characteristics.

In the case of wallboard panels, the core matrix may be disposed about the facing material or about one face on one side, with the opposite side or face of the wallboard panel being uncovered, or at least partially uncovered, to provide a rough, porous surface defined by the composition and configuration of the core matrix. In other words, the building material is constructed with an at least partially exposed core matrix. In the case of a shear panel, the core matrix may be arranged with opposite sides exposed around the facing material. The facing material can be any useful material such as paper, cloth, polymers, metals, and the like. The components of the sound attenuating building materials and systems of the present invention, as well as other features and systems, are described in more detail below.

It has now been found that the exposed surface of the core matrix greatly enhances the sound attenuation properties of the building material. Sound waves impinging on an exposed surface exhibit reduced acoustic reflections as compared to a building material lacking such an exposed surface. As a result, the acoustic waves are more efficiently absorbed and attenuated by the material comprising the core matrix of the building material.

Referring to fig. 1, a detailed perspective view of a building material formed according to one exemplary aspect of the present invention is shown. As noted above, the building material includes an exposed face or side to provide a rough, porous surface. As shown, the building material 10 is in the form of a panel similar to a wallboard panel, having dimensions of about 4 feet wide by about 8 feet long, which are the same as most conventional wallboard products. Of course, building material sizes other than 4 feet by 8 feet, as well as different thicknesses are also contemplated. The illustrated building material 10 includes a core matrix 14 disposed adjacent a single facing sheet or layer, i.e., facing material 34. The exposed side 18 of the core matrix 14 allows sound to be attenuated by the particles and binder with less acoustic reflection than if both sides of the building material 10 were covered with facing material. In one aspect, the exposed side 18 of the core matrix 14 can face inward and the facing membrane 34 faces outward when the building material is installed or assembled to a structure, such as a stud wall. On the other hand, the exposed side 18 of the core matrix 14 may face outward and the facing membrane 34 facing inward when the building material is installed or assembled to a structure.

The core matrix 14 is comprised of a plurality of particulates and at least one binder, wherein the particulates are at least bound or adhered together, and in some cases are bonded together, by the one or more binders to form a core matrix structure having a plurality of voids defined therein. The voids are formed by point contacts between the particles when they are held in place by the adhesive. When bonded together, the particles provide a significantly rougher surface than if the building material included an additional facing membrane. The effect of providing a rough, porous surface is to significantly improve the sound attenuation properties of the building material by enabling better absorption of sound as it attempts to pass through the core matrix.

It is contemplated that the particles used herein may comprise many different types, sizes, shapes, compositions, etc. In one aspect, the microparticles can be microbeads. In one aspect, the particulates used in the building materials of the present invention can have an average size ranging between about 10 microns and about 1500 microns. In another aspect, the microparticles can have an average size ranging between about 10 microns and about 1000 microns. In yet another aspect, the microparticles can have an average size ranging between about 200 microns and about 800 microns. In yet another aspect, the microparticles may have an average size ranging from about 300 microns to about 600 microns. In yet another aspect, the microparticles may have an average size ranging from about 350 microns to about 450 microns. In addition, the microparticles may have a bulk density of about 0.4g/ml to about 0.6g/ml, thus providing a product that is much lighter than conventional building materials, such as gypsum-based drywall or Oriented Strand Board (OSB). The size of the microparticles may thus depend on the application and the desired performance characteristics. However, the particulates should not be so large as to cause run off or failure of any adhesive disposed thereon.

The size of the particles also plays a role in affecting the permeability of the building material. The microparticles should be compatible with any adhesive, additive and/or veneer. In the case of hollow particles, the shell thickness of the particle can be kept to a minimum as long as the particle maintains structural integrity as desired in the core matrix material. In one aspect, the microparticles can have a shell thickness of less than about 30% of the diameter of the microparticle. For non-spherical particles, the diameter of the particle can be calculated based on the effective diameter of the particle, using the total area of the cross-section of the particle and equating that area to a circular area and determining the diameter from that value. In yet another aspect, the shell thickness can be less than about 20% of the particle diameter.

In one exemplary aspect, the microparticles may comprise hollow, inert, lightweight, naturally occurring glass particles that are substantially spherical in geometry. One specific type of microbead under the trademark Extenddospheres^TMSold, manufactured and sold by Sphere One Corporation. In certain aspects, the hollow interior can be beneficially used to reduce the weight of the building material and provide good insulation properties. In one aspect, the particles canSo as to be naturally occurring hollow, inert, glass microspheres obtained from the fly ash by-product. Such microbeads are often referred to as floating beads. The floating beads can be separated from other by-product components present in the fly ash and further processed, e.g., cleaned and separated into a desired size range. The floating beads consist primarily of silicon dioxide (silica) and aluminum oxide (alumina), and may have hollow interiors that are filled with air and/or other gases. Floating beads have many desirable characteristics, such as compressive strength between 3000psi and 5000psi and low specific gravity, as well as the ability to withstand high temperatures (above 1800F). While the overall shape of the floating beads is substantially spherical, many are not truly spherical because many are crushed or include an uneven surface due to additional silica and/or alumina.

As described above, the microparticles or microbeads may include a quantity of air or other gas within the hollow interior. Where possible, the composition of the gaseous material within the beads can be optionally selected to provide enhanced characteristics of the practical material. For example, the hollow interior may include a noble gas or other known barrier gas, such as argon, to improve the barrier properties of the overall practical material.

In another aspect, the microparticles may comprise hollow, spherical structures made from synthetic materials. One advantage of using synthetic materials is the uniformity between microbeads, thereby making their performance, as well as the performance of the formed core matrix and building materials, more predictable. However, in some cases, these advantages may not be sufficiently pronounced to justify their use, as synthetic microbeads are often expensive to manufacture. The use of naturally occurring microbeads instead of synthetic microbeads to form a building material may depend on several different factors, such as the intended application, and/or desired performance characteristics and characteristics. In some applications, naturally occurring microbeads may be preferred, while in other applications, synthetic types may be more desirable.

The core matrix material of the present invention may include any amount of particulates depending on the desired characteristics of the resulting practical material. In one aspect, for example, the amount of microparticles present in the core matrix can be between about 25% and about 60% (by weight) of the total core matrix in the form of a wet mixture. In another aspect, the microparticles may be present in an amount between about 30% and about 40% (by weight). Other amounts, particularly those aspects in which other additives or fillers are included in the core matrix, such as perlite, or hardeners, such as class C fly ash, are also contemplated. It should be noted that any type of fly ash can be utilized as a filler material and/or alternatively as a source of floating beads. In one aspect, the class C fly ash can be one or the only source of microbeads. In one aspect, the amount of class C fly ash contained in the core matrix can range from about 0.5wt% to about 50 wt%. In another aspect, the class C fly ash can be present in combination with synthetically manufactured microbeads, wherein the ratio of class C fly ash to synthetic microbeads is about 1: 15 to about 15: 1. in yet another aspect, the amount of class C fly ash can be less than about 1/3 of the amount of microbeads. The class C fly ash used can optionally include greater than about 80wt% calcium aluminosilicate silicate, and less than about 2wt% lime.

As noted above, the present invention also includes one or more binders operable to bind the particulates together and facilitate formation of the porous core matrix. The particles may be bonded in any manner, including physically bonded structures, chemically bonded particles, boundaries of fused particles, and the like. In one particular aspect, the microparticles may be bound in a physical binding manner, such as by holding the microparticles together in a matrix of a binder, wherein the binder adheres or physically immobilizes the microparticles but does not form covalent bonds or other chemical bonds with the microbeads. The binder may adhere the microbeads together, wherein the binder is allowed to dry if a water-based binder or allowed to cure in a high temperature environment if a non-water-based binder. In one aspect, the binder can be crosslinked, wherein the binder functions to bind the particulates together and improve the water resistance of the building material.

The ratio of binder to particulate may vary depending on the building material to be formed. A higher ratio of binder to particulate makes the construction material stronger and denser than if the ratio were smaller. The smaller ratio of binder to particulate makes the building material more porous.

A number of adhesive materials are contemplated for use in various aspects of the present invention. It should be noted that any binder capable of binding a plurality of particles together within a core matrix should be considered within the scope of the present invention. Different binders can be selected as part of the composition to facilitate the composition of the building material and to help provide the building material with specific physical and performance characteristics. It is contemplated that both water-based and non-water-based adhesives may be used. Examples of common adhesive classes include, but are not limited to: thermoplastics, epoxies, vulcanizing agents, urethanes, thermosets, silicones, and the like.

In one exemplary embodiment, the binder comprises an inorganic binder, such as sodium silicate in one form or another, in combination with an organic binder, such as a polyvinyl acetate copolymer or ethylene vinyl acetate. The proportion of these binders may vary. In one aspect, the ratio of inorganic binder to organic binder may be about 7: 1 to about 10: 1. more typically, the inorganic binder is present in an amount between 50% and 60% by weight (or about 20wt% to about 36wt% dry inorganic binder) of the total weight of the core substrate in the wet state (the binder includes, or is mixed with, an amount of water), and the organic binder is present in an amount between 5% to 15% by weight (or about 2wt% to about 6wt% dry organic binder) of the total weight of the core substrate in the wet state. The amounts listed may be based on the form of the pure binder material (the percentage weight of the binder in the overall core matrix described herein is reduced to between 40% and 60%), for example based on pure sodium silicate, or may be based on a binder mixture including optional water, similar chemical forms such as silicates, etc. and other additives. As a non-limiting example, a commercially available sodium silicate binder solution includes about 35wt% to 40wt% sodium silicate in solution. Furthermore, more than one type of inorganic and/or organic binder may be employed simultaneously.

Depending on the desired properties of the resulting practical material, multiple components of the material making up the core matrix are contemplated. In one particular embodiment, the core matrix composition may comprise between 400g and 600g of microbeads mixed with between 600g and 800g of sodium silicate binder solution and between 60g and 100g of ethylene vinyl acetate. Of course, other ranges are possible depending on the application. For example, it may be desirable to mix between 200g and 1500g of sodium silicate or other binder with between 300g and 800g of microbeads, with between 20g and 180g of ethylene vinyl acetate copolymer. Other ratios and ranges of the various ingredients of the various formulations are also contemplated. In addition, more than one organic binder may be used, as may more than one inorganic binder.

In one particular example, the inorganic binder solution is present in the wet mixture in an amount of about 55.5% by weight of the total weight of the core substrate, wherein the binder solution comprises sodium silicate and water. More specifically, the inorganic binder solution includes sodium silicate in an amount between about 40% and about 60% by weight, and water in an amount between about 40% and about 60% by weight. In many cases, the inorganic binder solution includes a ratio of 1: 1 sodium silicate and water. The sodium silicate may be premixed and provided as a solution in liquid form, or the sodium silicate may be in powder form and subsequently mixed with water.

In one aspect, the latex or organic binder is present in the wet mixture in an amount of about 7.4% by weight of the total weight of the core substrate and comprises an ethylene polyvinyl acetate (EVA) emulsion. The latex binder facilitates the formation of a flexible, porous composition that is subsequently formed into the core matrix of the wallboard. One particular example of a latex adhesive used is ethylene vinyl acetate (water-based adhesive) sold under the trademark Airflex (e.g., Airflex 420), which is manufactured and sold by Airproducts corporation. This particular binder can be used to facilitate the flowable and formable formation of the core matrix, as well as to provide a flexible or semi-rigid composition. The latex binder may be pre-mixed with water to be in liquid form. The latex binder includes EVA in an amount of about 40% by weight and water in an amount of about 60% by weight. In one aspect, the latex binder comprises in the range of from about 2.5wt% to about 30wt% of the total weight of the core substrate in the wet mixture. In yet another aspect, the latex binder can range from about 5wt% to about 20 wt%. Non-limiting examples of latex binders include Airflex (specifically including 323, 401, 420, 426), UCAR (specifically 154s, 163 s), conventional adhesives and pastes, Vinac (including XX 210), and mixtures and combinations thereof.

A water soluble polymer may be included in the formulation of the core matrix. The water soluble polymer may be added to the core matrix composition, which has been dissolved in water or in dry form. The function of the water-soluble polymer is to act as a stabilizer for any surfactant or foaming agent present in the mixture. In particular, the water soluble polymer helps stabilize the composition until the adhesive is cured or crosslinked. Non-limiting examples of water-soluble polymers that may be included in the formulation include water-soluble polymers sold by Airflex, such as polyethylene oxide (e.g., WSR 301). The water-soluble polymer may also act as a thickener and prevent water from flowing out of the mixture during formation of the core matrix. Such polymers can be used to control the stiffness, flexibility, tear strength, and other physical properties of the building material, as well as to stabilize any surfactants, if present. In some embodiments, it may be desirable to eliminate or at least substantially reduce the amount of organic ingredients in the core matrix composition. This is particularly the case where it is desired that the building material comprises further enhanced fire protection properties. The amount of organic ingredients remaining in the core matrix composition may thus depend on the specific application.

As noted above, and depending on the type used, the adhesive may be cured only without crosslinking, or may be crosslinkable. By crosslinking the binder, a stronger, more durable physical connection is formed between the binder and the beads. Also, the present invention contemplates the use of one or more measures to effectively crosslink the adhesive. In one exemplary embodiment, polymerization and bonding may be achieved by crosslinking the adhesive by raising the temperature of the adhesive to an appropriate temperature for an appropriate period of time. This can be done using conventional radiant heating methods or also using microwaves acting continuously or at different intervals and microwaves of different intensities. The use of microwaves is significantly faster and less costly. Furthermore, the effect of using microwave crosslinking is to produce stronger building materials, since the amount of binder actually crosslinked is increased. In addition, depending on the particular adhesive used, chemical crosslinkers may be employed. Such chemical crosslinking agents are well known in the art.

Crosslinking within building materials has significant advantages over building materials having uncrosslinked compositions. For example, the binders are stronger in the case of crosslinking, they do not readily absorb water, and the connection between microbeads is stronger. Furthermore, building materials are generally less weakened over time. Other advantages may be recognized by those skilled in the art. It should be noted, however, that there may be applications where crosslinking is not desired and where unbonded components are preferred.

The present invention also contemplates the use of surfactants or foaming agents that are mixed with the binder and beads to achieve a building material with a lower density. With respect to the foaming process, once the ingredients are combined, they may be whipped or agitated to introduce air into the mixture, which is then dried. Mechanical agitation or compressed air can be used to physically introduce air into the mixture and create the foaming process. The foaming process effectively causes the particles to be supported in a more discrete position relative to each other than in the non-foamed composition. In the presence of foam, the particles are suspended and thus are able to dry in a more dispersed configuration. On the other hand, suspension of the microbeads due to the presence of the blowing agent may also be used to ensure higher flowability or pumpability, and formability of the core matrix composition. Examples of suitable surfactants or blowing agents include, but are not limited to, anionic blowing agents such AS Steol FS406 or Bio-terge AS40, cationic blowing agents, and nonionic blowing agents, among others.

As one particular example, the core matrix material may include from about 25wt% to about 60wt% of particulates (where the size of the particulates is between about 10 microns and about 1000 microns), from about 20wt% to about 36% sodium silicate, and from about 5wt% to about 15wt% vinyl acetate, based on the wet formulation. More details regarding Wallboard building Materials are described in co-pending U.S. provisional patent application No. _____ filed on 25.9.2008 and entitled "Wallboard Materials Incorporating a particulate Matrix" (attorney docket No.2600-32683.np. cip2) and co-pending U.S. provisional patent application No. _____ filed on 25.9.2008 and entitled "Shear panel building Materials" (attorney docket No.2600-32683.np. cip3), which are incorporated herein by reference in their entirety.

The facing material may comprise many different types of materials or combinations of materials having different properties. In one exemplary aspect, the facing material comprises a paper material similar to paper materials found on various wallboard products as described above, such as drywall or wallboard incorporated by reference herein. In another exemplary aspect, the facing material may be cloth, a polymer, or a metal or metal alloy.

Referring to fig. 2, a building material formed in accordance with another exemplary embodiment of the present invention is shown. Building material 110 is similar in many respects to building material 10 described above and shown in fig. 1. However, the building material 110 includes a mesh membrane 154 disposed around the exposed side 118 of the core matrix 114, opposite the facing membrane 134. The mesh membrane 154 includes a plurality of cross members that form a large number of grid-like openings. The mesh membrane 154 serves to provide support and stability to the core matrix 114 similar to the facing membrane 134, but still leaves a substantial portion of the core matrix 114 exposed on that side to maintain the rough, porous surface of the building material 110. The mesh membrane 154 can be many different types of materials, and the grid-like openings can have many different sizes and configurations.

In one aspect, the mesh membrane 154 may comprise fiberglass or a plastic mesh or mesh material. The reinforced mesh material provides bending strength to the building material 110 and further supports the particulates as they are exposed on one side of the building material 110 for the specific purpose of receiving and dissipating sound by absorbing sound waves and damping vibrations. The mesh membrane 154 may be made of glass, plastic (e.g., extruded plastic), or other material, depending on the particular application and needs. The mesh membrane 154 may be bonded to the core matrix 114 in a similar manner as the facing membrane 134 or by any other method known in the art.

One significant advantage over conventional products is the ability of the building materials of the present invention to attenuate or absorb sound. It has been found that the sound transmission rating for a building material (1/2 inches thick) formed in a similar manner to that shown in fig. 1 and 2 is between 40 and 60, depending on the composition of the core matrix, the thickness of the wallboard panel, and the presence or absence of reinforcing material. Conventional drywall board, also 1/2 inches in thickness, has an STC rating of about 33. When testing building materials based on the embodiments described above and shown in fig. 1 and 2, it was found that sound absorption around.89 ±.10 could be achieved. Furthermore, at 3000Hz, the noise reduction is between 55dB and 65 dB. At 2000Hz, the noise reduction is between 35dB and 45 dB. At 1000Hz, the noise reduction is between 10dB and 20 dB. In contrast, the noise reduction of drywall at 3000Hz was 40 dB; the noise reduction at 2000Hz was 28 dB; the noise reduction at 1000Hz is 3 dB. It can be seen that the building material is significantly better in terms of sound absorption.

In addition to its improved or enhanced sound attenuation properties, the building materials of the present invention provide a number of additional improved properties and features over conventional building materials such as drywall, gypsum board, OSB. For example, the building materials of the present invention have significantly lower heat transfer than conventional building materials. For example, in the construction materials described above and shown in fig. 1 and 2, a temperature gradient of 400 ℃ can be achieved. In a particular test, one side of the building material of the present invention was heated to 100 ℃ without a significant temperature rise on the opposite side after 2 hours. This temperature gradient may vary depending on the composition of the composition, such as the ratio of beads to binder, the type of binder used, the presence of reinforcing materials, etc., as described herein. It can thus be seen that the building materials according to the invention exhibit excellent thermodynamic properties. Using standard ASTM testing, the building material was found to have 20 ℃ less heat transfer than drywall under the same test conditions (e.g., time and temperature). Tests have shown that the building material absorbs about.11 BTU compared to drywall board that absorbs about.54 BTU. Thus, the use of a core matrix based on microbeads increases the heat capacity, i.e., how much heat the material absorbs. It has been found that the thermal resistance or R value of the same building material compared to drywall of.45 for an 1/2 inch thick panel is between 2 and 3 for a 1/2 inch thick panel.

The same building materials described above have also been found to be between about 20% and 30% lighter than drywall. For example, a 4 x 8 panel weighs about 39lbs, compared to a similarly sized drywall panel weighing about 51 lbs. The 4 x 12 dry wallboard panels weigh about 80lbs, in contrast to the wallboard building material of the present invention which weighs about 60 lbs.

In addition to being lighter in weight, the same building material was found to be 10% to 20% stronger than drywall. In one example, various tests indicate that the building material will break between 170lbs and 180lbs in a flexural strength test. In contrast, drywall boards typically break at around 107 lbs. The panels used in these tests were of comparable size and thickness. In the edge hardness test, the average value of the building material was about 15lbf, while the dry wallboard was tested to be 11 lbf. In the nail holding test, the average value of the building material was tested to be 99lbf, while the gypsum board was tested to be 77 lbf.

The building materials of the present invention may also include rigid materials or reinforcing components configured to provide enhanced features in one or more areas as compared to the exemplary building materials of fig. 1 and 2. In one exemplary embodiment, the building material may include a rigid material disposed within (sandwiched within) the core matrix or between an outer surface of the core matrix and the facing material. The rigid material may be configured to enhance or enhance one or more properties or characteristics of the building material. For example, the rigid material may be configured to enhance resistance (or increase impedance) to sound transmission, heat transfer, or a combination thereof. The rigid material may also be configured to increase the overall strength of the building material. The rigid material may comprise various types of materials, such as metal, woven or non-woven fabric or fiberboard, plastic film, etc., and may have any necessary thickness.

The present invention also provides systems and methods for improving and enhancing noise reduction across a partition using sound traps. Such sound traps may be formed by disposing the building materials of the present invention around a building structure such as a column or other wall, wherein the opposing building materials form a sound trap configured to absorb sound and significantly reduce sound transmission through the wall. In this configuration, the opposing exposed surfaces would be positioned facing each other. The sound attenuation system may be formed from a variety of suitably positioned building materials of the present invention in a variety of configurations. Thus, the materials specifically set forth herein are not intended to be limiting in any way.

Generally, sound waves entering the sound trap are attenuated by the associated building materials with different degrees of sound reflection, depending on the configuration of the sound trap and the building materials used. As described above, the exposed surface of the core matrix greatly improves the sound attenuation properties of the building material. Sound waves impinging on an exposed surface exhibit reduced acoustic reflections as compared to a building material lacking such an exposed surface. As a result, the acoustic waves are more efficiently absorbed and attenuated by the material comprising the core matrix of the building material. For a sound trap that has been surrounded by building material with an exposed face, sound attenuation is increased by all building material in the sound trap. For a sound trap employing a first building material having an exposed face on one side and a second building material having a facing material opposite the exposed face of the first building material, sound may be primarily attenuated by the exposed face of the first building material while the facing material of the second building material is used to reflect sound waves into the exposed face of the first building material. Thus, for both configurations, the sound waves are trapped and effectively attenuated between the building materials.

In an alternative embodiment, the sound trap may be constructed using two facing building material panels, each panel comprising a core matrix material sandwiched between two facing material layers as described herein. The facing material layer may be made of various materials, as described herein, such as paper, cloth, metals and metal alloys, polymeric materials, and combinations thereof.

Referring to fig. 3, a sound attenuation system 200 in accordance with an exemplary embodiment of the present invention is shown, wherein the sound attenuation system forms and defines an exterior partition 204. The sound attenuation system 200 and the exterior partition 204 include a first building material 210 supported about a first side of a building structure, such as an exterior stud wall (not shown), and a second building material 310 supported about a second side of the building structure opposite the first building material 210. In this case, the second building material is a shear panel having a rigid material disposed therein. The first and second building materials are supported or mounted to the building structure according to embodiments known in the art.

The first building material 210 comprises a wallboard panel and has a core matrix 214 disposed about a facing membrane 234, one side 218 of the core matrix being exposed, or at least substantially exposed. The exposed side 218 of the core matrix faces inward and is disposed against the members making up the stud wall with the facing membrane 234 facing outward. The second building material 310 comprises a shear panel and has a core matrix 314 disposed between a first facing membrane 334 formed of a metal, such as aluminum, and a second facing membrane 354 formed of a paper material. Optionally, the wallboard building material 210 and/or the shear panel building material 310 may include a rigid material 374 sandwiched between the core matrix 314 of the shear panel building material 310.

After installation on a stud wall in this configuration, the wallboard building material 210 and the shear panel building material 310 collectively serve to provide and define a volume of space or sound trap 284 that extends between the interior surfaces of each building material within the building structure. This sound trap is intended to block the transmission of sound waves in any direction through the partition wall 204, as these sound waves are more efficiently absorbed by the core matrix 214 with the help of the exposed rough surface 218 of the wallboard building material 210. Sound waves originating indoors and propagating through the wallboard building material 210 towards the shear panel building material 310 are partially absorbed and partially reflected by the shear panel building material 310. Those deflected acoustic waves propagate toward the exposed side 218 of the core matrix 214 of the wallboard building material 210, where they encounter the rough, porous surface of the exposed side 218. Due to this rough, porous configuration, most of the sound is absorbed into the core matrix and attenuated. The core matrix 314 of the shear panel building material 310 also contributes to sound absorption and attenuation. Thus, the sound attenuation system 200 and, in particular, the partition 204 provides higher STC and OITC ratings than exterior partitions formed from conventional drywall and OSB materials. The addition of insulation to the partition of the present invention results in a further increase in STC and OITC ratings as compared to a partition of drywall, OSB and insulation.

Fig. 4 illustrates a sound attenuation system 400 according to an exemplary embodiment of the present invention, wherein the sound attenuation system forms and defines an inner partition 404. The sound attenuation system 400 and the interior partition 404 include a first building material 410 supported about a first side of a building structure, such as an interior stud wall (not shown), and a second building material 510 supported about a second side of the building structure opposite the first building material 410, thereby defining a sound trap 484. The first building material 410 is similar to the first building material 210 of fig. 3, the description of which above is incorporated herein. The second building material 510 is also similar to the first building material 210 of fig. 3, but differs in that the wallboard building material 510 includes a core matrix 514 disposed between a first facing sheet 534 and a second facing sheet 554. In other words, the sides of the core matrix 514 of the second building material 510 are not exposed, but are covered. The sound absorption and attenuation characteristics of sound attenuation system 400 are enhanced by the direct and deflected sound waves penetrating exposed side 418 of first wallboard building material 410, where they are buffered and at least partially absorbed by core matrix 414, and the sound waves are trapped in sound trap 484.

Fig. 5 illustrates a sound attenuation system 600 according to an exemplary embodiment of the present invention, wherein the sound attenuation system 600 also forms and defines an inner partition wall 604. The sound attenuation system 600 and the interior partition 604 include a first building material 610 supported about a first side of a building structure, such as an interior stud wall (not shown), and a second building material 1710 supported about a second side of the building structure opposite the first material 610, thereby defining a sound trap 684. First building material 610 and second building material 1710 are similar to each other, each including a core matrix 614 and 1714, respectively, and each having an exposed side 618 and 1718, respectively. Both exposed sides 618 and 1718 operate to receive and absorb sound, thereby trapping a substantial portion of the sound waves within the sound trap 684 and preventing them from passing out of the sound trap 684. Thus, the sound attenuation system includes a significantly higher STC rating than the partition of standard drywall.

In each of the above exemplary sound attenuation systems, sound is designed to penetrate the outer layers or membranes of various building materials and be trapped in the formed sound traps, thus significantly reducing sound transmission through the partition wall, whether it be an interior wall or an exterior wall. It should be noted that the sound trap may also be formed and defined around the ceiling or any other partition, as will be appreciated by those skilled in the art. Sound waves entering the sound trap are attenuated by their action on and penetrating the exposed side of at least one of the building materials. The rough, porous surface of the exposed core matrix serves to reduce the deflection and transmission of acoustic waves, and the core matrix generally operates to at least partially absorb and dampen undeflected acoustic waves. The thickness of the core matrix of the building material will affect the noise reduction or sound transmission characteristics, as will the composition, density and configuration of the core matrix.

It is contemplated that any combination of the building materials of the present invention may be used on either side of the building structure and define a sound trap, including the various embodiments disclosed in the applications incorporated by reference herein. Furthermore, it is contemplated that the building materials of the present invention may be made in accordance with the teachings of the applications incorporated herein.

In certain aspects, the core matrix may be configured to further enhance the sound attenuation properties of the building material. In one aspect, the building material of the present invention includes an exposed face or side to provide a rough, porous surface. In addition, the building material of the present invention includes an exposed core matrix surface having a multi-lobed surface configuration formed therein.

As shown in fig. 6, the building material 710 is in the form of a panel similar to a wallboard panel, having dimensions of about 4 feet wide, about 8 feet long, and about 1/2 inches thick, which are the same as most conventional wallboard products. Of course, other dimensions than the 4 foot by 8 foot dimension are contemplated, as well as different thicknesses. The illustrated building material 710 includes a core substrate 714 disposed adjacent to a single facing sheet or layer, i.e., facing material 734. The other side 718 of the core matrix 714 is exposed, thereby exposing a portion of the configuration of the particles and binder. The exposed surface of the core matrix provides and defines a rough, porous surface designed to better attenuate sound. In one aspect, the exposed side 718 of the core matrix 714 is intended to face inwardly and the facing membrane 734 is intended to face outwardly when the building material is installed or assembled onto a structure such as a stud wall. On the other hand, the exposed side 718 of the core matrix 714 should face outward and the facing membrane 734 facing inward when the building material is installed or assembled to a structure.

Fig. 6 also shows that the exposed side 718 of the core matrix includes a multi-lobed surface configuration. The purpose of providing a multi-lobed surface configuration formed adjacent to one surface, particularly the exposed surface, of the core substrate is at least two: 1) significantly further enhancing the sound attenuation or damping characteristics of the building material, i.e. ensuring sound insulation and absorption over a wide frequency range; 2) the bending strength of the building material is enhanced by eliminating shear lines. As will be described below, many different multi-projection surface configurations are contemplated herein. Those skilled in the art will recognize the benefits of providing a series of peaks and valleys on a surface to create different surfaces located at different heights and oriented at different slopes, particularly for the specific purpose of attenuating sound. Acoustic waves incident on these surfaces at different heights and/or orientations are more effectively attenuated.

In the particular embodiment shown, the multi-lobed surface configuration has a lattice pattern (waffle pattern) with a plurality of lobes 718, the lobes 718 having a square or rectangular cross-section and defining a plurality of recesses 726. This series of peaks and valleys effectively forms a large number of surfaces (horizontal surfaces 730 and 734 in this example) located at different heights across the surface of core matrix 714. In addition, the projections 718 may be configured to provide surfaces oriented at different angles (in this example, the projections 718 also define a number of vertically oriented surfaces 738).

It is also contemplated that a separate mesh veneer may or may not be provided on the exposed multi-lobed surface of the core substrate 714. If a mesh veneer is used, the mesh veneer is preferably configured to have flexibility to conform to the multi-lobed surface configuration.

Fig. 6 and 14 further illustrate that the building material 710 includes a number of cavities or air pockets 746 strategically formed and located throughout the core matrix 714 and designed to reduce the overall weight of the building material without significantly affecting the strength or other properties of the building material. Preferably, the cavities 746 are randomly located throughout the core matrix 714, but the cavities may be arranged in a predetermined pattern. The cavity 746 may be formed during the manufacture of the building material according to any known method. In essence, the cavity 746 functions to define a plurality of voids or air pockets at various locations within the core matrix 714. Cavity 746 may be sized to have about 0.2cm³To about 200cm³Preferably about 5cm³To about 130cm³The volume of (a). These not only help to reduce weight, but also help to increase the overall R-value due to the still/stagnant air space. In addition, these help to further attenuate sound, as these provide additional surfaces for absorbing sound waves rather than transmitting them.

Referring to fig. 7-a and 7-B, a building material formed in accordance with another exemplary embodiment of the present invention is shown. Building material 810 is similar in many respects to building material 810 described above and shown in fig. 6. However, the building material 810 includes slats 854 disposed or sandwiched within the core matrix 814. The slats 854 include a plurality of cross-over portions 856 forming a grid having a plurality of openings 858. The purpose of the slats 854 is to provide support and stability to the core matrix 814 as well as to provide enhanced strength. In addition, the slats 854 increase the mass of the building material 810, which reduces the likelihood of vibration, thereby contributing to the sound attenuation characteristics of the building material 810. The slats 854 may include a number of different types and configurations with the grills and openings having different sizes and configurations. The slats 854 shown in FIG. 7 are not intended to be limiting in any way.

In one aspect, the slats 854 may comprise a metal, fiberglass, or plastic mesh or netting material. This reinforcing batten material provides strength to the building material 810 and further supports the beads. The slats 854 may also be made of glass, plastic (e.g., extruded plastic), or other material, depending on the particular application and needs.

Referring to fig. 8-10, a construction material 910 formed in accordance with another exemplary embodiment of the present invention is shown. In this embodiment, the construction material 910 includes a core matrix 914 having a first surface 918. A multi-lobed or non-planar surface configuration is formed in first surface 918 in the form of a repeating pillow-like projection pattern to provide a plurality of different surfaces or surface areas with a plurality of different projections. The projections can have any desired size, configuration, and height. Accordingly, what is shown in the figures is exemplary only.

Referring to fig. 11, a side view of the building material 710 of fig. 6 is illustrated, the building material 710 having a multi-projection surface configuration in the form of a repeating grid pattern. The lattice type configuration extends between the perimeter edges of the building material and defines a plurality of projections 722 and recesses 726. Fig. 14 shows a cross-sectional view of a building material, wherein the building material 710 includes a plurality of cavities or voids 746 strategically formed and positioned in the core matrix 714.

Fig. 12 illustrates a detailed side view of another exemplary construction material 1010, the construction material 1010 including a core matrix 1014 having a first surface 1018, wherein the first surface 1018 has a multi-lobed surface configuration formed therein, the multi-lobed surface configuration including a repeating pattern of first lobes 1022 in the form of pyramids or cones, and a repeating pattern of second lobes 1024 having an arbitrary shape. The second protrusion 1024 is shown to include a main base protrusion having a square cross section, an upper secondary protrusion 1023, and a side secondary protrusion 1025, each having a pyramidal or conical shape. First and second projections 1022, 1024 define a recess 1026. While the present invention is not intended to be limited to any particular shape of protrusion, fig. 12 illustrates that any shape is at least envisioned.

Fig. 13 illustrates a detailed side view of another exemplary building material 1110, the building material 1110 including a core matrix 1114 having a first surface 1118, wherein the first surface 1118 has a multi-lobed surface configuration formed therein, the multi-lobed surface configuration including a repeating pattern of first projections 1122 and recesses 1126, wherein the projections and recesses form an egg carton-type (egg carton-type) pattern.

Fig. 8-13 thus illustrate several different multi-projection surface configurations. However, these should not be limiting in any way. Indeed, those skilled in the art will recognize other configurations and/or patterns which may be used to implement the designs of the present invention.

Examples of the invention

The following examples illustrate embodiments of the invention that are currently known. Thus, these examples should not be construed as limitations of the present invention, but are merely suitable for teaching how to make best understood compositions and forms of the invention based on current experimental data. In addition, some experimental test data is included herein to provide guidance on optimizing the composition and form of practical materials. Thus, a representative number of compositions and methods for their manufacture are disclosed herein.

EXAMPLE 1 testing of practical materials of Floating beads and sodium silicate

Will Extenddospheres^TMThe floating bead mixture in form is combined with sodium silicate and allowed to dry and form a fire barrier. Extensindospheres with diameter size range of 300-600 microns were measured at a ratio of 1: 1 in combination with a sodium silicate solution (type O of PQ corporation). The wet slurry is injected into the cavity around the turbine and allowed to dry. It forms a hard mass of Extenddospheres and sodium silicate. The material was tested using an Ipro-Tek single shaft gas turbine. Tests show that the material has high insulating capability and heat resistance. Will separate the interlayer violentlyExposed to temperatures up to 1200 ℃. However, it was found that when the material was directly exposed to a flame for a period of more than a few minutes, the material cracked and foamed and began to lose physical strength.

EXAMPLE 2 formation of a mold to form wallboard

In one aspect, the utilitarian material can be a wallboard panel. The panels may optionally be formed by exposing uncured wallboard to microwaves. Such formation, as well as the formation of ordinary wallboard, may utilize a mold. An example of a mold may consist of a vinyl ester resin mold having a top member and a bottom member. To form the vinyl ester resin mold a wood mold is first constructed.

To form the vinyl ester resin mold, an outer wood mold was attached to the wood mold base using double-sided tape. Any releasable adhesive or attachment structure may alternatively be used. The resin mixture was formed from 97.5wt% vinyl ester resin mixed with 2.5wt% Methyl Ethyl Ketone Peroxide (MEKP) catalyst. Mixing the raw materials in a ratio of 1: 1 ratio of Extenddospheres form of microbeads and resin mix were added to form a core mix. The core mixture is well mixed using a stirring device installed in a drilling machine, such as a stirring device used to mix paint. The mixing time was about 3 minutes. The core mixture is injected into a prepared wood mold and dispensed to cover the entire mold, including all corners. Although not pressed into the mold, the mixture is gently smoothed using short drop, hand shaking, mechanical vibration, and spreading tools, such as a spatula. The mixture is not pressed into a wood mold because pressurizing it would reduce the porosity of the resulting vinyl ester resin mold and render it unusable. The mixture cures at room temperature until it is hard and firm upon contact. The curing time is typically about three hours. The porous vinyl ester resin mold was then carefully removed. The resulting vinyl ester resin mold had a cavity 11.625 inches by 15.25 inches by 0.5 inches deep with 0.375 inch walls around the outer edge. The same method was used to form the top member of the vinyl ester resin mold and the mold was formed in a rectangle measuring 12.375 inches by 16 inches by 0.5 inches deep.

EXAMPLE 3 preparation of wallboard Using molds

As noted above, the utilitarian material may be in the form of a wallboard panel. The panels may optionally be formed by using a porous vinyl ester resin mold. First, the wallboard liner is cut using a liner template. Although a particular liner paper shape is shown, it should be understood that the liner paper may have any shape or size sufficient to form a section of wallboard. The facing paper is cut into rectangles of a size just smaller than the larger size of the backing paper. In this example, the facing paper was cut into a rectangular shape of 11.625 inches by 15.25 inches. The liner paper is folded and placed in a porous mold. The following materials may be used to form the wallboard mixture:

700g to 900g of microbeads;

1100g to 1300g of sodium silicate solution, for example sold as "O";

300g to 500g of latex binder;

20cc to 30cc of blowing agent.

Specifically, the blowing agent was first added to the sodium silicate solution and mixed for 2 minutes using a 540RPM squirrel cage mixer (squirrel mixer). The latex binder was added to the mixture and mixed for an additional 30 seconds at the same setting. The beads were slowly added while mixing for 1 to 2 minutes or more until the mixture was homogeneous.

The wallboard mixture is poured into a liner mold and flattened using a spatula or paint stick (paint stick). It should be noted that any tool or method can be used to smooth the mixture at this point. The mixture was further leveled by vigorous shaking. A facing paperboard was placed over the mixture and covered by the top panel of the vinyl ester resin mold. The mold is placed in a microwave and the panel is irradiated for a desired amount of time. Preferably, the mold is rotated often to dry the panel more uniformly. The panel should not be continuously irradiated for any lengthy amount of time to reduce or prevent large voids in the wallboard core. The power level of the microwave radiation may be set to control the amount of time the microwaves are on. The microwave turn-on and turn-off times can be according to table 1:

TABLE 1

Power level	Opening time (second)	Closing time (seconds)
			1	3	19
2	5	17
			3	7	15

4	9	13
			5	11	11
6	13	9
			7	15
8	17	5
			9	19	3
10	22	0

Once properly heated, the resulting wallboard panel can be carefully removed from the mold.

EXAMPLE 4 flexural Strength test

An important characteristic of wallboard is the flexural strength of the board. Each sample plate was prepared by forming a core matrix material comprising the ingredients listed in table 2, dispersing the mixture into the mold cavity and leveling it. The resulting sample was 0.50 inches thick and 2 inches wide. Each sample was dried in an oven at 100 ℃ until drying was determined by an Aquant hygrometer. The sample was suspended between two supports 6 inches apart so that 1-1.5 inches rested on either side of the supports. The quart size paint can was placed in the center of the hanging sample and slowly filled with water until the sample broke, at which point the weight of the can was measured and recorded. Flexural strength is important for conventional handling, installation and use. For applications where wallboard can replace conventional gypsum wallboard, it is desirable that the strength be at least equal to that of gypsum wallboard. Each wallboard included a different composition as listed in table 2.

TABLE 2

The components in each row were combined and then mechanically whipped to produce a foamed product. The foamed product is then shaped in a mold. All binders used are sodium silicate based binders. The type O binder is a viscous sodium silicate solution from PQ corporation. RU type adhesives are also from PQ corporation and are sodium silicate solutions similar to, but less viscous than, type O. RU type contains more water and has a lower solid content. BW-50 type adhesives are also available from PQ corporation. BW-50 is also a sodium silicate solution with a lower ratio of silica to disodium oxide (disodium oxide). As shown in the table, the amount and type of binder can be optimized to create a wide range of flexural strengths.

EXAMPLE 5 bending Strength test II

The bending strength test was performed on seven sample plates according to the procedure outlined in example 4. The composition and flexural strength test weight of each sample panel are recorded in table 3.

TABLE 3

As shown in the table, increasing the sample density and increasing the binder content in the sample generally resulted in a stronger sample. Increasing the amount of water in the sample mixture generally decreases the density of the mixture and results in a decrease in the strength of the sample. In samples including tests with manila clips and/or cardboard, the material was placed on both sides of the sample. Such an arrangement is comparable to conventional gypsum wallboard, with the core material flanked by the paper product. As shown in the table, including cardboard on both sides, either side in the form of the manila paper clips or cardboard as shown, significantly increased the strength of the samples.

EXAMPLE 6 bending Strength test III

A number of sample panels were formed according to the method set forth in example 4, except that the thickness of the tape was 2 inches wide by 11 inches long. A piece of paper tape is placed in the mold cavity before the core matrix material is injected. After the mixture was poured and leveled, another piece of paper tape of the same thickness was placed on top of the mixture. The mixture was covered with a wire mesh and pressed down to keep it in place during drying. For the results listed below, the paper did not adhere properly to the core substrate, so the test results reflect samples with only one piece of paper attached. The bending strength test was performed with the paper side down. It is speculated that the sample including both veneers should be higher in result.

The core matrix material of each sample included 250g of Extenddospheres, 40g of water, 220g of binder, 10g of blowing agent. The dry weight of each sample was 334.9. For a paper thickness of 0.009 ", the breaking weight was 6.6 kg. For a 0.015 "thick paper, the breaking weight was 7.5 kg. For a paper thickness of 0.020 ", the breaking weight was 5.2 kg.

EXAMPLE 7 additional testing of sample plates

A number of sample panels were formed according to the methods and compositions listed in the above examples. Typically, the mixture, such as the mixture given above, is shaped in a mold comprising paper arranged above and below the core and a frame around the perimeter of the sample to accommodate the wet core material as the mixture dries and cures. The mechanical properties of the wallboard samples were tested after drying and heating. The composition of each sample and the associated results are shown in table 4.

Bending strength test- "bending"

A 2 inch wide by 6 to 8 inch long sample with a thickness of 0.5 inch was placed on the test fixture, suspended between two legs. The legs are spaced apart by about 4.25 inches. The test device is equipped with a curved test accessory, on which a rod is positioned parallel to the test specimen. The bending test attachment is centered at the midpoint between the two legs of the test fixture. A bucket was hooked up on the end of the test apparatus and the weight of the bucket was slowly increased until the test specimen failed. The weight of the barrel was measured to obtain a bending resistance result.

Nail holding strength test

A 6 inch wide by 6 inch long sample of 0.5 thickness was drilled to form an 5/32 inch pilot hole in the center of the sample. The sample was placed on the holding fixture and the pilot hole was centered over a 2.5 inch diameter hole in the holding fixture. A nail is inserted into the guide hole. The diameter of the nail shank should be about 0.146 inches and the diameter of the nail head should be about 0.330 inches. The screw was inserted into an index hole on the test equipment so that it extended a distance of about 2 inches. The head of the screw should be smaller than the head of the nail used in the test. The sample and fixture were positioned under the apparatus so that the centerlines of the nail and screw were aligned. A bucket was hooked up to the end of the test apparatus. The weight of the bucket was slowly increased until the test sample failed. The weight of the bucket was measured.

Cure, end and edge hardness test

A sample 2 inches wide by 6 to 8 inches long and 0.5 inches thick was clamped to the fixture of the test apparatus. The screw was inserted into an index hole on the test equipment so that it extended a distance of about 1.5 inches. The screw head should be 0.235 inches in diameter. The fixture and sample were positioned under the test apparatus such that the screw head was centered on the 0.5 inch edge of the sample. A bucket was hooked up to the end of the test apparatus. The weight of the barrel was slowly increased until the screw penetrated at least 0.5 inches into the sample. If the screw slips off the side and tears through the paper, the sample is discarded and the test repeated.

TABLE 4

Example 8 test results II

The wallboard sample included 50g of Extenddospheres and 2cc of surfactant. The first wallboard tested included 100 grams of the sodium silicate binder mixture. The second wallboard tested comprised 75g of sodium silicate binder mixture and 25g of latex binder. The test plate has a thickness ranging from 0.386 inches to 0.671 inches. The tests were performed according to ASTM 473-3, 423, E119 and D3273-00.

The flexural strength tested and determined for the first wallboard was an average of 170lbf (white side up) based on three samples. Based on the three samples, the second wallboard was found to be an average of 101lbf (white side down). The highest measurement of the six test samples was 197 lbf. The comparative conventional gypsum wallboard was 107 lbf.

The edge hardness was determined to be an average of 15 lbf. The average minimum edge hardness of gypsum wallboard was 11 lbf. The sample showed a 36% improvement compared to the gypsum sample.

The measured nail holding strength was 99lbf based on the average of 3 samples. On the other hand, the holding nail strength of the gypsum wallboard was measured to be 77 lbf.

The thermal resistance of the sample wallboard was tested. One side of the wallboard was allowed to warm to 100 c for two hours without a measurable temperature rise on the cold side of the sample.

Comparing the sample weight to conventional gypsum, the sample was found to be about 30% lighter than gypsum board.

EXAMPLE 9 wallboard Forming

As another example of wallboard formation, sodium silicate wallboard is formed by the following steps. First, sodium silicate was foamed by adding 2cc of Steol FS406 to 100g of sodium silicate solution (PQ Co., O type binder). The mixture was placed in a 6 inch diameter paint container. The mixture was mixed using a "Squirrel cage" mixer attached to a drill press operating at 540rpm and 3 inches in diameter. The operator rotates the paint container in a direction opposite to the direction of rotation of the mixer. The mixture was allowed to foam for about one-half and fifteen seconds. The volume of the sodium silicate is at least doubled during the foaming process. 50g of Extenddospheres^TM(having a size of 300 microns to 600 microns) was added to the mixture and mixed with a "Squirrel" mixer for an additional one minute. The finished mixture is then poured into a mold and leveled with a paint bar.

Once the foamed mixture was leveled in the mold, the mold was placed in an oven set at 85 ℃. The mixture was allowed to dry at this temperature for about 12 hours.

The liner paper is added to the core after the core has been sufficiently dried. A thin sodium silicate coating was applied to the back of the paper and the paper was placed on the core substrate. The core and paper were covered on all sides with a polyester breathable material and then placed in a vacuum bag. The vacuum bag was placed in an oven set at 85 ℃ and a vacuum was applied to the part. The part was allowed to dry in the oven for 45 minutes to one hour. The finished part is then removed from the oven and trimmed to the desired dimensions. Various materials may optionally be added to the core composition to accelerate drying.

Example 10 wallboard Forming II

Another wallboard was produced according to the method in example 9. The composition of the wallboard was modified by using 75g of sodium silicate binder solution and 25g of organic binder. The organic binder was added to the sodium silicate binder solution along with the Steol prior to foaming.

EXAMPLE 11 wallboard Forming III

Another wallboard is produced by first covering the mold. A substrate is lined with FEP. The FEP is wrapped tightly to reduce wrinkles on the surface. The edge piece (boarderpiece) of the mold was clad with Blue Flash Tape. The edge piece was attached to the base component using a Killer Red Tape to form a border with internal dimensions of 14 inches by 18 inches.

500g of microbeads (300 and 600 microns in size), 750g of an "O" type binder, 250g of an organic binder and 20cc of a foaming agent were measured and set aside. The binder of type O and the blowing agent were mixed using a Squirrel mixer at 540RPM for about 2 minutes. The organic binder was added to the mixture and mixed for an additional 30 seconds. The beads were added slowly while mixing. When all the beads had been added, the mixture was mixed for an additional 30 seconds or until the mixture was homogeneous. The mixture is poured into a mold and leveled with a spatula. The mold was again shaken vigorously for further leveling. The mold was placed in an oven at 100 ℃ and dried for 12 to 18 hours until completely dry. The paper was attached to the sample by first cutting a piece of backing paper and a piece of facing paper slightly larger than the panel. A uniform coating of sodium silicate solution was applied to one side of the paper. The paper is placed on the top and bottom surfaces of the panel, and pressure is applied uniformly across the surface. Pressure may optionally be applied by vacuum bagging the panel. The panel may be placed back in the oven at 100 ℃ for about 15 minutes until the paper is fully adhered to the surface of the panel.

Example 12-Sound trap Acoustic testing

The control sound trap was constructed in a configuration as described herein, wherein the first and second building materials each had a core matrix of microparticles in a binder, with facing materials on both sides of the first and second building materials. The test sound trap was constructed in a similar configuration but with the first building material lacking facing material on the side facing the second building material. The two sound traps were further tested as follows:

each sound trap is placed in an anechoic chamber with a sound transmission speaker on one side of the sound trap and a sound pressure gauge positioned on the other side of the sound trap. A series of tones ranging from 110Hz to 8000Hz are sequentially transmitted at about 100dB from the loud speaker towards the sound trap and the sound pressure level is recorded on the other side of the sound trap. For the control sound trap, the average sound pressure level for the tones of 110Hz to 8000Hz is about 58.5 dB. For the test sound trap, the average sound pressure level for the tones of 110Hz to 8000Hz is about 51.5 dB. Thus, removing the facing paper from one of the building material components results in a sound reduction of about 7.0dB across the sound trap.

The foregoing detailed description describes the invention with reference to specific exemplary embodiments. It should be understood that various modifications and changes may be made without departing from the scope of the invention as set forth in the claims below. The detailed description and drawings are to be regarded as illustrative rather than restrictive, and all such modifications and changes, if any, are intended to be included within the scope of the present invention as described and illustrated herein.

More specifically, although illustrative exemplary embodiments of the invention have been described herein, the invention is not limited to these embodiments, but includes any and all embodiments having modifications, omissions, combinations (e.g., of aspects across various embodiments), adaptations and/or alterations as would be appreciated by those in the art based on the foregoing detailed description. The limitations in the claims are to be interpreted broadly based the language employed in the claims and not limited to examples described in the foregoing detailed description or during the prosecution of the application, which examples are to be construed as non-exclusive. For example, in the present invention, the term "preferably" is non-exclusive, wherein the term is intended to mean "preferably, but not limited to". Any steps recited in any method or process claims may be executed in any order and are not limited to the order presented in the claims. The device + function or step + function limitations will only be applied if all of the following conditions are present in the particular claim definition: a) the "means for …" or "step for …" are expressly stated; and b) clearly state the corresponding functionality. The structure, materials, or acts that support the means + functions are expressly set forth in the description herein. The scope of the invention should, therefore, be determined only by the appended claims and their legal equivalents, rather than by the descriptions and examples given above.

What is claimed and desired protected by letters patent is:

Claims (17)

1. An acoustic attenuation building material comprising:

a core matrix disposed between the first facing material and the second facing material, the core matrix comprising:

a plurality of microparticles in an amount between about 25% and about 60% by weight, wherein each microparticle has an outer surface and a hollow interior, an average size between about 10 microns and about 1500 microns; and

a sodium silicate binder configured to support the particulates, the binder in an amount between about 40% and about 60% by weight.

2. The building material of claim 1, wherein the core matrix further comprises between about 2% to about 6% by weight of an organic binder.

3. The building material of claim 1, wherein the particles are filled with an inert gas.

4. The building material of claim 1, wherein the particulates are made of fly ash.

5. The building material of claim 1, wherein the second facing material is an acoustically transparent material.

6. The building material of claim 5, wherein the acoustically transparent material is a mesh material.

7. The building material of claim 1, further comprising a rigid material associated with the core matrix.

8. The building material of claim 7, wherein the rigid material is disposed within the core matrix.

9. A system for attenuating sound using a construction material, comprising:

a first building material;

a second building material disposed in a substantially parallel orientation to the first building material such that the first building material and the second building material are separated by a distance to form a sound trap space;

wherein the first building material and the second building material comprise a core matrix disposed between the first facing material and the second facing material, the core matrix comprising:

a plurality of microparticles in an amount between about 25% and about 60% by weight, wherein each microparticle has an outer surface and a hollow interior, an average size between about 10 microns and about 1500 microns; and

a sodium silicate binder configured to support the particulates, the binder in an amount between about 40% and about 60% by weight.

10. The system of claim 9, wherein the core matrix further comprises between about 2% to about 6% by weight of an organic binder.

11. The system of claim 9, further comprising a building structure located within the sound trap space.

12. The system of claim 11, wherein the first building material is supported about a first side of the building structure and the second building material is supported about a second side of the building structure.

13. The system of claim 9, wherein the first building material, the second building material, and the building structure form a partition.

14. The system of claim 9, further comprising a barrier material disposed within the sound trap between the first building material and the second building material.

15. The system of claim 9, wherein at least one of the first building material or the second building material further comprises a rigid material associated with the core matrix.

16. The system of claim 15, wherein the rigid material is disposed within the core matrix.

17. An acoustic attenuation building material comprising:

a core matrix disposed between the first facing material and the second facing material, the core matrix comprising:

a plurality of microparticles in an amount between about 25% and about 60% by weight, wherein each microparticle has an outer surface and a hollow interior, an average size between about 10 microns and about 1500 microns;

a sodium silicate binder configured to support the particulates, the binder being in an amount between about 40% and about 60% by weight; and

between 2% to about 6% by weight of an organic binder.