Acoustical ceiling panels
A ceiling panel assembly is provided, including: a sound damping layer including a constraining layer and a first viscoelastic layer; and an acoustical absorption layer coupled to the sound damping layer. A suspended ceiling assembly is provided, including: a support structure attached to a structural ceiling of a room, the support structure including a plurality of support flanges; and a plurality of ceiling panel assemblies, each ceiling panel assembly positioned on the support flanges and comprising a sound damping layer including a constraining layer and a first viscoelastic layer. A method of manufacturing a ceiling panel assembly is provided, the method including: providing a sound damping layer including a constraining layer and a viscoelastic layer; and applying an acoustical absorption layer to the sound damping layer.
1. A ceiling panel assembly, comprising:
a sound damping layer comprising a first mass layer, a first viscoelastic layer, a constraining layer having a first side and a second side, a second mass layer, and a second viscoelastic layer, wherein the first viscoelastic layer is positioned between the first side of the constraining layer and the first mass layer, and the second viscoelastic layer is positioned between the second side of the constraining layer and the second mass layer;
an acoustical absorption layer coupled to the sound damping layer, said acoustical absorption layer having a higher Sound Absorption Average (SAA) value than the sound damping layer; and
a compressible material, which provides sound attenuation, provided along one surface of at least one edge of the ceiling panel assembly; further wherein
said compressible material is in direct contact with at least one of said sound damping layer and said acoustical absorption layer.
2. The ceiling panel assembly of claim 1 , wherein the acoustical absorption layer has a SAA value of at least 0.20.
3. The ceiling panel assembly of claim 2 , wherein the ceiling panel assembly has a Ceiling Attenuation Class (CAC) rating of at least 25.
4. The ceiling panel assembly of claim 1 , wherein the acoustical absorption layer comprises fiberglass, cellulose, mineral wool, foam, or a granular material.
5. The ceiling panel assembly of claim 4 , wherein the acoustical absorption layer comprises melamine foam.
6. The ceiling panel assembly of claim 1 , further comprising a facing layer coupled to the acoustical absorption layer.
7. The ceiling panel assembly of claim 6 , wherein the facing layer comprises vinyl, cloth, fiberglass, or paint.
8. The ceiling panel assembly of claim 1 , wherein the first viscoelastic layer comprises a first viscoelastic adhesive layer and the constraining layer is coupled to the first mass layer by the first viscoelastic adhesive layer, and the second viscoelastic layer comprises a second viscoelastic adhesive layer and the constraining layer is coupled to the second mass layer by the second viscoelastic adhesive layer.
9. The ceiling panel assembly of claim 8 , wherein the constraining layer comprises a metal.
10. The ceiling panel assembly of claim 9 , wherein the constraining layer comprises a layer of galvanized steel.
11. The ceiling panel assembly of claim 9 , wherein the constraining layer comprises a sheet metal layer of selected thickness.
12. The ceiling panel assembly of claim 8 , wherein the constraining layer comprises a layer of material selected from the group consisting of: solid petroleum-based synthetic material, mass-loaded vinyl, ceramic, and composite.
13. The ceiling panel assembly of claim 12 , wherein the constraining layer comprises a layer of composite material comprised of fiberglass, carbon fiber, or aramid fiber.
14. The ceiling panel assembly of claim 8 , wherein the first mass layer comprises gypsum board.
15. The ceiling panel assembly of claim 8 , wherein the first mass layer comprises a material selected from the group consisting of: wood, a cellulose based material, metal, ceramic, a composite material, and wood.
16. The ceiling panel assembly of claim 1 , wherein the second mass layer comprises a material selected from the group consisting of: gypsum board, wood, a cellulose based material, metal, ceramic, a composite material, and wood.
17. The ceiling panel assembly of claim 1 , wherein the compressible material is provided along one surface of at least one edge of the ceiling panel assembly; wherein said surface is a front face edge of the ceiling panel assembly.
18. The ceiling panel assembly of claim 1 , wherein the compressible material is provided along a side of the ceiling panel assembly along the at least one edge.
19. The ceiling panel assembly of claim 1 , wherein the compressible material comprises a compressible tape, a v-seal, a fin seal, or a compression bulb seal.
20. The ceiling panel assembly of claim 1 , wherein the first and second mass layers are non-metal.
21. The ceiling panel assembly of claim 1 , wherein the sound damping layer and the acoustical absorption layer are separated by ¼ of a wavelength.
22. The ceiling panel assembly of claim 1 wherein said constraining layer is a layer of gypsum.
23. The ceiling panel assembly of claim 1 wherein said constraining layer is selected from a group consisting of metal, plastic, and ceramic.
24. The ceiling panel assembly of claim 1 wherein said constraining layer has a thickness that is between 0.001 inches and 4 inches.
25. The ceiling panel assembly of claim 1 wherein the area of the panel is selected from a group consisting of 2 feet wide by 2 feet long panels and 2 feet wide by 4 feet long panels.
26. The ceiling panel assembly of claim 1 wherein said assembly provides a CAC rating of at least 25.
27. The ceiling panel assembly of claim 1 , wherein the first viscoelastic layer comprises a viscoelastic adhesive and the acoustical absorption layer is coupled to the sound damping layer by the viscoelastic adhesive.
28. A method of manufacturing a ceiling panel assembly, the method comprising:
providing a sound damping layer comprising a first mass layer, a first viscoelastic layer, a constraining layer having a first side and a second side, a second 1 mass layer, and a second viscoelastic layer, wherein the first viscoelastic layer is positioned between the first side of the constraining layer and the first mass layer, and the second viscoelastic layer is positioned between the second side of the constraining layer and the second mass layer;
coupling an acoustical absorption layer to the sound damping layer, wherein said acoustical absorption layer has a higher Sound Absorption Average (SAA) value than the sound damping layer; and
providing a compressible material, which provides sound attenuation, provided along one surface of at least one edge of the ceiling panel assembly; further wherein
said compressible material is in direct contact with at least one of said sound damping layer and said acoustical absorption layer.
29. The method of claim 28 , wherein the coupling an acoustical absorption layer to the sound damping layer comprises applying an adhesive layer to the sound damping layer and coupling the acoustical absorption layer to the adhesive layer.
30. The method of claim 28 , wherein the acoustical absorption layer comprises fiberglass, cellulose, mineral wool, foam, or a granular material.
31. The method of claim 30 , wherein the acoustical absorption layer comprises melamine foam.
32. The method of claim 28 , further comprising applying a facing layer to the acoustical absorption layer.
33. The method of claim 32 , wherein the facing layer comprises vinyl, cloth, fiberglass, or paint.
34. The method of claim 28 , wherein the first viscoelastic layer comprises a first viscoelastic adhesive layer and the constraining layer is coupled to the first mass layer by the first viscoelastic adhesive layer, and the second viscoelastic layer comprises a second viscoelastic adhesive layer and the constraining layer is coupled to the second mass layer by the second viscoelastic adhesive layer.
35. The method of claim 34 , wherein the constraining layer comprises a metal.
36. The method of claim 35 , wherein the constraining layer comprises a layer of galvanized steel.
37. The method of claim 35 , wherein the constraining layer comprises a sheet metal layer of selected thickness.
38. The method of claim 34 , wherein the constraining layer comprises a layer of material selected from the group consisting of: solid petroleum-based synthetic material, mass-loaded vinyl, ceramic, and composite.
39. The method of claim 38 , wherein the constraining layer comprises a layer of composite material comprised of fiberglass, carbon fiber, or aramid fiber.
40. The method of claim 34 , wherein the first mass layer comprises gypsum board.
41. The method of claim 34 , wherein the first mass layer comprises a material selected from the group consisting of: wood, a cellulose based material, metal, ceramic, a composite material, and wood.
42. The method of claim 28 , wherein the second mass layer comprises a material selected from the group consisting of: gypsum board, wood, a cellulose based material, metal, ceramic, a composite material, and wood.
43. The method of claim 28 , wherein the compressible material is provided along one surface of at least one edge of the ceiling panel assembly; wherein said surface is a front face edge of the ceiling panel assembly.
44. The method of claim 28 , wherein the compressible material is provided along a side of the ceiling panel assembly along the at least one edge.
45. The method of claim 28 , wherein the compressible material comprises a compressible tape, a v-seal, a fin seal, or a compression bulb seal.
46. The method of claim 28 , wherein the first and second mass layers are non-metal.
47. The method of claim 28 , wherein the first viscoelastic layer comprises a viscoelastic adhesive and the acoustical absorption layer is coupled to the sound damping layer by the viscoelastic adhesive.